Documente Academic
Documente Profesional
Documente Cultură
TS TIDINGS
RAIGARH TPP
OCTOBER
VOLUME
: 2010
: 14.05
AMARKANTAK UNIT 5:
72 hours
full
was completed.
was completed.
MUDDANUR UNIT - 5 :
KOTHAGUDAM UNIT - 11 :
OCTOBER 2010
TS TIDINGS
INSIDE
Feed backs and suggestions from all departments of BHEL for improvement of TS
TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER
(TSX)/BHEL-PSSR/CHENNAI
OCTOBER 2010
TS TIDINGS
Unit was
synchronized
preparations.
TG PG test (100% and 80% load) , auxiliary power consumption test and Boiler
PG test were completed successfully and MOM signed on 30.10.2010.
NALCO - UNIT 9 :
Unit is running at
NALCO UNIT 10 :
Calibration
Unit was stopped on 09.10.2010 due to HPCV-2 drain line leakage and was
attended and cleared for unit start up.
Calibration of hot air damper and cold air damper for mill AB was completed.
AC-JOP suction line modification was carried out as per revised scheme. ACJOP alignment of new pump and pump trial were completed.
OCTOBER 2010
TS TIDINGS
4 hours trial
run of Mill CD lube oil motors and
drive lube oil motors were
completed.
ESP : Charging of ACP and controller panels was completed. ESP A pass
CERM, EERM & GDRM trial
run was completed. Dummy
load test of all
field controller panels was carried out in ESP A pass. OCC and SCC tests
for five rectiformers were completed.
BFP B motor trial run was completed and released for alignment and coupling.
tracking was
carried out.
completed.
was
completed at unit
auxiliary
KRL KOCHI :
GT was
running around 17MW with around 40 TPH HRSG steam flow.
tripped on 11.10.2010, as PLC both processors got hanged.
During restarting flow divider was found jammed. After attending to the flow
divider problem, GT was restarted on 14.10.2010.
Presently GT is
running
was completed
It
and charged.
OCTOBER 2010
TS TIDINGS
RAICHUR UNIT 8 :
down since
21.09.2010
due to
ID fan
on 10.10.2010 and loaded to
80 MW with
ID fan A
on 14.10.2010.
Trial run
8 hours
Fibre optic cable from CW pump house to control room was laid and all the
CW pump house parameters were checked from control room.
fan motor
and
completed.
DC scanner air
fan motor
trial
run
was
were
completed.
OCTOBER 2010
TS TIDINGS
GD test
of
was completed.
KUTTIYADI UNIT 1 :
balancing
72 hours
full
11.10.2010.
load trial
work,
operation
unit
was
was synchronized
completed
successfully
on
on
KUTTIYADI UNIT 2:
Nozzle 1 & 3
72 hours
full load
30.10.2010
trial
operation
completed
successfully on
VIJAYAWADA UNIT 7:
Unit was synchronized on 03.10.10 after erection of PG test flow nozzle and
attending to EHTC problem.
to attend to
replacing the
GT - Y phase
same, unit was
OCTOBER 2010
TS TIDINGS
KAKATIYA UNIT 1 :
Unit was under shut down since 07.10.2010 due to PA fan A NDE
bearing failure Unit was synchronized on 13.10.2010 and loaded to 200
MW.
Mill D scrapper
test
was
completed on
02.10.10
in the presence of
LDO pump A was run and fuel was charged upto all four corners.
SG-DMCW pumps A & B were run after attending to the seal leakage and
jamming problem.
DMCW lines flushing in CC pump cooling water suction side was carried out.
on 13.10.2010.
draught system was established.
erected.
OCTOBER 2010
TS TIDINGS
4 hours
Stage 1 to stage 2
completed.
LT-APRDS
& B for
was
SAT & UAT were charged for the first time and power extended to boards.
SA fan - 1B motor and IA compressor motor cable hi-pot test was carried
out.
Detergent flushing motors trial run for 4 hours was carried out.
OCTOBER 2010
TS TIDINGS
OCTOBER 2010
10
TS TIDINGS
Shifting of total turbine rotor along with combined thrust and journal bearing in
axial direction towards Generator by 1 mm when compared to previous assembly
position ( 2008).
Heavy pitting and impression were found in axial key contact areas of thrust
cum journal bearing no.2 and the pedestal along with slight pitting on the
spherical piece/spherical support (right side).
OCTOBER 2010
11
TS TIDINGS
The thrust cum journal bearing No.2 along with its support was replaced by new
one purchased from M/s .BHEL/Hardwar.
Axial key pitting marks in the pedestal were removed by grinding and matching
was ensured.
