EVENT ANALYSIS

UNIT NO: 6
Event No: 01/2005
Date: 27/01/2005
Time: 15:58 Hrs.
Load: 393 MW

Coal cycle in service: A B D E F Oil support: Nil

Description: TDBFP- 6B tripped at 15:57 Hrs. on Turbine bearing metal temp very high
indication. MDBFP-6D picks up auto. Meantime TDBFP- 6A got unloaded.
Initially drum level observed decreasing trend. There after drum level low
indication appear on desk. MDBFP-6D suction flow immediately shoot up to 1300
T / Hr. and motor amp rise to 600 amp.
Then, drum level 3-element control fail. There after, drum level observed fast rising
trend. Manually drum level control tried by lowering scoop of MDBFP 6D. But
drum level not came down to normal level and drum level very high indication
appears on desk. Immediately and unit tripped at 15:58 Hrs. on drum level very
high protection.
Observation:
1) Turbine trip gear 1 or 2 operated.
2) Boiler fire off.
3) Gen-6 lock out relay 2X 32 G operated.
4) Gen-6 lock out relay trouble 2X 32G trouble.
5) Trip fluid pressure very low.
6) GT-6 bay breaker trip circuit fault.
7) GT-6 bay air pressure low.
8) Main turbine AOP did not pick up during coasting down and did not cut off on
auto.
9) FC NRV not getting close on auto (LPH 2, 3). Hence close manually. (During
turbine tripping).
Action Taken: Nil

Page.1

Analysis:

1) On Dt. 27.01.05 at 15:55:44, TD BFP B tripped on turbine gear journal

bearing metal temp. very high (greater than 110 0 C) due to malfunctioning of
RTD element. (Load 393 MW).
2) MDBFP D (stand by pump) picked up on auto.
3) MDBFP D flow increased from 0 value to 1300 T / Hrs after a delay time 1517 secs. (From curve.)
4) Drum level 3E control can fail on the following interlocks.
a) If the boiler load index < 25% [0-2000].
b) Drum level left or right measurement, transmitter releases (at least one
release should be there).
c) BLI signal failure. [Found ok].
d) Feed flow after control station signal failure [found ok].
e) None of the BFPS are ON and auto (scoop / EHG).
For the above no DAS signal available in SOE to as certain that 3E has failed.
5) Drum level shoot up with fast rising trend, may be due to
a. MDBFP 6 D shared flow T / Hr. (max) for min (3min-10sec).
b. And BS 4 / BS 5 failed to respond on high-level interlock due to actuator
problem (it is seen on other day also).
6) Due to this drum level shoot up to tripping value even after manual intervention.
Flow reached to max value of 1300 T / Hr. at 15:56:40. Flow remain up to 1300 T
/Hr. at 15:59:50.
7) For the entire period of disturbance, it is seen from the curve that TDBFP 6 A
was on EHC control & was not on hydraulic.
8) Due to above, boiler ultimately tripped on high drum level more than 10 sec.

Recommendation: For fault analysis purpose following points is incorporated in DAS.

1) BFP A/B EHC to hydraulic changeover.
2) Drum level 3E auto fail.
3) BFP scoop auto / manual changeover.
4) BFPB journal bearing, RTD to be replaced in shut down.
Remark:
1) Above additional information on DAS will be made available at the earliest in
unit V & VI which will be helpful for analysis.
2) 3E failure not analyzed.

