PROJECT SUBJECT

: KAYAMKULAM CCPP GAS TURBINE2 : BALANCE OF AIR COOLED GENERATOR ROTOR AT KAYAMKULAM SITE

The Generator rotor of Gas Turbine 2 was taken out for rotor inspection. The retaining rings were also removed for inspection of the overhang windings and wedges during the overhaul carried by BHEL SAS from 21 st June to 18 th July 2002. Subsequent to Box up of the generator, it was rolled on 21st July 2002. The Vibration levels were observed at different grid frequencies at 50 MW load. The exciter bearing vibration were crossing the alarm levels (12.5 mm/sec) at grid frequencies above 49.5 Hz. Since the signature analysis indicated mechanical unbalance, it was decided to carryout balancing to reduce vibration levels. The Vibration vector diagram for exciter bearing indicated that addition of correction weights in diode wheel plane will not help in reducing vibrations both in vertical and horizontal directions. Also quite a number of weights were already present on the diode wheel plane. Hence it was decided to carryout generator rotor balancing since reduction of levels on generator bearing also reduced exciter bearing vibrations. Usually the generator rotor balancing is carried out by placing correction weights on the fan planes. But for air cooled generator rotor the end retaining ring planes are more easily assessable from opening inspection doors from bottom. Two trials were conducted with couple balance weights 180 degrees apart on generator front and rear end retaining ring planes. The correction weights and position were arrived at using graphical method. The final balance weights are 2 x 100 grams at generator front plane and 2 x 100 grams on generator

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Location Generator Front Generator Rear Generator Exciter

Direction Vertical Horizontal Axial Vertical Horizontal Axial Vertical Horizontal Axial

1 X 23 18 44 23 16 15 57 49 48

Phase 348 109 170 153 223 26 205 54 197

Overall 23 19 43 23 16 16 58 50 50

planes. The balance weights an end retaining ring planes are shown in enclosed photographs. The vibration analysis and balancing was carried out using Bently Nevada vibration instruments. Vibration Levels before balancing Displacements in microns Peak Peak Location Direction Vertical Generator Horizontal Front Axial Vertical Generator Horizontal Rear Axial Vertical Generator Horizontal Exciter Axial 1 X 48 29 88 48 20 29 89 74 89 RPM : 3001 Phase 335 100 157 149 220 18 197 59 175 Overall 48 30 88 48 22 29 90 74 88

Vibration Levels after balancing Displacements in microns Peak Peak RPM : 3001

VIBRATION LEVELS AT FULL LOAD Load :102.1 MW GT front : 2.2 / 2.8 mm/s GT rear : 1.8 / 2.3 mm/s Gen rear : 2.6 mm/s Speed : 2910 rpm

GT middle : 3.9 mm/s

Gen front : 3.2 mm/s Exciter : 4.9 mm/s

THE ABOVE PHOTO SHOWS GENERATOR END RETAINING RING WITH 2 Nos. OF BALANCE CORRECTION WEIGHTS ON EXCITER END.