RELIABILITY OF POWER SUPPLY TO

PREVENT TURBINE / GENERATOR FAILURE

TURBINE DEPARTMENT
POWER SECTOR TECHNICAL SERVICES, NOIDA

AGENDA POINTS
FOOL PROOF SCHEME OF POWER SUPPLY (24 V DC, UPS, 220 V BATTERY SUPPLY)
QUALITY OF HARDWARE SUPPLIED BY THE VENDOR OF UPS ETC.
ALARM / TRIP LIMITS OF TURBINE / GENERATOR BEARING METAL TEMPERATURE
CHECKS TO BE CONDUCTED BEFORE STARTING OF TURBINE AFTER AN OIL
STARVATION INCIDENCE
QUALITY OF BEARING BABBIT METERIAL
COMPLETE COMMISSIONING OF ALARMS, INTERLOCK AND PROTECTION SYSTEM
SOFTWARE RELATED ISSUES LIKE FREEZING OF DISPLAY IN MAX DNA ETC
SUMMARY

FEEDBACK OF LEHRA MOHHABAT UNIT NO.3

FEEDBACK OF LEHRA MOHHABAT UNIT NO.3

-

At Lehra Mohhbat Unit no.3, On

04.09.08 unit tripped due to AC

Power failure. DC Supply also failed to take over.

-

Unit came to standstill (0 rpm) within 10 min. Bearing-3 babbit

temperature increased to 126 C

Attempt to bring back the machine under strict supervision was

abandoned due to increasing trend in bearing-3 metal temperature

Bearings 1 & 3 found damaged

FEEDBACK OF LEHRA MOHHABAT UNIT NO.3

Root Cause of Failure
-

DC supply failed to take over due to Inadvertent opening of 220 V DC

Incoming feeder .. Due to this, no breaker could be operated

In this unit, both DC supplies fed from a same Bus

Action Taken
-

Scheme modified to ensure that each DC supply comes from different

bus

Bearing 1 & 3 replaced and machine put on bar

FEEDBACK OF LEHRA MOHHABAT UNIT NO.3

Issues
-

Provision for pad locked for important isolators to avoid any

accidental operation

Identification of sites where similar scheme (both DC feeders from

single Single bus) were supplied and necessary modification in
schemes at the affected sites

As per PEM, Total 9 sites are affected.

STATUS OF AFFECTED SITES

In Three projects : Customer Approval Required / Obtained
S.N.

1.

2.

3.

Rating

2*125
MW

2*250
MW

2*125
MW

PROJECT

220V DC
CONFIGURATION

220V DC FEEDER
DISTRIBUTION

BARSINGHSI
R Ext 1&2

UNIT & STN

UNSECTIONALISED
DCDBS WITH EACH
DCDB HAVING ITS
BATTERY + CHGR
CONNECTED THRU
COMMON BKR

UNIT LOADS
CONNECTED ON
UNIT DCDB &
STN LOADS ON
STATION DCDB
W/O ANY
SEGREGATION
FOR R + S FDRS

NEYVELI

UNIT & STN

UNSECTIONALISED
DCDBS WITH EACH
DCDB HAVING ITS
BATTERY + CHGR
CONNECTED THRU
COMMON BKR

UNIT LOADS
CONNECTED ON
UNIT DCDB &
STN LOADS ON
STATION DCDB
W/O ANY
SEGREGATION
FOR R + S FDRS

SLPP 3&4

UNIT DCDB HAVING

ITS BATTERY + CHGR
CONNECTED THRU
COMMON BKR,
STANDBY DCDB &
COMMON S/BY FCB
CONNECTED TO UNIT
& S/BY DCDB

UNIT LOADS
CONNECTED ON
UNIT DCDB &
STN LOADS ON
STATION DCDB
W/O ANY
SEGREGATION
FOR R + S FDRS

ANY
CORRECTIVE
ACTION
REQUIRED

REMARKS

YES

BOARDS MFRD.
SWAPPING OF
FDRS/ NAME
PLATES/ USAGE
OF SPARES/
CUSTOMER APPL
REQD

YES

BOARDS NOT
MANUFACTURED
. REVISED LOAD
INPUTS GIVEN
TO VENDOR/
CUTOMER APPL
OBTAINED

YES

BOARDS MFRD.
SWAPPING OF
FDRS/ NAME
PLATES/ USAGE
OF SPARES/
CUSTOMER APPL
REQD

STATUS OF AFFECTED SITES

In Four projects : Intimation sent to sites by PEM
S.N.

