HIGH CRONIC VIBRATION AT ANPARA U# 1

Anpara Unit # 1 210 MW reported sever Axial and High Vertical vibration in Brg # 6 and Brg # 5 also showed High Vertical Vibration High Vibrations were also noted in Stator End shield and water header. The axial vibration and vertical vibration suddenly increased to the tune of above 50 microns ad machine had o be debarred Spectrum showed sever 2x components and other higher frequency components

USPV test Ultrasonic Pulse Velocity Test 54KHZ , 24KHZ Velocity=Distance/time Homogeneity Presence of Cracks/voids, imperfections Change in structure which occurs with time PUNDIT :- Portable Ultrasonic Non-destructive Digital Indicative tester >4.5 Km/sec >4 km/sec 3.5 to 4 Km/sec 3.0 to 4.0 km/sec <3.0 Km/sec :- Excellent :- Very good to Excellent :-Good to very good :- Satisfactory but integrity suspected :- Poor and loss of integrity exist

COLUMNS 11 & 12 FELL BETWWEN POOR & SATISFACTORY BUT SUSPECTED INYEGRITY AND REVEALED HONEYCOMBIMG

BEARING NO .06 PADESTAL MAPPING(v)

15

14 13

16 12 2 3

1
10

5
8

7
11

4 METAL BASE PLATE

18

17

CIVIL FOUNDATION AREA

A CRACK IS BEING NOTICED(PIC S ATACCHED)

NUMBER 1 2 3 4 5 6 7 8 9

VIBRATION() 32.20 30.00 31.00 34.70 42.80 41.80 46.10 47.10 54.70

PEAK TO PEAK NUMBER 10 11 12 13 14 15 16 17 18

VIBRATION() pk-pk 53.10 45.80 41.60 32.40 55.00 32.10 46.10 65.4 63.4

*READING OF THE COLUMN OF THE PEDESTAL WAS TAKEN AT 6M AND 0M FRONT (BRG # 6)6 METER 60.1 0 METER 43.1 REAR COLUMN BRG # 5 6 METER 34.3

OBSERVATIONS
THERE IS SEVERE VIBRATION IN THE STATOR WATER INLET AND OUTLET LINE. DUMMY WOODEN SUPPORT AT BENDS WERE PROVIDED AND SOME REDUCTION IN VIBRATION WAS OBSERVED BUT STILL NOTICABLE VIBRATION IS OBSERVED WHICH REDUCES GOING AWAY FROM THE GENERATOR THE ENDSHIELD OF TURBINE SIDE SHOWS NOTICABLE VIBRATION THERE IS VIBRATION IN FOUNDATION AREA OF BRG # 6 . THERE HAS BEEN DAMAGE OF COPPER TUBE OF THE BUSHING OF Y PHASE IN APRIL 2013. THE TUBE WAS FOUND IN 2 PIECES (BROKEN) WE HAD INSISTED CUSTOMER FOR NFT BUT NFT HAD NOT BEEN DONE SEAL OIL FLOW WAS AROUND 30L/MIN AT TE AND 35L/MIN IN EE WHICH HAS NOW INCREASED TO 45L/MIN IN TURBINE SIDE AND 50L/MIN IN EXCITER END AFTER INCREASE IN VIBRATION IN BRG # 6

CRACKS WITNESSED IN BRG # 6 PEDESTAL

ACTION TAKEN
1. INTEGRITY OF SECONDARY FOUNDATION GROUTING WAS SUSPCTED AND CHECKED BY NCCBM. 2. INSPECTION OF FOUNDATION WAS ALSO DONE BY BHEL ENGINEERS 3. UPV REVEALED HONEYCOMBING IN COLUMNS 11 & 12 AND ALSO CRACKS WAS FOUND IN SECONDARY GROUTING OF BRG # 6 PEDESTAL 4. AS SUGGESTED BY NCCBM AND BHEL ENGINEERING ,THE HONEYCOMB IN THE FOUNDATION WAS REPAIRED BY PRESSURE EPOXY GROUTING AND SECONDARY GROUTNG WAS REDONE BY REMOVING BRG # 6 BASE PEDESTAL AND REGROUTING USING CONBETRAX GP2 . 5. DESTRETCHING & STRETCHING OF FOUNDATION BOLTS WAS ALSO DONE. 6. BRG. 4 WAS REPLACED 7. GENERATOR ROTOR WAS REPLACED TO REMOVE GENERATOR INDUCED VIBRATION COMPONENTS. RESULTS : MACHINE SUCESSFULLY SYNCHRONISED WITH VIBRATIONS OF SHAFT BELOW 60 MICRONS PK-PK AND PEDESTAL BELOW 30 PK-PK IN ALL BRGS

