Overhauls

Presented by

Abhilash Chandra Aron

Consultant, Turbogenerators

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General

Define scope of mandatory works.

Define possible areas of additional and unforseen work activities.

Work out list of spares and consumables that shall or may be required. This list to be as exhaustive as possible.
Consult BHEL / contractor well before.

Schedule as many activities in parallel as possible. Special task group may be made to give emphasis to longest cycle activity.

Within the organization, create and develop specialists for main products. They should not only assist in overhauls or
operational emergencies,but also work for improvements in O & M areas of the product.
CRITERIA FOR OVERHAULS

Initial Inspection: Dictated by stator end winding and stator slot support systems. Synthetic and insulating material tend
to flow(creep) under pressure and temperature during initial period. Deficiencies of manuf. assembly or design can be corrected.

Start up stresses:
Effects of expansion, friction on winding and insulation due to thermal & centrifugal force cycles.
Special vibratory forces arising when passing through natural frequencies of components.
Material fatigue, especially of rotating parts resulting from centrifugal force cycles.

Normal recommendations for inspection intervals apply to normal operation without any major disturbances.
OVERHAULS
VDEW RECOMMENDATIONS

INITIAL, SHORT, INTERMEDIATE AND MAIN INSPECTIONS

TEQIV = K1 . T1 + K2 . T2 + n . T3
K1, T1 FACTOR/TIME-RELATING TO OPERATION
K2, T2 RELATE TO BARRING GEAR OPERATION
K3, T3 FACTOR/ TIME - RELATING TO
START UP
>600 MVA TG: K1 = 1.0, K2 = 0.5, T3 = 20 <600 MVA TG: K1 = 0.9, K2 = 0.3, T3 = 10
<250 MVA TG: K1 = 0.8, K2 = 0.1, T3 = 10 < 50 MVA TG: K1 = 0.7, K2 = 0.1, T3 = 5
FOLLOWING LEAD TO EARLY INSPN:
FAULTY SYNCHRONISING
CLOSE IN SYSTEM FAULTS
ASYNCHRONOUS OPERATION
HIGH UNBALANCED LOADS
ALSO FOLLOWING FACTORS:
WEAR/DETERIORATION OF COMPONENTS OR RUNNING BEHAVIOUR.

LOAD REJECTIONS, ROTOR FAULTS...

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OVERHAULS - 3
CHANGE

IN COOLANT FLOW RATES.

FOULING IN AIR COOLED GENERATORS.
HYDROGEN OR WATER LEAKS.
SHAFT INSULATION DETERIORATION.

RECOMMENDATIONS FOR INSPECTIONS

TEQUIV -

INITIAL: 10 - 20 THOU HRS

TEQUIV - MAIN:
40 - 60 THOU HRS

ONE OR MORE SHORT & INTERMEDIATE

INSPECTION BE DONE BETW. 2 MAIN.
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OVERHAULS - 4

INITIAL & MAJOR NEED ROTOR REMOVAL

REGARDLESS OF ABOVE, FOR >250 MVA:
MINOR

INSPECTION IN 2 YRS.
MEDIUM INSPECTION IN 5 YRS.
MAJOR INSPECTION IN 10 YRS.

FOR < 250 MVA IN 3, 6, 12 YEARS

CHECKS FOR INITIAL & OTHER INSPN. TO
BE AGREED WITH MANUFACTURER
UNCHAHAR - 1: 463 TRIPS BET 1989-94
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EQUIV.

C
12
100 STARTS/YR

90 300 ST/YR
10
80
70

OPER.
HRS. 60
50
Tequiv
3 40
10 Hr 30

6
4

2 2
10

4
2

10

10

6
TIME (YEARS)

6
4

20

10ST/YR

12

FIRST MAJOR
INSPECTION 10

FIRST INSPECTION
20

30

40

50

ACTUAL OPERATING HRS.: T

60

(10
act )

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A. C.
ARON

70

OVERHAULS

1st INSPECTION: 10 - 20 THOU HRS.

SUBSEQUENT: 40 - 60 THOU HRS.
MINOR INSPECTIONS IN BETWEEN.
DATA BEFORE SHUT DOWN.
CASE OF NARORA ROTOR - LOW IR
DETECTED AFTER ROTOR REINSERTION.
DATA AFTER REROLLING.