1.

2.

Rating

2*210
MW

1*500
MW

PROJECT

220V DC
CONFIGURATION

220V DC FEEDER
DISTRIBUTION

BAKRESHWAR
4&5

UNSECTIONILSED
DCDB WITH 1
BATTERY & 2
CHRGRS

R + S FDRs
CONNECTED ON
SAME SECTION

BELLARY

UNIT & STN

UNSECTIONALISE
D DCDBS WITH
EACH DCDB
HAVING ITS
BATTERY + CHGR
CONNECTED THRU
COMMON BKR

R + S FDRs
CONNECTED ON
SAME SECTION

ANY
CORRECTIVE
ACTION
REQUIRED

REMARKS

YES

REDISTRIBUTI
ON OF
FEEDERS AT
SITE
REQUIRED

YES

REDISTRIBUTI
ON OF
FEEDERS AT
SITE
REQUIRED

STATUS OF AFFECTED SITES

In Four projects : Intimation sent to sites by PEM
S.N.

3.

4.

Rating

2*210
MW

1*210
MW

PROJECT

220V DC
CONFIGURATION

RAYALSEEMA 3
&4

UNIT & STN

UNSECTIONALISED
DCDBS WITH EACH
DCDB HAVING ITS
BATTERY + CHGR
CONNECTED TO
COMMON S/BY CHRGR

Rayalseema 5

UNIT & STN

UNSECTIONALISED
DCDBS WITH EACH
DCDB HAVING ITS
BATTERY + CHGR AND
CONNECTED TO
COMMON S/BY CHRGR

220V DC FEEDER
DISTRIBUTION

UNIT R + S
FEEDERs
CONNECTED ON
SAME UNIT BUS

R + S FDRs
CONNECTED ON
SAME DCDB

ANY
CORRECTIV
E ACTION
REQUIRED

REMARKS

YES

SWAPPING OF
FDRS/ NAME
PLATES
BETWEEN
TWO UNIT
DCDBs
REQUIRED.

YES

BOARDS
MFRD.
BUSCOUPLER
TO BE
INTRODUCED
IN DCDB &
FEEDERS
REDISTRIBUT
ED.

STATUS OF AFFECTED SITES

Already implemented at one project
S.N.

1.

Rating

2*250
MW

PROJECT

220V DC
CONFIGURATION

LEHRA
MOHABAT 3 &
4

UNIT & STN

UNSECTIONALISED
DCDBS WITH EACH
DCDB HAVING ITS
BATTERY + CHGR
CONNECTED THRU
COMMON BKR

220V DC FEEDER
DISTRIBUTION

R + S FDRs
CONNECTED ON
SAME DCDB

ANY
CORRECTIVE
ACTION
REQUIRED

REMARKS

YES

REDISTRIBU
TION OF
FEEDERS
ALREADY
CONVEYED
TO SITE FOR
IMPLEMENT
ATION

STATUS OF AFFECTED SITES

At one site, panel are under manufacture at vendor works, same is being modified

S.N.

1.

Rating

1*250
MW

PROJECT

220V DC
CONFIGURATION

SANTALDIH
6

MAIN DCDB
UNSECTIONALISED
WITH 1 BATTERY & FCB
CHGR WITH COMMON
CONN TO BUS & 1 FC
AS S/BY. NO STANDBY
DCDB BUT TIES TO
MAIN DCDB FROM UNIT
-5 MDCDB & S/B DCDB

220V DC
FEEDER
DISTRIBUTION

R + S FDRs
CONNECTED ON
SAME SECTION

ANY
CORRECTIVE
ACTION
REQUIRED

REMARKS

YES

NEW S/BY
DCDB REQD
FOR WHICH
INPUTS
ALREADY
GIVEN TO
VENDOR

STATUS OF AFFECTED SITES

Apart from these affected site, site information seeked regarding 220 V
DC feeder distribution for following two projects, to know whether any
corrective action required or not ?
S.N.

1.

2.

Rating

2*250
MW

2*250
MW

PROJECT

220V DC
CONFIGURATION

220V DC FEEDER
DISTRIBUTION

ANY
CORRECTIVE
ACTION
REQUIRED

MEJIA 5 & 6

SECTIONALISED
DCDB FED BY TWO
SEPARATE
CHARGERS &
COMMON BATTERY

SITE HAS BEEN

RQSTD TO
CONFIRM
FEEDER
DISTRIBUTION
ADOPTED AT
SITE

TO BE
DECIDED
AFTER SITE
FEEDBACK, IF
REQD.

