PROBLEM :

HP STOP VALVE TRIPPING SUDDENLY AFTER LOADING

PROJECT : Problem :

RAMAGUNDAM UNIT-7 500 MW

During the first commissioning trial of this Unit, the HP Stop valve (left) was tripping suddenly after unit was run on load for a few hours at 100 MW. This happened a couple of times and caused turbine tripping also. attended. Analysis: Following pages contain images of the HP stop valve coupling with details. When the stop valve is closed the status of the coupling parts is as shown in schematic Drg.3, Fig.1. When the valve is opening When this The coupling Further loading of the unit required this problem to be

under hydraulic forces, the status is as in Drg.3, Fig.2. valve is fully opened, the status is as in Drg.3, Fig.3.

gaps indicated in the design drawing shown in Drg.2 ensure there is provision for thermal growth of the valve stem when hot steam is passing through the valve. If the assembly of the coupling does not follow the gap dimensions recommended, then tripping can occur, when thermal expansion of the valve stem pulls down on the servomotor stem and causes release of trip fluid pressure. This will happen every time, when the turbine is on load. For analyzing this,

1.

The tripping of the stop valve was observed under shut down conditions by lowering the trip fluid pressure. It was found to be tripping early at 6 Ksc. of trip fluid pressure.

2.

Then a 0.5 mm shim washer was inserted between parts 35.1 & 35.2 at AA as shown in Drg.2 . By doing this, the coupling gap was increased. With this correction, the stop valve tripping

was occurring after 350 MW. 3. Further correction at AA to increase the gap by 1 mm solved the problem. No tripping was observed at any load. 4. As a permanent correction, the coupling part 35.1 was machined by 1 mm at the location BB shown in Drg.2. Conclusion: The problem was resolved as explained above but some improvement is suggested for future sets. The machining that was done was a necessary correction because the provision for thermal expansion of the valve stem was found inadequate. It is better to have the dimensional tolerance for individual components ensured at unit so that the product manufactured does not require any rework, as indicated in blueprint, at site, and further, does not lead to any operational problems.

HP STOP AND CONTROL VALVE 500 MW

Drawing 2 has expanded view of this coupling

Drawing 1

Shim washers were added at AA for trials. Final machining done at BB for permanent solution after removing all shim washers from. AA

Drawing 3