Page. 2

EVENT ANALYSIS
UNIT NO: 6
Event No: M1/2005
Date: 12/02/2005
Time: 20:00Hrs.
Load: 435 MW

Coal cycle in service: A+B+D+E+F+H Oil support: AB ele.3 guns

Description: Heavy system jerk observed. AVR came on manual. Lighting supply
(partial) failed. As per GCR, Chandrapur, Parli circuit 3 tripped.
Observation:
1) Station SWGR SF-11 / 1 incomer breaker trip.
2) Station SWGR SF-13 incomer breaker trip.
3) Station SWGR SF-14 incomer breaker trip.
4) Station 4 MB auxiliary supply fail.
5) Station 4A MB auxiliary supply fail.
6) Gen AVR fault.
7) Gen AVR manual.
8) Fast transformer mode 6A not available.
9) 220 V battery chargers 4 trouble.
Action Taken: SF 11 / 1 under voltage relay & its timer will be tested after availability
& ST-3 or SF-11/1 board shutdown.
Analysis: During system jerk SF- 11 / 1 incomer breaker tripped. Master trip 86, 30B,
2.271 relays found operated. Due to which SAT 4A, lighting boards section- I and
OPB board section-I tripped. Relay resetted and all boards normalized. Tripping
of any station board supply due to tripping of any transmission line did not occur
before.
Recommendation: Nil
Remark: Nil

Page. 3

EVENT ANALYSIS
UNIT NO: 6
Event No: 03/2005
Date: 30/03/2005
Time: 02:48Hrs.
Load: 450 MW

Coal cycle in service: BDEFGH

Description: At 02:18 Hrs. PA fan 6A DE bearing temp high alarm appeared & PA fan
6A tripped. All running mills tripped, oil support in AB & CD taken but BLR tripped on
flame failure @ 02:48 Hrs. TA set tripped at 02:48 Hrs.
Observation:
1) Gen. Lockout relay 86 GT operated.
2) Boiler fire off.
3) PA fan 6A could not be started immediately, Same started with the help of I &
C II.
Action Taken:
1) Oil elevation with 4 guns should be taken in service.
2) Oil elevation should be taken in service such that it is in gap of running coal
feeders.
e.g. : Coal feeder- E
Coal feeder- C
Coal feeder- B
Coal feeder- A
Analysis:
a) At 02:18 Hrs, PA fan-6A tripped on Motor DE bearing temperature
high. Protection. Due to tripping of PA FAN 6A, running top coal mill
F,G & H tripped. Immediately oil support in AB & CD elevation was cut
in at 02:19 Hrs, remaining coal mills Viz. B, C & D tripped on PA
header pressure very low. Between 02:22 to 02:40 Hrs, coal mills A, B
& D were taken in service one by one. At 02:48 Hrs, boiler tripped on
Flame failure though coal mills A, B, & D were in service along with
oil support in AB and CD elevation. AB oil & CD oil elevation taken in
service therefore AB & CD fire ball scanner logic defeated. C/F C and
C/F E was not in service hence scanner flame of BC and DE was
flickering (poor). AB and CD oil elevation were proven with only 3
guns. If 1 /3 gun in AB and CD got out leaving 2 gun in service, AB and
CD oil elevation not in service is sensed & when AB. CD, BC, DE have
voted for No flame Boiler tripped on flame failure.
Page. 4

b) P.A. fan 6A motor both end bearings (DE & NDE) greasing done as per
greasing schedule on 18.03.2005. Bearing temp noted after greasing
were DE side- 55 0C to 70 0C and NDE 44 0C to 59 0C .Some PA fan
tripped on dt 30.03.2005 at 02:18 Hrs on motorDE side bearing temp
high.
It is observed during greasing of DE side motor bearing that;
back pressure was acting on greasing pump. This phenomenon may be either due
to blockage of grease path to the bearing or the bearing may be having adequate
grease. It is suspected that, reason for tripping of motor on DE side bearing temp
may be due to some foreign material (most probably hard grease) present in
bearing grease.
In order to as operation the exact reason of tripping, PA fan motor bearing
will be checked in short shut down of 4 to 5 days.
Recommendation: Nil.
Remark:
1) Healthiness availability of oil gun should be ensured.
2) Ensure weekly trials of oil guns.