Turbine cold rolling was done on 18.09.2010. The load could not be raised beyond
115 MW due to very high value of vibration at bearing No.2 pedestal.
On 19.09.2010, the turbine was hand tripped as the pedestal vibration at bearing
no.2 reached the trip value of 45 microns. Again turbine rolling was done and the load
was raised gradually up to about 190 MW. The pedestal vibrations were found to be
higher compared to prior levels of the above rectification works.
Machine vibrations are changing and sometimes allowing to synchronize and load.
Sometimes even synchronization was not possible. It is attributed to self aligning
problem as the bearing No.2 is of self aligning type.
Unit got tripped on some other protection on 20.09.2010. Again while the unit was
brought back into service, the vibration values at HP front and HP rear shaft went
beyond trip level( more than 200 microns) and hence the unit was hand tripped.
REINSPECTION WORKS CARRIED OUT:
Further to forced shut down, inspection and rectification works were carried out by
BHEL-SAS from 01.10.2010 to 09.10.2010 . The major defects noticed are given
below in brief.
OBSERVATIONS ON DISMANTLING:
Bearing No.2 level was checked using master level at P/P and found to have a slope
of 0.85 mm/meter (High at turbine side i.e., front).
When bottom half was removed and inspected, it was observed that the contact
between torus and support was only on the right side with slight pitting.
OCTOBER 2010
12
TS TIDINGS
The support was removed form location and checked .The measurement reveal slope
as follows
L-R slope at front 0.16 mm over 700 length
L-R slope at rear 0.24 mm over 700 length
No significant slope in front-rear
Support seating surface inside the pedestal was checked and the measurement
levels slope as follows.
Front to rear slope of 0.20 to 0.24 mm over 280 mm width
No significant slope in L-R
RECTIFICATIONS:
Bearings 1 & 2 Torus to support matching was done to improve and ensure proper
self aligning of the bearings as the existing contact was limited.
Pedestal 1&2 loading packers were removed, eased and put back.
OCTOBER 2010
13
TS TIDINGS
BrgNo
Shell vibrations
(microns)
Shaft vibrations
16
127
21.5
88
50
16
65
5(V/H)
14/8.5
6(V/H)
11/6
(microns)
Prepared by :
V.Naga Raju,
Jr.Executive(Engg)
Staff No : 2767554
BHEL-PSSR-SAS
Secunderabad.
14
OCTOBER 2010
TS TIDINGS
FEEDBACK NO. 2
PROJECT : KOTHAGUDAM UNIT 11 (500MW)
PROBLEM : JAMMING AND SEAL LEAKAGE OF SGDMCW PUMP
Problem Detail:
Two Nos. SG DMCW Pumps were supplied by M/s FlowMore Ltd at KTPS Unit XI .
Pump B was first commissioned on 02/10/2010 after completion of flushing with
ACW water and subsequently with DMCW water. High vibration and noise was heard
during first trial run. After 4hrs, when pump was stopped, it got jammed.
Pump casing was opened. Pebbles, welding slag and rust were found in the casing
and NDE side wear ring was found jammed on to the impeller. It was cleaned by light
emery polishing, and pump was reassembled. During the reassembly, the DE / NDE
end seal face covers were found having pin holes at parting plane through which,
water was leaking profusely upon charging. Hence for attending the same, pump had
to be opened 4 times and finally silicone sealant was applied to arrest the leak.
Suction line and discharge lines flushing with DM water was thoroughly done and
pump was reassembled after realignment. During running of pump, high vibration was
observed along with heavy NDE seal leak. Pump was hand tripped and got jammed.
Again upon opening of the pump casing, NDE wear ring was found struck up in impeller
and rubbing/ scoring marks were observed on the impeller wear ring area. Polishing
was carried out on wear ring,.
In spite of repeated efforts by suppliers technicians, the seal leaks, and NDE
wearing jamming in pump B could not be resolved .
On 08/10/2010, a senior pump service engineer was deputed by M/s. Flow more
to assist in rectification of SG DMCW pump. Pump B which was jammed, was opened
in his presence and found that seal got worn out by 0.4mm (slightly) due to dislocation
of spring retention pin (Refer seal drawing),caused by jamming.
Seal was reassembled and pump was run. After 4hrs of trial run, pump was
hard to rotate on coasting down. Entry of foreign materials in the pump casing such
as rust, pebbles etc. were suspected for the problem by M/s FlowMore.
15
OCTOBER 2010
TS TIDINGS
Hence a suction strainer from ACW system was borrowed from customer and
was introduced in common suction header of SG DMCW with one isolation valve.
Thorough flushing of lines was again carried out.