CHANDRAPURA
7&8

SECTIONALISED
DCDB FED BY TWO
SEPARATE
CHARGERS &
COMMON BATTERY

SITE HAS BEEN

RQSTD TO
CONFIRM
FEEDER
DISTRIBUTION
ADOPTED AT
SITE

TO BE
DECIDED
AFTER SITE
FEEDBACK, IF
REQD.

REMARKS

FEEDBACK OF SANTALDIH UNIT NO.5

FEEDBACK OF SANTALDIH UNIT NO.5

-

In this unit, during rolling on 12/08/2008, at 3000 rpm, TG bearing no.3

babbit metal temperature started increasing and unit tripped on high
bearing

metal

temperature

protection.

During

coasting

down

temperature and vibration of all bearings shoot up. All bearings got
damaged.

FEEDBACK OF SANTALDIH UNIT NO.5

-

Earlier, in this unit, on 06/08/08, due to failure of UPS (240 V AC,

Single Phase) supplies power to control room computers and 24 V DC
supplied failed. Due to this, machine trips and record of coasting down
time, bearing metal temperature, vibration, vacuum, lube oil, jacking
oil, lube oil temperature and other operating parameters including
SOE / Trend charts could not be available for about 43 minutes

No oil pumps started on Auto.

During UPS failure, the unit suffered Oil starvation, which went
undetected

FEEDBACK OF SANTALDIH UNIT NO.5

UPS supplier :- M/s HIREL (Vendor of EDN Bangalore)
As per failure analysis report of UPS supplier:-

UPS tripped on SAT (Saturation) trip fault

Reduction of bypass stabilizer output voltage to 210V (Against rated

voltage of 240V)

On testing, it was found

-

One of the buffer card (phase shift) found damaged

Bypass stabilizer voltage was low due to failure of capacitor in

stabilizer main control board.

FAILURE ANALYSIS REPORT SUBMITTED BY UPS SUPPLIER

UPS SCHEME

AT SANTALDIH, RATED OUTPUT

OF AUXILIARY PANEL (BYPASS
TRANSFORMER

AND

SERVO

VOLTAGE STABLIZER) IS 240 V

AC SINGLE PHASE, WHICH WAS
DROPPED TO 210 V DUE TO
CAPACITOR FAILURE

FEEDBACK OF SANTALDIH UNIT NO.5

Action taken
-

All bearing replaced

During restart, following checks carried out

- Direct starting of DC Emergency oil pump from pressure switch
after switching off the UPS power supply
- Availability of Alarms for failure of UPS system

FEEDBACK OF SANTALDIH UNIT NO.5

Issues
-

Incomplete commissioning
- Checking of start of DC EOP from pressure switch
- Alarms of UPS failure
- Availability of SoE, Trends charts prior to rolling

Poor quality of UPS hardware and incorporation of adequate alarm

system

ALARM / TRIP LIMIT OF TURBINE /

GENERATOR BEARING BABBIT METAL
TEMPERATURE

Combined Journal Cum Thrust Bearing

Journal Bearing

ALARM / TRIP LIMIT OF TURBINE / GENERATOR

BEARING BABBIT METAL TEMPERATURE
As per KWU manual for 210 / 250 / 500 MW machines

ALARM / TRIP LIMIT OF TURBINE / GENERATOR

BEARING BABBIT METAL TEMPERATURE
Giral :- 125 MW, KN Series Turbine
-

At 3000 rpm, temperature of brg no.1 found increasing and machine

was stopped at temperature of 94 deg.C.

During coasting down, value of temperature went upto 140 deg.C

Bearing no.1 found damaged

ALARM / TRIP LIMIT OF TURBINE / GENERATOR

BEARING BABBIT METAL TEMPERATURE
Mejia -5 250 MW, KWU Turbine
-

At load, temperature of brg no.1 found increasing and machine did

not trip on High brg metal temperature protection because only 1 point
(BR) went above trip value (130 deg.C)

During coasting down, value of temperature went upto 140 deg.C

Bearing no.1 found damaged.

ALARM / TRIP LIMIT OF TURBINE / GENERATOR

BEARING BABBIT METAL TEMPERATURE
Lehra Mohhabat unit no.3, 250 MW, KWU Turbine
-

On 16.12.2008 Turbine tripped due to grid disturbance from full load

.Machine overspeeded to 3300 rpm and during coasting down high
bearing vibration were observed on bearing number 3 while passing
critical speed .