Page. 5

EVENT ANALYSIS
UNIT NO: 6
Event No: M2/2005
Date: 31/03/2005
Time: 04:30Hrs.
Load: 310 MW

Coal cycle in service: A + C + D + E

Description: ID fan 6B tripped as soon as PA fan 6A made ON.

Observation: ID fan 6B motor tripped indication appeared on COD 2.
Action Taken:
1) ID fan motor relay checked no abnormality found.
2) ID fan motor checked at motor end and panel end no abnormality observed at
both ends. Megger Values are normal.
Analysis: On checking, motor differential protection and masters trip relay, 86 found
operated.
Recommendation: Nil.
Remark: Nil.

Page.6

EVENT ANALYSIS
UNIT NO: 6
Event No: 04/2005
Date: 31/03/2005
Time: 18:11Hrs.
Load: 435 MW

Coal cycle in service: CDEFGH

Description: At 18:09 Hrs. dearator level low indication appeared in PCR6. CEP 6A &
6C were in service. CEP 6B, which was stand by taken in service, but dearator
level drop to very low and TDBFP 6A tripped on low dearator level TDBFP 6B
tripped on over speed. Boiler tripped on All BFP tripped.
Observation: All BPF tripped on boiler desk.
Dearator level very low, boiler off turbine tripped.
Gen-6 lockout relay 2X / 32G trouble. / Gen 6. lockout relay 2X / 32
operated / boiler fine off.
The oil gun AB elevation not proved. Hence oil return in CD & EF was
taken.
Action Taken:
1) Pressure gauge of pneumatic positioner removed and dummy plug are fixed.
2) PFT was mal functioning due to improper operation of spring used inside and
mechanical vibration. It is replaced by new one.
3) Critical control valves where line vibration are high will be attended for i)
mounting fixture. ii) Replacement of pneumatic positioner pressure gauges by
dummy plugs.
4) Manual standby valve CD 31 shall be taken in service.
5) It is maintained in O / H and defects raised. Based on portion feedback the
frequency promptly of maint. Can be intending.
It is taken in P.M schedule.
Analysis: CD 34, valve (condenser control valve to dearator) chose, due to air leakage,
from pressure gauge and 50% opening was indicating at PCR control desk.
Recommendation:
1) Periodical checking required.
2) P.M schedule taken.
Remark: Nil
Page. 7

EVENT ANALYSIS
UNIT NO: 6
Event No: M3/2005
Date: 11/04/2005
Time: 15:50 Hrs.
Load: 450 MW

Coal cycle in service: BCDEFG

Oil support: Nil

Description: After getting clearance from CHP at 15:15 Hrs. mill made normal and &
bunker outlet (feeder inlet) got opened from B/M at 15:48 Hrs. At 15:50 C /
M, 6A tried to taken on load but no coal observed, Inform to B/M for
checking coal feeder internally at 16:40 Hrs. and to B/M for internal
inspection. At 17:35 B/M reported belt found burnt.
Observation: Nil.
Action Taken: Due to burning coal, belt burned. It replaced. All damage bending are
replaced.
Analysis: As the bunker was under permit for scraping. CHP staff reported the smoke
was coming from the bunker. Due to fire in coal scrapping was not carried out
and some coal and water sprayed inside bunker for stopping fire but smoke
was not stopped hence permit cancelled by CHP for removing coal through
mill by opening bunker gate as soon as the gate opened burning coal was fall
down on belt and belt burn out. To avoid such incidence it is better to remove
scrapped coal (i.e smoke etc) to be removed backside of feeder.
Recommendation: Nil.
Remark: CHP to ensure that burning coal fire is quenched.

Page. 8

EVENT ANALYSIS
UNIT NO: 6
Event No: M4/2005
Date: 17/04/2005
Time: 18:50 Hrs.
Load: 450 MW

Coal cycle in service: 6

Oil support: Nil.