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BEFORE OVERHAUL

BEARING VIBRATIONS BE RECORDED.

CHECK BEARING & SHAFT SEAL INSULN.
ROTOR WDG. IMPEDENCE & RESISTANCE.
STATOR & ROTOR WINDING IR MEASURED.
WINDING TEMP, WATER FLOWS RECORDED.
GAS LEAKS & SEAL-OIL FLOWS TO BE KNOWN.
SLIP RINGS PERFORMANCE RECORDED.

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DURING OVERHAUL
INITIAL AND MAJOR

CORE CONDITION & ELCID CORE TEST.

IF FAULT CURRENT > 100 mA , AND IF ANY CORE
DAMAGE VISUALLY SEEN, AND / OR REPAIRED
ETC., POWER CORE LOSS TEST TO BE DONE.
STATOR END WINDING SUPPORT SYSTEM AND
OVERHANG CONDITION.
STATOR WINDING INSULATION CONDITION.
STATOR WINDING IR AND LEAKAGES.

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DURING OVERHAUL - 2
INITIAL AND MAJOR

STATOR WEDGE TIGHTNESS.

LEAKAGE TEST OF HYDROGEN SYSTEM.
SLIP RINGS & BRUSHGEAR.
CHECK ALL RUBBER GASKETS.
LEAKAGE TESTS ON STATOR WINDING, WATER
SYSTEM, FILTERS CLEANING.
BEARING LINER & BODY INSPECTION.

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DURING OVERHAUL - 3
INITIAL AND MAJOR

ROTOR RETAINING RING SURFACES.

CHECK IF ROTOR SHAFT IS MAGNETISED.
RUN OUT CHECKS ON ROTOR.
CHECK REMOVED ROTOR VISUALLY.
ROTOR WINDING IR.
ROTOR BEARING & SEALS JOURNALS.
PURGE TESTS ON ROTOR.
CHECK ROTOR FANS VISUALLY.
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DURING OVERHAUL - 4
INITIAL AND MAJOR

ROTOR C.C. BOLTS FOR LEAKAGES.

ALL COOLERS TO BE CLEANED CW SIDE.
CHECK BEARING AND SEALS INSULATION.
BEARING CLEARANCES, BABBIT, ALL OIL
CATCHERS, JACKING OIL LIFT, TCs / RTDs.
SPHERICAL SURFACES OF BEARING.
SLIDING CONTACT FACES OF SEAL RINGS, SEAL
BODY, SHAFT SEAL CLEARANCES.

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DURING OVERHAUL - 5
INITIAL AND MAJOR

CLEANLINESS WHEN BOXING UP.

LEAKAGES IN COMPLETE H2 GAS SYSTEM.
FUNCTION OF TOTAL SEAL OIL SYSTEM.
SEAL OIL FLOWS AT FULL & ZERO SPEED
CHECK BEARING VAPOUR EXHAUSTERS.
ALL TEMPERATURE GAUGES & ALARMS.
LIQUID LEVEL ALARM SWITCHES ETC.
CONDITION OF GROUNDING BRUSHES.
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Practices
REPLIES TO QUERRIES BY BHEL IN 1985

Based on 20 replies to queries following

maintenance planning periods obtained:
Rotor, Stator, Auxiliary systems and
Bearings - for each 15 days
Hydrogen shaft seals
3 days
Shaft insulation and earthing 5 days
Brush gear and slip rings
2 days
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Practices - 2
REPLIES TO QUERRIES BY BHEL IN 1985

Usual activities:
Stator wedges tightness
Stator core tightness, core flux test
Hydraulic tests on stator wdg.,coolers
Purge tests on rotor and gastightness
IR on stator,rotor,bearing insulation
Gas tightness test on complete m/c
OCC & SCC after resynchronization
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Practices-Frequency of Maintenance
REPLIES TO QUERRIES BY BHEL IN 1985

Bearing Inspn.8-10thou hrs. (8) BHEL

15-18thou hrs. (7) Annually
Shaft seals Annually
(12) Annually
Stator o/hang One year
(7) In Major
3 - 5 years (8) overhaul
Rotor withdrawl 3-5 years
Stator core inspection
In 1st,then
Stator wedge tightness
(16)4-6, 8-10 yr
Slip rings & brushgear
Gas coolers Annually
In overhauls
Systems
Annually
BHEL:In o/hauls
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Mettur 1 : Overhaul scope

