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INSPECTION
HPT INNER CASING REFINNING BLADE LOOSENESS/SHROUD GAP
OBSERVATIONS
PARTIAL REFINNING AT BHEL RC PURAM NIL
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4
BLADE DEPOSITS
TG BEARING INSPECTION
NORMAL
UT&DPT , OK
INSPECTION
LPT ROTOR AND BLADES MPI FREE STANDING BLADES NFT BLADE DEPOSITS BEARING INSPECTION
OBSERVATIONS
LP-1R 08 BLADES REPLACED (6 ROOT CRACKS & 2 NFT) LP-IL 04 BLADES REPLACED DUE TO ROOT CRACKS NORMAL UT&DPT , OK
HPT EVACUATION SYSTEM ORIGINALLY NOT ENVISAGED. INSTALLED AND COMMISSIONED IN 2006. SYSTEM IN SERVICE. LOGIC OF VALVE CLOSING ON TURBINE START UP TO BE REVIEWED.
ON 10.08.2009 FROM 16:30 HRS, TURBINE SHAFTS & BEARINGS VIBRATIONS STARTED INCREASING & FLUCTUATING. BEARING NO.1 VIBRATION REACHED 45 MICRONS FROM 13 MICRONS AND SHAFT VIBRATION AT BRG No.1 REACHED 125 MICRONS FROM 75 MICRONS. BEARING NO.1 TOP RIGHT SIDE TEMPERATURE INREASED FROM 79 TO 100 DEG. UNIT WAS STOPPED AT 08:03 HRS ON 11.08.2009 FOR INSPECTION AND RECTIFICATION. TG CAME ON BARRING GEAR. CONTROLLED COOLING OF TURBINE CARRIED OUT AS PER LMI. BARRING GEAR STOPPED AT 16:00 HRS ON 14.08.2009. OIL PUMPS STOPPED AT 09:00 HRS ON 15.08.2009.
AFTER TURBINE COOLING, HAND BARRING WAS NOT FREE AND RUBBING SOUNDS OBSERVED AT HPT REAR SIDE.
AFTER DECOUPLING LPT ROTOR ALSO, HP-IP ROTOR SYSTEM HAND BARRING WAS NOT FREE. AFTER DECOUPLING IP ROTOR FROM HP ROTOR, IP ROTOR WAS FREELY ROTATING, BUT HP ROTOR NOT ROTATING.
AS HPT ROTOR WAS NOT FREE, HPT EXHAUST (CRH/HRH) CIRCUIT WAS CHECKED FOR ANY BLADE/FIN DEBRIS. METALIC DEBRIS (FIN MATERIAL) FOUND AT HPT EXHAUST WHEN INSPECTED THROUGH EXHAUST PIPE STEAM WASH CONNECTION FLANGE. HRH STEAM CIRCUIT WAS INSPECTED. METALIC DEBRIS FOUND COLLECTED AT HRH STRAINERS,HRH DRAIN POT, HRH HEADER AT BOILER . THE ABOVE OBSERVATIONS INDICATED HPT MOVING/STATIONARY BLADES FAILURE.
PHOTOS
HPT EXHAUST
HRH STRAINERS 1,2,3,4 HRH DRAIN POT CRH INLET HEADERS (BOILER) CRHNRVs MS STRAINERS 1-4 CONDENSER HOT WELL
BASED ON ANALYSIS OF MACHINE VIBRATIONS AND SUBSEQUENT INSPECTION/OBSERVATIONS , PLAN FOR UNIT RESTORATION UNDER BHEL SUPERVISION WAS MADE AS REPLACE HPT MODULE WITH SPARE MODULE WHICH WAS READILY AVAILABLE AT SINGRAULI. INSPECTION OF IPT AND LPT MODULES ALSO, AND CARRY OUT COMPONENTS INSPECTION AND NDT.
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SPARE HPT MODULE TRANSPORATED FROM SINGRAULI TO RAMAGUNDAM IN 10 DAYS. MODULE REACHED RAMAGUNDAM ON 05.09.2009. IPT BLAST CLEANING IPT CASINGS AND ROTOR MPI DONE, OK. TG BEARINGS DPT & UT ,OK.
ROTOR BLADE GROOVE MPI : ONE BLADE ROOT CRACK IN 1R FREE STANDING BLADESNFT: NORMAL
TG BEARINGS INSPECTION
: DPT &UT
IN MPI OF LP ROTOR, A CRACK WAS DETECTED AT BLADE ATTACHMENT (STEEPLE) AREA AT STAGE 1R OF THE ROTOR. THIS IS FIRST OBSERVATION IN 500 MW LP ROTOR IN NTPC. LPT ROTOR WAS REPLACED WITH POOL SPARE ROTOR (FULLY BLADED ROTOR) WHICH WAS PARKED AT RAMAGUNDAM
HPT MODULE AND LPT ROTOR REPLACEMENT NECESSITATED REAMING AND HONING OF COUPLING HOLES IN HP-IP,IP-LP & LP-GEN COUPLING.
HRH STEAM LINE STEAM BLOWING SCHEME WAS FINALISED IN CONSULTATION WITH CC/OS . STEAM BLOWING WAS CARRIED OUT AT 25 KSC PRESSURE THROUGH 100NB PIPE WITH MOV AND TARGET PLATE.
UNIT WAS RESTORED ON 23.09.2009 IN 43.5 DAYS. MACHINE VIBRATIONS AND OTHER PARAMETERS ARE NORMAL
THANK YOU
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