After this trip,during restart on the same day babbit temp. of this
bearing was 125 at front and 92 at the rear of the bearing. Customer
decided to keep the unit in operation and was stopped for bearing
inspection after few days of operation on load.

ALARM / TRIP LIMIT OF TURBINE / GENERATOR

BEARING BABBIT METAL TEMPERATURE
Lehra Mohhabat unit no.3, 250 MW, KWU Turbine
-

Bearing#3 found damaged. After replacing bearing and flushing of

luboil line machine started and loaded to full load without any problem

Present difference in babbit metal temp. between front and rear is

within 4 degree centigrade at 3000rpm as well as full load and is
approx.80 degree centigrade.

Issues
-

Quality of babbit

Review of Alarm / Trip limit value for bearing metal temperature

Redundancy of bearing metal temperature protection need to be

examined (2 out of 4 logic)

Instruments became faulty if difference in bearing metal temperature

measurement of two points is about 3% .It is to be reviewed

CHECKS TO BE CONDUCTED AFTER AN OIL

STARVATION INCIDENCE

Checks to be conducted after an Oil Starvation Incidence

Bearing Inspection
-

Heavy loaded bearing (Brg no.3 /4)

Bearings which has faced maximum temperature

Bearings which has faced temperature more than trip limit of brg metal
temperature

All the bearings

Checks to be conducted after an Oil Starvation Incidence

Turbine Insulation
-

At Santaldih -5, due to non-replacement of oil soaked turbine

insulation, fire incidence occurred twice and later decision was taken
to replace the insulation with new. Lot of time wasted on account of
this.

Replacement of oil soaked Turbine Insulation with new one to avoid

Fire incidence during restart

Checks to be conducted after an Oil Starvation Incidence

Checking of Alarm, Interlock, Protection of oil system
-

Checking of start of DC EOP from direct pressure switch in case of

UPS / 24 V DC supply failure

Ensure availability of emergency power (DG set) prior to next start up

Checking of all SLC of oil system

Starting of DCJOP at 2800rpm in case of AC power failure as per Hwr

technical circular no. X-59 (May 1997)

COMPLETE COMMISSIONING OF ALARMS,

INTERLOCK AND PROTECTION SYSTEM

COMPLETE COMMISSIONING OF ALARMS,

INTERLOCK AND PROTECTION SYSTEM
Commissioning of Alarms, Interlock and Protection System prior to
first rolling and synchronization
-

Interlock and protection of oil system

Alarm

Sequence of Events

Trend Charts

Configuration of operating parameters to historian

COMPLETE COMMISSIONING OF ALARMS,

INTERLOCK AND PROTECTION SYSTEM
Delay in commissioning of DG set (in EPC projects)
-

It has been observed that, DG may not be available during initial

rolling / synchronization due to non availability of buildings / cabling /
time constraint etc.

OTHER ISSUES

Turbine Trip Circuit

Remote Main Turbine Trip Solenoid of 210 / 250 / 500 MW KWU machine
-

Energise to Trip

No Alarm for Power Supply failure

Whether with 24 V DC supply failure, Turbine trip solenoid will trip or not

Kahalgon Feedback
-

Recently at Kahalgaon, Turbine did not tripped on protection due to

turbine trip solenoid (TTS) supply switch in off condition. (There breaker
QF 26 of CIJ 05 & 06 was found dropped and as a result of this supply to

A101 & A 201 also failed resulting in failure of power to TTS)

Issue : Need to relook into the Power Scheme and Alarm Scheme of
trip circuit

FEEDBACK ON HANGING OF MAX DNA DPUs

-

Failure of maxDNA systems reported from New Parli unit no.1. On

investigation by EDN ad PSWR engineers, it was found that this
happens due to fluctuation in 24V DC supply and Non renewable of
antivirus license

ISSUES:-

Fluctuation in 24V DC supply.

License for antivirus software renewal.

OVERLOAD PROTECTION OF DC EOP

In one of the 250 MW, KWU Turbine (Mejia)
-

Once during the power supply failure, DC EOP started but tripped due
to blowing of fuse (overloading) but, nothing happened as rotor came
to stand still before tripping of DCEOP.

ISSUE:-

Overload protection need to be examined.

THANK YOU