Description: At 18:50 Hrs. heavy system jerk, observed and following indication appear
on 1) CUP 17- station switchgear SF 15 incomer breaker trip, Generator AVR
manual, generator AVR fault, Generator 6 negative phase sequence relay 46G
alarm, AHP supply failed, all relay reset and resume all auxiliary.
This is due to Parli III lighting arrester burst.
Observation: Running 6A/A series tripped.
Action Taken: Tripping is due to External fault in under voltage protection.
Analysis:
1) Generator AVR fault and generator AVR on manual indication resetted and AVR
put on Auto.
2) On SF 15 86 master relay, 30-B, 2.27, and under voltage on R-phase relay reset
and SF 15 breaker charged.
3) AHP supply normalized.
Recommendation:
Healthiness of breaker / control circuit relay to be checked for this breaker though the
preventive maintenance was carried out periodically. (SF-1S BKR).
Remark: Nil.

Page.9

EVENT ANALYSIS
UNIT NO: 6
Event No: M5/ 2005
Date: 20/04/2005
Time: 23:35 Hrs.
Load: 450 MW

Coal cycle in service: B C D E F G

Oil support: Nil.

Description: At 23:35 Hrs.H.P sent water pump No.1 tripped without indicator and 6-BB Ash line tripped in protection. H.P seal water pump No.2 did not start due to
failure of 240 V control supply at 3:25 Hrs on 21.04.05. Furnace draft shoot up
to +80mm, it was controlling manually. It was reported that, due to heavy
clinker, seal through broken at mid point (PCR side) and water
Leakage started. LP Ash water No.1 was under permit for motor bearing
abnormal sound.
Observation: Nil.
Action Taken: 240 V control supply of AHPLT Board U # 6 failed due to burning of
looping cable at control bus end. The burnt portion of cable cut and relugged.
Supply normalized LPAWP-1 was not under permit as the permit taken for
preventive maintenance of LPAWP-1 was cancelled on 20/04/2005 it self
(Permit No.EP-21758 Dtd.20.04.05), However, LPAWP-1 was under
mechanical permit for pump maintenance works.
Analysis: Both section of 415 V AHP PA. Board, were charge individually but 240 V
A.C. supply bus is common for both section, which can be fed-individually by
any one of control supply-source. Hence due to failure of common 240 V
control supply; stand by HP seal water pump 2 could not be started.
Recommendation: Individual 240 V control supply may please be providing for each
section of 415 V,AHP Board. The parts may please be checking availability to
solenoid the control supply of end section to other section of 415 V AHP
Board.
Remark: Modification in control supply source is to be done in next available
opportunity to avoid re-occurrence.
Page.10

EVENT ANALYSIS
UNIT NO: 6
Event No: M6/ 2005
Date: 21/04/2005
Time: 14:20 Hrs.
Load: 340 MW

Coal cycle in service: B C E F D

Oil support: Nil.

Description:
For decouple trial of L.P Ash water pump no.1 Motor, 415 V, A.C. feeder putting
power fuses and remaining fuse puller, flashover occurred and shri. Pandurang R.
Nimasade, Art-B got injured. (Burn injury)
Observation:
Both incomer powers supply and control supply failed, and running L.P. ash water
pump No.2, seal water pump and running series 6B tripped. No water in hopper.
Water filling started through F / F-system.
Action Taken:
L.T. feeder isolator checking in progress & proposal for rubber mat is in process.
Analysis: Nil.
Recommendation:
1) Necessary isolation will be ensured and requisite the PPSS such as hand glove,
safety shoes, hamlet etc.
2) Rubber mat should be kept in front of panel in proper position.
Remark: All artisans doing isolation needs further training. EE (Trg) to arrange.
Page.11

EVENT ANALYSIS
UNIT NO: 6
Event no: 16 / 2005
Date: 28/12/2005
Time: 18:18 Hrs.
Load: 470 MW

Coal cycle in service: ABC DEF.