Total running hours upto Aug 1993 : 34,700

Previous Major overhaul done : Nov 1989
Number of start ups so far
238
Since last overhaul 70
LP rear bearing vibration was high: 36H, 25V
High eccentricity problem: 380 Micron at start up
and later on load 110 Microns.
Excessive bearing clearances and change in
catenary over period of time was reported
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Mettur 1 : Overhaul scope - 2

Bearing 1 liner replacement, cutting of 7 nos.

seized cap nuts on HP & IP.
Generator rotor replacement by the spare rotor
- TNEB decision because of its low IR.
LP rotor 20th,29th stage, IP 23rd stage lacing wire
old brazing was debrazed and rebrazed. Blades
natural frequency check performed.
Minor works on front pedestal, MOP, Valves,
Ejector and cam shaft assembly were done.
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Mettur 1 : Overhaul scope - 3

Stator: 30% wedges found loose-retightened.

Epoxy glue EA-12 applied in wdg. Overhangs.
All terminal bushings removed - two replaced.
Existing rotor: Purge tests, gas tightness test,
DPT done on fan blades and retaining rings.
New rotor : IR, DC resist., AC Impedence,
Purge & Gas tightness tests, Holes Reaming.
H2 gas coolers: Scaled water tubes cleaned with
conc. HCl 2lit + Rhodine litre and 200 litres of
DM water.
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Mettur I : Completion days

2nd Capital overhaul : 1st Aug to 14th Oct 1993

00
07
12
14
15
18
22
30
32

Unit tripped - on barring gear

Slip ring machining incl. groove
cutting, dismantling started.
Lifting of top LP casing.
Generator rotor threaded out.
Lifting of top IP casing.
Lifting of top HP casing
Dismantling works completed.
LP box up
Stator slot wedge tightening.
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Mettur I completion days -2

41
44
50
60
61
64
66
72
74

IP box up
Generator rotor threaded in.
HP box up
Generator re-assembly work,
C & I calibration completed.
Oil flushing started.
Oil flushing completed.
Barring gear operation.
Steam rolling started.
Synchronization
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Neyvali-4 210 MW : Scope

OVERHAUL IN OCT - DEC 1994

LP module, Generator, Turbine valves, CRH NRV,

servomotors, Turning gear and MOP bearings,
Main & HRH strainers, Rollcheck & Bumpcheck of
HP and IP, Hanger supports, Governing rack, LP
Byepass rack mechanical components only.
Lub oil coolers tank - filters - pumps, Coolers
-valves - filters - tanks of generator seal oil,
gas, stator winding water systems.

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Neyvali-4 210 MW : Scope - 2

Replacement of rubber grommets around

teflon tubes of winding in stator. (Erection
point - pending from BHEL side)
After dismantling, in LP turbine LHS & RHS
clearances found unequal. These were
corrected by shifting LP inner outer casing
Running hours upto overhaul : 18,600
Number of trips upto overhaul
270
After o/haul: All bearings vibrations reduced
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Neyvali-4 210 MW : Scope - 3

Generator

Rotor purge test, gas tightness - leak in

small CC bolts - nuts tightened. DPT of fan
blades and retaining rings done. Rotor
journals were polished.
75% stator wedges loose - retightened.
42 swollen teflon tubes rubber gromets
replaced without opening nose joints.
Stator overhang was injected with glue.
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Neyvali-4 210 MW : Completion

00
08
11
12
18
31
45
54

Set tripped.
Stoppage of barring gear.
Generator rotor threaded out.
Dismantling of LP.
Purge test on generator rotor.
LP Boxed up.
Generator rotor threaded in.
Generator assembly completed.
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Neyvali-4 210 MW:Completion-2

67
Oil flushing started.
70
Oil flushing completed.
** Barring gear operation started.**
79
Set steam rolled.
80
Synchronized
83
Achieves full load smoothly.

**Barring gear date got delayed by 23 days : Stator

works held rotor threading by 15 days. LPGenerator holes were reamed for 12 days !

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GOOD BYE !
TO ALL OF U
AFSHA CLASS 5

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