Project : CPCL Frame V GT, units 1 & 2

Problem: Failure of rotary flow dividers of fuel supply line to

GT Combustion chamber
The flow dividers of M/s Ropar make supplied to Gas Turbines at
CPCL site were not performing well during commissioning phase of the
Gas Turbines, due to various reasons. All the four flow dividers
supplied in both On base and Off base skids have failed. The
condition of the flow dividers were such that one or two could not be
even rotated slightly. There were no flow dividers available with
manufacturing units or with any authorized service agency.
Complete
commissioning was held up leading to non-completion of
contractual obligations. Replacement against insurance will be a longdrawn affair, which will not meet neither BHEL nor
CPCLs
requirements. Hence the flow dividers were serviced at site.
All the flow dividers have been working satisfactorily since servicing,
for around 10000 hours and hence it was strongly felt that servicing
would restore the healthiness.
Engineers from hyderabad
have also
felt that
servicing
had
extended the life of flow dividers beyond the normal 8000 working
hours. The entire works were carried out in a controlled, closed and
clean environment. Sufficient care was taken to ensure availability of
proper tools, required lifting arrangements, etc. Before disassembly,
all the components were match marked. The self-locking bolts were
replaced in the probe gear wheel.

During assembly at every stage of plates assembly, care was taken to

check the freeness for rotation, condition of O rings, etc. The gears

in the gear pumps were very high degree of finish

were very close, at the order of less than 0.l
scratch affects the freeness of rotation. The sun
planetary gears and does not allow differential
plates are isolated with O rings.

and the clearances

mm. Even a minor
gear locks all the
flow. All the ring

Collection of paste like ferrous matter on the needle bearing holding

areas was observed. The bearings were soaked in naphtha and the
paste like ferrous matter was
cleared. The bearings are to be
absolutely clean and in good condition, after cleaning. Initially it took
3-4 days to service one flow divider. But later on one flow divider
could be easily serviced in a day. By now, the customer & Hyderabad
Engineers have been acquainted with the art of servicing after
witnessing the servicing of flow dividers carried out by our Engineers.
Thus, we could save the total cost of replacements, cost of contract
extensions and insurance, etc.
The figures in the next few pages explain the various steps in assembly
and the construction features

RING TYPE
SOLID PLATES
WITH LIFTING
LUGS, 'O' RINGS
FOR
ISOLATION

10 NO. OUTLET
TO COMB.
CHAMBER
1 NO.
FUEL OIL
INLET

I
II

III
IV

BUSH IN ALL
HOLES SHALL BE FREE

I
TOP PLATE WITH SPEED PICK
UP WHEEL

II

II PLATE WITH GEAR PUMP

SPINDLE, BUSH AND LOCKING
ARRANGEMENT

III
IV

III PLATE HOUSING 10 NO. GEAR

PUMPS

NEEDLE BEARINGS FOR PUMPS

IV

PLATE HOUSING 20 NO.

V
BOTTOM END PLATE WITH OIL INLET AND OUTLET
CONNECTIONS

LIFTING LUG

TOP PLATE

GEAR OF
ONE PUMP

'O' RING
NEEDLE BEARINGS
RING PLATE WHERE
NEEDLE BEARINGS LOCATED

PLANETARY GEAR

10 NO. GEAR PUMPS

PLATE HOUSING GEAR PUMPS

MESHED WITH PANETARY GEAR

The following important precautions to be taken to ensure good servicing

of the flow divider.
01. During assembly the bush inserted in all the holes shall go free.
02. All the bolts shall be tightened uniformly.
03. All O rings of required dimensions, new and required quality shall
be used.
04. Gear pumps and gear shall be checked for scratches, clearances
are in the order of 0.015 mm.
05. During assembly at every stage check for free rotation of gears.
For this, just if the probe stem is rotated with thumb and finger
it shall rotate the gears.
06. In a good serviced divider with the index finger and middle finger
in the probe gears, it shall be possible to rotate freely.
07. Ensure the divider is not dummied/blocked in suction and discharge
sides.
08. Servicing shall be carried out in a clean and closed environment.
09. Pure naphtha was filled in vessels and bearings were soaked for 24
hours.
10. Plastic toothbrushes were used for removing contaminants.
11. Uniformly free rotation is important than free rotation itself.