Description: Heavy jerk with negative phase sequence alarm, P.A. fan 6A tripped on
differential relay. Boiler tripped on feed low as coal mill tripped on Low P.A
header pressure. MDBFP 6C started manually. TA set outage approved for
attending R/H spray line leakage.
Observation:
1) Boiler fires off.
2) Gen. 6 lockout relay 2X / 32G operated.
3) Trip fluid pressure very low.
4) Gen. Negative phases sequence operated.
5) Gen. AVR faults.
6) Gen. AVR on manual.
7) FD fan A IGV control was on manual but sudden sec air flow at flow less than
30% indication appeared @ 23:52 Hrs. and boiler tripped after light up. Same
incident again happened @ 23:58 Hrs. though Both FD fans on manual control.
Inform to I & C.
8) ESV opening criteria was not working proper as MS temp before HPBP was
showing 0-in criteria no. 1 & no. 7.
Action Taken: Diff. Relay type DIXIII of PA fan 6A is replaced by PA-5A relay. New
relay tested and found OK. Motor IR and resistance measured and found in order. Old
relay is being sent to ABB works Baroda for detailed testing and root cause analysis.
1) Checking / cleaning / tightening of connections at motor end on phase side and
neutral side connection found normal.
2) Checking tightness of connections at HT switchgear end and found normal.
3) Megger value by 1 KV hand operated. Megger taken and found OK.
Ph-Ph = 0 Mega ohm.
IR Ph-E = 1000 Mega ohm.
4) Balance winding resistance of motor ensured.
Page. 25
Analysis: 1) During shutdown. Reheat spray line heavy leakage through NRV body
attended.
2) Motor is normal from EM II side. Hence PA fan tripping analysis from EM II
could be carried out.

Recommendation: After receipt of analysis report from ABB. Baroda, action will be
initiated accordingly.
Remark: Nil

Page.26

EVENT ANALYSIS
UNIT NO: 6
Event no: 14 / 2005
Date: 27/09/2005
Time: 23:54 Hrs.
Load: 100 MW.

Coal cycle in service: Nil.

Oil support: AB elevation

Description:
1) TA set forced withdrawn due to boiler tube leakage in LTSH zone.
2) Turbine hand tripped from COD7 and boiler tripped on drum level very low.
Observation:
1) Gen.6 lockout relay 2X / 32G operated.
2) Trip fluid pressure very low.
3) Boiler fire off.
4) While withdrawing the TA set BFP 6C did not taken sufficient flow on auto.
Action Taken:
1) Material mixed up in the LTSH terminal tubes will be checked up in all coils
during AOH using portable spectrometer from metallurgical laboratory,
Mumbai.
2) Tube metal temperature shall be monitored and maintained.
Analysis:
1) Tube no.5 of coil no. 109 found burst opened after 90 0 bends due to
Overheating.
2) Thin edge found along the opening in 200 mm length and half portion of tube
In 200 mm length was found tear off and missing.
3) No wastage of material seen on outside surface.
4) No significant oxide.
5) Tube was found bulged with maximum diameter 52 mm (original diameter 51
mm).
6) Multi surface cracks seen OD of tube facing to flue gas side near failure.
Recommendation:
1) Damaged tubes were replaced by new one.
Page.23

2) Overheating should be avoided by monitoring tube material temp at LTSH

zone.
3) Suspected material mix up will be checked during overhaul.
Remarks: Instruction for scrupulous monitoring of boiler metal temperature has been
issued.

Page. 24

EVENT ANALYSIS
UNIT NO: 6
Event No: 13/2005
Date: 21/09/2005
Time: 09:58 Hrs.
Load: 431 MW.

Coal cycle in service: AB DE GH

Oil support: Nil.