MOULDS PREPARED FOR TEXT BEFORE SECONDARY GROUTING

MOULDS TEXTED FOR STRENGTH

Primary

BRG #5 SPECTRUM AFTER RESTORATION WORK

BRG # 6 SPECTRUM AFTER RESTORATION WORK

UNIT # 4 PANKI 105 MW HEAVY SPARKING AT EXCITER

Heavy Sparking in exciter commutator of Unit # 4 Panki TPS was reported and soon the problem rose to alarming level and machine had to be debarred on June 21 2013. Vibrational analyses and electrical test were carried out by UPRVNL and based on that following were suggested. 1)Undercutting of mica on the commutator 2)Carrying out the drop test on the commutator segments and on pole pitchapart. This check will give you data about any dry soldering joints. 3)Checking the commutator for any non uniform wear out 4)Checking all the brush holders for their correct spring pressure and the usage of correct grade of carbon brush. 5)Check for the parallality of collecting mechanism arms. 6)Check for the magnetic neutral axis of the collecting mechanism for any shifting during running of the Machine. 7) Groove chamfering has to be carried out, using form tool Results : The sparking though reduced but still was totally resolved

ACTION TAKEN BY RSC VARANASI

RSC ENGINEER VISITEDTHE SITE AND FOUND THAT THE UNDERCUTTING AND GOOVE CHAMFERING WERE IMPROPER AND STILL DEMANDED MORE BUT THE COMMUTATOR BEING OLD AND RESUED CONTINOUSLY RAISED SUSPICIONS OVER POSSIBILITY OF FURTHER UNDERCUTTING THE EXCITER ARMATURE WAS SUGGESTED FOR REPLACEMENT AND UNIT WAS BROUGHT BACK TO BAR WITHIN 7 DAYS.

Chronic axial Vibration Problem at Unit # 3 Unchahar TPS

Unchahar Unit # 3 NTPC during overhauling in April 2012 discussed with BHEL RSC Engineers regarding high axial vibration of LPT Rear Bearing Unit # 3. The axial vibrations were reportedly high to the tune of above 50 microns zero-pk and velocity above 20 mm/sec The spectrum was analysed which revealed unloading of Brg # 4

Velocity-mm/s

10

20

30

40

50

60

70

0
11/20/00 11/20/01 11/20/02 11/20/03 11/20/04 11/20/05 11/20/06 11/20/07 11/20/08 11/20/09

U-3 LPT rear brg vibration

Measurement Samples Axial Vertical

ACTION TAKEN
1. CATENARY CORRECTION AND DECK CORRECTION 2. PROPER BLUE MATCHING OF BRG WITH TORUS AS WELL AS TORUS WITH PEDESTAL 3. DESTRETCHING & STRETCHING OF FOUNDATION BOLTS WERE CARRIED BUT THE REAR BRG WAS STRETCHED TO 2.43 AND THE FRONT BOLTS WERE STRETCHED TO 2.30 DEVIATING FROM THR NORMAL APPROACH OF STRETCHING THE FRONT TO A HIGHER VALUE AS COMPARED TO THE REAR . 4. ALIGNMENT CORRECTION .

RESULTS The axial vibration were brought to below 25 microns and velocity to less than 8 mm/sec.

U#3 PEDESTAL 4 BOLT STRETCHING

U #3 BRG. 4 PEDESTAL BOTTOM

STRETCHING DETAILS U # 3 BRG NO 4,O/H 12

BOLT NO. FRONTFRONT -L FRONTFRONT -R REARREAR -L REARREAR -R DESIGN VALUE 1.83 1.83 1.80 1.80 STRETCHI NG VALUE 2.30 2.30 2.43 2.43

SEVERE EARTH FAULT AT DEVIGHAT NEPAL

(MACHINE BROUGHT TO GRID WITHIN 20 DAYS)

NEA had reported about the earth fault of stator Unit # 2, Devighat. BHEL RSC engineer reported at site on 3/01/12 for attending the earth fault. The fault after analyses was found to be severe in nature and had resulted in melting of overhang portion of two coils of B phase and burning down of insulation of the nearby three other coils. Constraints : Space constraint on removal of poles & Time on removal of rotor. Solution: Stator Removal Causing Both Time, Cost and Work easier Machine Relevelled aligned and Brought Back to Grid on 23/1/12 with better running parameters compared to other running Units

After replacement of the individual coils HV of the new coils were carried out at 14.2 KV for 1 minute. After finalization of the stator the HV of all coils/phases was carried out at 9Kv in two parts. The stator was then re-position and final IR & PI was recorded.
IR AND PI AFTER PLACEMENT OF STATOR AND FINALISATION OF LEVELLING AND ALIGNMENT
DATE 15/1/2012

15 secs R-E Y-E B-E RYB- E R-Y B-Y Y-B 1000 1000 1000 200 2500 2500 2500

60 secs 3500 3500 3250 1500 8500 8000 8000

600 secs 9000 9500 8500

PI 2.57 2.71 2.62

U# 2 with better vibration parameters as compared to U # 3