After clearance from piping on 12/10/10, Pump-B was run for 20 min. After
stopping, again it got jammed. Minor buffing on NDE wear ring saw it run for 72hrs
continuously. But upon stopping it again got jammed.
Resolution:
Pump B was opened and the wearing ring to top casing blue contact was
checked. It was found that there is no contact of top half casing with the wearing
ring due to higher 2.5mm parting plane gasket thickness put at shop. Hence during
servicing the wearing ring was getting jammed. It was corrected by introduction of
1mm parting plane gasket. The wearing ring was also found to be oval and hence both
NDE and DE wearing rings ovality were removed. After box up of pump B it was
rotating freely after trial run for 2hrs. No further correction was necessary.
16
OCTOBER 2010
TS TIDINGS
17
OCTOBER 2010
TS TIDINGS
Conclusion:
In the absence of site specific O&M manuals / drawings site had to waste
precious erection and commissioning time in attending trivial problems probably caused
by poor assembly / testing of these pumps at works.
However, introduction of suitable suction strainers can be made as permanent
feature in closed CW systems were foreign material entry is inevitable during initial
commissioning. Higher size DMCW piping is being TIG welded as per plan. However
TIG welding of piping less than 200NB also needs to be introduced in place of arc
welding in the quality plan for erection.
OCTOBER 2010
18
TS TIDINGS
19
OCTOBER 2010
TS TIDINGS
Figure 1:Typical protection Scheme For a 100 MW Generator along with Gen Transformer and Unit
Transformer
20
OCTOBER 2010
TS TIDINGS
The phase distance function (21) is designed for system phase fault backup
protection and is implemented as a two-zone mho characteristic. Three separate
distance elements are used to detect AB, BC, and CA fault types. The diameter,
offset, system impedance angle (relay characteristic angle), and definite time delay
need to be selected for each zone for coordination with the system relaying in the
specific application.
Typically the first zone of protection is set to an impedance value enough in
excess of the first external protective section (typically the unit transformer) to
assure operation for faults within that protective zone. (See Figure 2, Phase Distance
(21) Coverage.)
A negative or positive offset can be specified to offset the mho circle from the
origin. This offset is usually set at zero. (See Figure 3, Phase Distance (21) Function
Applied For System Backup.) The impedance angle should be set as closely as possible
to the actual impedance angle of the zone being protected. The time delays are set
to coordinate with the primary protection of those overreached zones and, when
applicable, with the breaker failure schemes associated with those protective zones.
The Phase distance Second stage zone settings can be set for the second
external section of protection on the system (typically transmission Zone 1 distance
relays) plus adequate overreach.
OCTOBER 2010
21
TS TIDINGS
Volts/Hz (24)
The overexcitation protection is used to detect impermissible overexcitation
conditions which can endanger generators and transformers. The overexcitation
protection must pick up when the induction admissible for the protected object (e.g.
power station unit transformer) is exceeded. The transformer is endangered, for
example, if the power station block is disconnected from the system from full-load,
and if the voltage regulator either does not operate or does not operate sufficiently
fast to control the associated voltage rise. Similarly, decrease in frequency (speed),
e.g. in island systems, can endanger the transformer because of increased induction.
An increase in induction above the rated values leads very quickly to saturation
of the iron core and to large eddy current losses.
The overexcitation protection feature servers to measure the voltage/frequency
ratio which is proportional to the B induction and puts it in relation to the BN nominal
induction. In this context, both voltage and frequency are related to nominal values of
the object to be protected (generator, transformer).
22
OCTOBER 2010
TS TIDINGS
OCTOBER 2010
23
TS TIDINGS
Voltage controlled:
Voltage restraint:
OCTOBER 2010
24
TS TIDINGS
25
OCTOBER 2010
TS TIDINGS
26
OCTOBER 2010
TS TIDINGS
27
OCTOBER 2010
TS TIDINGS
28
OCTOBER 2010
TS TIDINGS
29
OCTOBER 2010
TS TIDINGS
For generators that are paralleled to a power system, the preferred method is
to monitor for loss of field at the generator terminals. When a generator loses
excitation power, it appears to the system as an inductive load, and the machine
begins to absorb a large amount of VARs. Loss of field may be detected by monitoring
for VAR flow or apparent impedance at the generator terminals. The power diagram
(P-Q plane) of Fig. 9 shows the characteristic with a representative setting, a
representative generator thermal capability curve, and an example of the trajectory
following a loss of excitation. The first quadrant of the diagram applies for lagging
power factor operation (generator supplies VARs). The trajectory starts at point A
and moves into the leading power factor zone (4th quadrant) and can readily exceed
the thermal capability of the unit. A trip delay of about 0.2-0.3 seconds is
recommended to prevent unwanted operation due to other transient conditions. A
second high speed trip zone might be included for severe underexcitation conditions.