Description:
1) T. G. Set triped on grid over frequency 51.66 Hz protection.
Observations:
1) GT 6- lockout relay 86G1 operated.
2) Generator frequency high.
3) Trip fluid pressure very low.
4) 4T6 bay breaker pressure low.
5) Turbine trip generator 1/2 operated.
6) LPBP-1 v/v not getting open (I & C problem).
7) CRH main line (HP exhaust to CRH) developed leakage at 8.5 meter level and
decision of attending / Not attending is pending.
8) Main turbine bearing no.3 vibrations pick up replacement work carried out.
Action Taken:
1) Due to grid disturbance, Parli Line I / II / III tripped on power swing protection,
resulting in to tripping of U6 on over frequency protection. Over frequency relay
setting 51.5 c/s with 1.65 sec.
2) PA fan 6A, DE bearing checked for high temp. No abnormility observed in the
bearing.
Analysis: Unit tripped on over frequency (51.66 Hz). At that time 400 KV lines Parli I, II
and III were tripped.
Recommendation: Nil.
Remark: Nil.

Page. 22

EVENT ANALYSIS
UNIT NO: 6
Event No: 13/2005
Date: 13/09/2005
Time: 03:15 Hrs.
Load: 431 MW.

Coal cycle in service: BC DE FH

Oil support: Nil.

Description: L.P By pass opened on auto, and turbine tripped on condenser pressure
high (condenser vacuum very low). Water leakage observed from CRH line at
turbine basement. Boiler tripped on In-adequate water wall re-circulation at 03:53
Hrs.
Observation:
1) Condenser pressure high.
2) Trip fluid pressure very low.
3) Turbine generator 6 lock out relay operated.
4) CRH line water flushed by opening atmospheric drain.
Action Taken: The wheel chamber (Ist stage) pressure transmitter of HP 7, replaced and
put in service.
Analysis: Let S.E. (O-II) mention the reason why LP by pass was not closed
immediately. What action has been taken to confirm immediate action from shift
staff to avoid recurrence.
Recommendation:
1) There was vibration in stand on which transmitter was mounted. Stand
disconnect from the beam from which vibration were reflecting.
2) All such type of stands to be verified and to be disconnected from the beam if
vibrations are reflecting to the stand.
Remark: Nil
Page. 21

EVENT ANALYSIS
UNIT NO: 6
Event No: 11/ 2005
Date: 01/09/2005
Time: 12:15 Hrs.
Load: 465 MW

Coal cycle in service: AB DE FH

Oil support: Nil.

Description: TA set withdrawn due to boiler tube leakage in platen Reheater zone.
Observation:
1) Gen. 6 lockout relay 2X / 32G operated.
2) Trip fluid pressure very low.
3) Boiler fire off.
4) RH spray V/V R-10 is passing by 10 T / Hr. Primary water Dp high indication got
persisting during rolling (Dp = 1.6 Kg / m2).
Action taken: Nil
Analysis: R/H tube coil no 43, Tube no 4 & 5 Burst opened.
Recommendations:
1) All damaged / visually overheated tubes replaced.
2) Steam flow through reheater shall be ensured before rolling of turbine by
opening HP / LP Bypass system.
3) Overheating of tube to be avoided by maintaining proper recommended temp.
4) Coil no. 38 to 46 will be replaced in the next over haul.
Remark:
1) BM recommendation of sufficient flow through reheater before rolling of turbine
is already being followed.
2) Corrective action is planned in next Over Haul.
Page.20

EVENT ANALYSIS
UNIT NO: 6
Event No: 10/2005
Date: 28/08/2005
Time: 16:07 Hrs.
Load: 65 MW

Coal cycle in service: 6A, 6C

Oil support: AB, CD

Description: TA set tripped on boiler drum level very high. No C.T. fans available at
14:30 hrs, running CT fans were tripped as Incomer-I hand tripped due to smoke
observed from Incomer-I beaker
Observation: Nil
Action Taken: Nil
Analysis: Due to non-availability of C.T. fans TA sets sharing load up to 65 MW. Boiler
drum level has to be maintained manually. Also the spray has to be maintained
manually to maintain temp.
Recommendations: Physical checking & contact resistance measurement cut of clusters
and replacement of clusters found high contact resistance in every annual Over
Haul.
Remarks:
1) Breaker contact resistance of cluster contact resistance is to measured in next
available shutdown.
2) Incomer I & II Full load (18 Nos) trial for 8 Hrs taken on 4th Sept 05 and 5th Sept
05 found O.K.
3) Whenever reference contact resistance value is not available we may take average
contact resistance of the various observations taken on similar breakers as
reference for corrective / preventative actions. Till such reference value is
available from authentic source.

