DEPARTMENTAL

PRESENTATION JULY2015
MECHANICAL MAINTENANCE(CPP)

1. Safety Update
2. Department KPIs
PM compliance
CBM Compliance
Equipment Maintenance based on CBM
Oil Consumption
Equipment Breakdown
Training

3. Modifications / Improvements
4. Major works done

SAFETY UPDATE
Safety Points

Jul-15

YTD

Identified

Closed

Identified

Closed

Safety Committee Review

Points

60

55

Safety Walk down

49

18

Near Miss Reporting

30

90

55

Safety meeting with contractors in the month of July'15

Meeting date Contractor
08.07.2015
&
M/s BISI
24.07.2015
01.07.2015
&
M/s Indure
03.07.2015
04.07.2015 M/s O&M Solution
14.07.2015
&
M/s Pump Seal Engineers
15.07.2015

Venue

Total

No. of attendees

CPP maintenance room

60

ESP (Unit#1,2) control room

51

TG (Unit#3&4) zero meter

20

CPP maintenance room

27

158

PM COMPLIANCE
plan

100

Actual

100

100

100

99

99.8

CBM COMPLIANCE
PLAN

100

100

100

ACTUAL

100

100

100

CBM (TREND ANALYSIS)

Equipment Maintenance Based on CBM
17

16

EQUIPMENT
CORRECTED

14

(#1&2)CONDENSAT
8
WATER
PUMP-2
(#1&2)CONDENSAT
WATER PUMP-3
FD FAN-1B LOP-A
PA FAN-2B LOP-B
DMCCW-1A
DMCCW-1A
SEAL AIR FAN-2B
PA FAN-2B LOP-A

TOTAL OIL CONSUMPTION

7254.5
5861.5

3152

1716.5

1858

2364.5

EQUIPMENT BREAKDOWN
3

EQUIPMENT
BREAKDOWN
1

BOILER FILL
PUMP-1
LDO
FORWARDING
PUMP-2
HP BYPASS V/V
SPRAY CONTROL
VALVE-#2

SERVICE BILL
7,372,326

6,930,363

4,361,300

3,887,027
3,383,743
2,844,968

ADITYA ALUMINIUM
CPP(6x150MW)
BREAK DOWN ANALYSIS REPORT

CPP/MMD/FY-2015/16-014

Break Down report for:#2 HPBYPASS SPRAY CONTROL VALVE

Date:21.07.2015
Start Time:4.00AM
End Time-9.30 AM
Brief Description: on dated 21st July 2015 morning 4 Am #2 HP Bypass ( HPBP) spray control valve oil leakage
occurred from piston seal. Then local operator informed to control room and then maintenance engineer reached at
site at 4.30am.Then it is found that the piston seal all Allen bolts were sheared-off. Oil seal and o' ring found ok.

Analysis Report:
1-Analysis has been done and found that 1 allen bolt was defective (has sheared) from the beginning. The rest of the
Allen bolts have sheared subsequently during the valve operation. (as 1 Allen bolt has failed, additional load was on
the rest of the allen bolts)
2-Spring washers as mentioned in the drawing , were not provided to absorb the jerks and sudden loads.
Corrective Measures:
1-Damaged Allen bolts were replaced with new bolts.
2-8 mm spring washers to be installed in each and every bolt in all HPBP systems in Unit 1, 2 , 3, 4 & 5 by 25 Jul 15
3-Now it is running normal with out any jerk and oil leakage.

Sunil sahoo

Sreenivas peri

jagadish patra

Concerned Engineer

Reporting Manager

Head of Dept.

DEPARTMENTAL TRAINING
190
174

123

118
92
68

33

TARGET

ACHIEVED

MAJOR MODIFICATION

NERATOR BRG OVEF LINE PROVISION

GENERATOR FRONT
GENERATOR REAR

AFTER MODIFICATION NO OIL LEAKAGE FOUND

MAJOR MODIFICATION
SERVICE WATER PUMP BEFORE AND AFTER MODIFICATION

INGS-50 KW/Hr per Pump x 2 pumps in service

MAJOR WORK DONE

1-Gate valve installation done in boiler fill pump-3 and service water pump-2.
2-Boiler fill pump-3 shaft, sleeve and bearing replacement done.
3-LDO forwarding pump-2 mechanical seal and bearing replaced.
4-Seal air fan-2B fan NDE side bearing replacement done.
5-1 no globe valve and reducer provided at service water pump at service water pump-2
6-PA FAN-2B LOP-A pump bearing and mechanical seal replaced.
7-Unit # 3 and #4 main line discharge valve replaced .
8-Unit # 3 common line discharge valve repaired.

THANK
YOU