INSUALTION REPORT

Executive Summary: Insulation system was found to be one of focus area of study for power plant study and optimization during walk down audit of the plant. A detailed audit was carried out using Infrared Thermography camera as well as site observations to identify area of insulations where heat loss was more than expected. In a good insulation system the outer skin temperature should not exceed 55 degree c. the tolerance limit was deliberately chosen low considering high cost of energy of IOCL where the main source of heat is oil and RLNG. The root cause of problem is poor workmanship and lack of coordination between maintenance and civil maintenance group looking after maintenance. However looking at the gravity of problem the root cause of the problem is structural deficiency which is evident from lack of ownership of the insulation system. Recommendations: It is recommended to reassign the task of insulation to Mechanical Maintenance or Operation group of Power Plant either in whole or in part but quality inspection should definitely lie with power plant. A time bound action plan is to be drawn to dilute all observations of this report and re -audit is to be carried out either by a independent agency or by a cross functional group of IOCL. A strong quality checklist should be developed and implemented All contractor worker deployed for insulation work should be trained. Root cause analysis of problem and action plan: Root cause of problem is structural deficiency. At present insulation system is being maintained by civil maintenance group. Lack of ownership was evident from insulation condition in many areas and from interaction with the people who were carrying out insulation work at site. Lack of coordination between outage and insulation work is evident in many areas. If the surface temperature is more than 200 C, the radiation loss is also taken into consideration. 5.4 The heat losses were calculated only for those areas, where the temperature is higher than the norm. 5.5 The high temperature zones were identified and their images were numbered for proper traceability/ reference w.r.t the identified action plan to be taken by the maintenance personnel. 6. BASIS OF HEAT LOSS CALCULATION Formula used for Heat Loss estimation if the temperature is < 200 Deg C: Q = (10 + (Ts - Ta) / 20) x (Ts - Ta) in Kcal / m2/ hr Where Ts = Surface Temperature in C Ta = Ambient Temperature in C Heat loss = Q x Area of the surface (m2) If Surface Temp > 200 Deg C the heat loss is calculated based on the following formula: Where S = Total heat loss E = Emissivity a = Area of the surface Ta = ambient Temperature in deg C Ts = Surface Temperature in deg C For estimation of heat loss reduction, the target temperature is taken as 55 C. OBSERVATIONS.& RECOMMENDATIONS; . There are areas of losses where insulation is damaged. These are to be corrected. The un-insulated areas like valves, flanges, steam turbines etc have high temperatures. An insulation spray eg. nonsulate may be applied where it is not possible to insulate with glass wool.