Page. 19

EVENT ANALYSIS
UNIT NO: 6
Event No: 09/ 2005
Date: 24/08/2005
Time: 15:28 Hrs.
Load: 465 MW.

Coal cycle in service: 6C

Oil support: CD

Description: TA set withdrawn due to boiler tube leakage observed DM make raised
from 30 T/Hrs to 100 T/ Hrs. boiler checked at 57 Mtr level at corner no. 3
abnormal sound with water observed. TA set hand tripped at 15:28 Hrs
Economizer tube leakage.
Observation: Nil
Action Taken: Nil
Analysis: Economizer (middle) coil no. 130 / Tube no. 1 top bend (rear side) found
punctured due to flue gas erosion.
Recommendation:
1) Cassette baffles on ends coils (2 Nos) repaired.
2) All work out baffles will be replaced during OH.
3) Thickness of top plate of cassette baffle will be increased to 5mm (existing thick
3.0 mm) & material composition will be ensured for SS304.
Remarks: Nil.

Page.18

EVENT ANALYSIS
UNIT NO: 6
Event No: 08/ 2005
Date: 16/08/2005
Time: 07:45 Hrs.
Load: 350 MW.

Coal cycle in service: A C E F H

Oil support: Nil.

Description: T.A. set tripped on Rotor E/F 64F Trip protection.

Observation:
1) Trip fluid pressure very low.
2) Generator-6 rotor E/F relays 64F Trip.
3) Generator-6 lockout relay 86 G1 operated.
4) BD block valve heavily passing.
5) BPE 1 / BPE 2 not working on auto.
6) CEP-6A not developing flow above 400T/Hr & CEP-B tripped on suction
strainer choke up.
Action Taken:
1) Separate wire is laid to connect rotor earthling brush with measuring lead
connected to male part of this assembly directly and the firm connects
between brush holders and holding assembly (male / female contact) is
ensured.
2) IR value of Generator rotor & Exciter winding measured by 250V megger &
found more than 50M ohms.
3) Rotor E/F relay checked for calibration & found OK.
4) All four slip ring brushes replaced by new one.
5) During preventive maintenance carbon brushes are checked regularly after
every two months. At the same time additional wire loop provided to ensure
firm contact with brush will be checked for its healthiness.
6) Visual inspection of diode wheel carried out. Found normal.
Page. 16
Analysis:
As per C/T- 1) Slip ring brushes tighten & all four brushes replaced.
2) I.R. value of generator rotor & rectifier windings & relay coil found
O.K.
Recommendation: Nil
Remark: Nil

EVENT ANALYSIS
UNIT NO: 6
Event No: 06/ 2005
Date: 17/07/2005
Time: 03:42 Hrs.
Load: 350 MW

Coal cycle in service: A C D E F G

Oil support: Nil.