Figure 9: FOR LOSS OF FIELD THE POWER TRAJECTORY MOVES FROM POINT A INTO THE
FOURTH QUADRANT.
OCTOBER 2010
30
TS TIDINGS
When impedance relaying is used to sense loss of excitation, the trip zone
typically is marked by a mho circle centered about the X axis, offset from the R axis
by X'd/2. Two zones sometimes are used: a high speed zone and a time delayed zone.
Figure 10:
With complete loss of excitation, the unit will eventually operate as an induction
generator with a positive slip. Because the unit is running above synchronous speed,
excessive currents can flow in the rotor, resulting in overheating of elements not
designed for such conditions. This heating cannot be detected by thermal relay 49,
which is used to detect stator overloads.
Rotor thermal capability can also be exceeded for a partial reduction in
excitation due to an operator error or regulator malfunction. If a unit is initially
generating reactive power and then draws reactive power upon loss of excitation, the
reactive swings can significantly depress the voltage. In addition, the voltage will
oscillate and adversely impact sensitive loads. If the unit is large compared to the
external reactive sources, system instability can result.
31
OCTOBER 2010
TS TIDINGS
OCTOBER 2010
32
TS TIDINGS
Frequency Protection(81)
The frequency protection function detects abnormally high and low frequencies
in the system. If the frequency lies outside the allowable range, appropriate actions
are initiated, such as separating a generator from the system.
TECHNICAL SERVICES / PSSR
33
OCTOBER 2010
TS TIDINGS
34
OCTOBER 2010
TS TIDINGS
35
OCTOBER 2010
TS TIDINGS
Figure 14: Profile of the 3rd Harmonic along the Stator Winding
Moreover, the level of the 3rd harmonic depends on the operating point of the
generator, i.e. a function of the P active power and the Q reactive power. For this
reason, the working area of the stator earth fault protection is restricted in order to
enhance security.
36
OCTOBER 2010
TS TIDINGS
starpoint, the 20 Hz voltage drives a current through the fault resistance. From the
driving voltage and the fault current, the protective relay determines the fault
resistance. The protection principle described here also detects earth faults at the
generator terminals, including connected components such as voltage transformers.
Figure 15: Basic Principle of Voltage Injection into the Generator Starpoint
37
OCTOBER 2010
TS TIDINGS
The rotor earth fault calculation calculates the complex earth impedance from
the auxiliary AC voltage URE and the current IRE. The earth resistance RE of the
excitation circuit is then calculated from the earth impedance. The device also
considers the coupling capacitance of the coupling unit CK, the series (e.g. brush)
resistance Rseries and the capacitance to the earth excitation circuit CE. This
method ensures that even relatively high-ohmic earth faults (up to 30 k under ideal
conditions) can be detected. In order to eliminate the influence of harmonics - such
as occur in static excitation equipment (thyristors or rotating rectifiers) - the
measured quantities are filtered prior to their evaluation
38
OCTOBER 2010
TS TIDINGS
Checking whether the current in all three phases drops below a set threshold
following a trip command,
Evaluating the position of a circuit breaker auxiliary contact for protective
functions, with which the current criterion is perhaps not expressive, e.g.
frequency protection, voltage protection, rotor earth fault protection.
If the circuit breaker has not opened after a programmable time delay (breaker
failure), a higher-level circuit breaker can be initiated for the disconnection
OCTOBER 2010
39
TS TIDINGS
OCTOBER 2010
40
TS TIDINGS
STATION
North Chennai
Neyveli
Raichur
Tuticorin
Ramagundam
Muddanur
Kothagudam
Vijayawada
VTPS - 7
Mettur
Talcher
Simhadri
Sipat
120.00
2009 - 10
87.09
85.42
77.38
78.30
89.07
82.11
93.08
90.69
91.52
85.28
92.97
91.65
PLF
2010 - 11
76.14
84.18
55.45
78.44
92.55
80.36
66.15
73.59
65.39
79.67
84.69
92.90
97.08
2009 - 10
2010 - 11
PLF PERCENTAGE
100.00
80.00
60.00
40.00
20.00
N
or
th
S
ip
at
Ch
en
na
i
N
ey
ve
li
Ra
ic
hu
r
T
ut
ic
Ra
or
in
m
ag
un
da
m
M
ud
da
nu
Ko
r
th
ag
ud
am
Vi
ja
ya
w
ad
a
VT
PS
7
M
et
tu
r
T
al
ch
er
S
im
ha
dr
i
0.00
UNIT