Description: At about 02:00 hrs DM make up observed rising for 40 T/Hr. to 100 T/Hr.
hence boiler inspected and observed abnormal sound near LRSB no.119 towards
unit 5 at 57 meter level hence load reduced and T.A. set hand tripped at 03:42 Hrs.
Observation:
1) CEP-B, BCW 6A, FD 6A tripped during set hand tripping. Indication fast
transfer mode 6A not available appear on cup-20.
2) Boiler tripped on drum level very high during light-up.
Action Taken:
Check synchronizing relay SLJ 21 of bus transfer panel 6A found sluggish. Same
replaced by spare one, change over trial taken & found ok.
Analysis:
Boiler tube leakage in LTSH zone. Total joints = 28 Nos.
Primary failure coil no. 109/1- Brush opened due to overheating.
Secondary failure coil no. 108/1, 108/2, 108/3
110/1, 110/2, 110/3
111/1, 111/3, 111/4
Recommendation:
1) Damaged tube replaced.
2) All terminal tubes inspected visually for overheating. No signs of overheating
seen.
3) Damaged sample sent to BHEL for detailed analysis.
Remark: Nil.
Page. 15

EVENT ANALYSIS
UNIT NO: 6
Event No: M7/ 2005
Date: 14/06/2005
Time: 11:30 Hrs.
Load: Description: After trial of F/F diesel pump No. 4.
a) Flame (fumes are observed near exhaust manifold).
b) Rubber elbow of turbocharger outlet was displaced.
c) Pump discharge line NRV passing and pump rotating in reverse
direction.
Observation: Nil.
Action Taken: NRV checked out.
Analysis:
Pump discharge line NRV failure, is the cause for reverse direction of pump,
trimming camshaft, lub. Pump etc. As a result of which pressurized air entered in
to the oil of suction air filter. The oil drops spread over exhaust manifold and
fumes are produced.
Recommendation:
1) F.C. NRV may pl. be provided, to diesel pump, as provided for AWP / non-DM
pumps.
2) EE T / M-II to include the activity of NRV inspection in them. Prevention maint.
schedule of the pump
Remark:
1) Pump NRV operation should be checked periodically after 3 month by open
discharge valve. It found detective operation would inform the same to maint.
Sect. for repairs maint. Sect. Will inspect NRV after every fixed month.
2) To prevent reverse rotation of pump ratchet arrangement need to be provided.
Page. 14

EVENT ANALYSIS

UNIT NO: 6
Event No: 05/ 2005
Date: 06/05/2005
Time: 17:07 Hrs.
Load: 450 MW

Coal cycle in service: A B C F G H

Oil support: Nil.

Description: At 15:40 Hrs. furnace draft shooted-up to +50 mmwc, DM make-up. 100 to
110 T / Hrs. boiler checked up. It was observed that there is tube leakage at 51
meters, level (RHS) near LRSB 127-129, load reduced and boiler hand tripped at
17:07 Hrs.
Observation:
1) Gl Gun A B 2,3 spark rod.
3
2) BS-5 valve sheet decoupled from steam. Boiler hand tripped and handed at
17:00 Hrs. Boiler relight at 19:15 Hrs. after attending problem of BS-5 valve.
Primary Failure:
1) Tube no.4 found eye opened near Eco. outlet header between hanger tube 1 &
2 due to flue gas erosion.
2) Tube no.6 & 7 found eroded due to flue gas erosion.
3) Tube no.3, 4, 5 found eroded due to flue gas erosion.
Secondary Failure:
1) Tube no.1 & 8 found eroded.
2) Tube no.5 found dislocated between hanger tubes no.1 & 2 due to reaction.
3) Tube no.1 found eroded, lifting of assays for access of tube of assays no.64.
Action Taken: Nil.
Analysis:
Coil no.128 / 4 burst opened due to flue gas erosion below Eco outlet header.
Coil no.127 / 4 flue gas erosion.
Coil no.129 / 1- Erosion.
Coil no.127 / 5 dislocated.
Coil no.126 / 6 dislocated.
Recommendation:
1) CBD valve may be connected to regulating to meet the emergency of drum level
control drip failure of BS 4 LBS 5 valve.
Page.12

2) There is no appreciable gain in reversal of coils. Hence complete assembly of

coil shall be replaced. It is proposed to replace all Eco coils (upper zone) during
OH in Dec 2007.
Remarks: Nil

Page.13