Dated: 07/05/2013

OBSERVATIONS AFTER AND DURING DISMANTLING OF LP AND IP CYLINDERS OF UNIT NO 1

OF MOUDA STPS
Background
Mouda-1 achieved full load on 19th April 2012.
Unit was synchronized on 15th March 2013 and tripped on electrical supply failure on
17th March at 0332 hrs.
Rotor came to standstill at around 0710 hrs on 17th March 2013.
Subsequently, after cooling down also machine failed to come on Barring Gear.
To investigate the Root Cause of the problem Roll Check, Bump Check of HPT & IPT and
Roll Check of LPT was done. Rotor was on able to rotate with hand barring also.
When LPT was opened rubbing marks were observed in the RHS of LPT.
Bump Check of HPT and IPT was found below designed value and therefore it was
decided to open both modules to further investigate the problem.
IPT and LPT were opened and following are the observations and remedial actions.

OBSERVATIONS
LP ROTOR
1. Minor rubbing on moving blades shroud fins and inter stage fins of stages 1 to 4 .- TO
BE LEFT AS IT IS.
2. Rubbing also observed in 5th stage blades tips(TS) TO BE DEBURRED AND CLEANED.
3. LPT rotor front 4th stage shroud gap (maximum 2 mm in one blade) NO GAP AT THE
CENTRE ZONE OF THE Z TYPE BLADE SHROUD. IT IS IN LINE WITH THE SPECIFICATION AT
THE CENTRE. MAXIMUM ALLOWABLE LIMIT IS 1.4 MM, HOWEVER IN THE OPINION OF
BHEL HWR, IT IS NOT GOING TO AFFECT THE PERFORMANCE.

4. LPT rotor shroud integrated sealings loose deposit observed it is to be cleaned.

LP CASING
1. Heavy rubbing on RHS casing blades shroud fins and inter stage fins of stages 2 and 3
upto the length of 200- 300 MM (both TS and GS) - Damaged fins of inter-stage to be
replaced.
2. Shroud gaps observed in the casing blades on the right side in the 2nd and 3rd stages
both sides (TS and GS) ( appx 13 blades each on top and bottom half Generator side
and bottom half turbine side). On tightening of the inner casing top and bottom half
clearances still remains. 0.03 mm filler should not go between the blades and
wherever fin is rubbed, such blades to be replaced with new blades. Blades with
machined shroud will be supplied.
3. Stage 4 and 5 (GBC 1 and 2) RHS damaged fins to be replaced.
IP ROTOR
1. Sealing fins in stage 1F ,8F, 12F,10F,3R,8R are found bent in some portion- bends fins
to be straightened and 1R, 8R to be replaced.
2. Rear Gland last segment sealing fin area found badly rubbed and lumps found in the
sealing fins Sealing fins to be replaced completely.
3. Minor radial rubbing on shrouds observed in stage 2R to be left as it is.
IP Casing:
1. Sealing fins found damaged and found loose and lying in the bottom half in stages 9R
upper half
2. to be replaced.
3. Sealing fin and caulking wire found to be come out from its slot in the stage 8R and 9R
lower half to be caulked again. NTPC request BHEL HWR to investigate the reason of
fin breakage in such short span of operation, as it has implications on future reliable
operation and review fitting process to prevent such occurrence.
4. Blade shrouds found axial shifted (maximum 2 mm) in top and bottom half at parting
plane in stage 10F, 11F, 12F and 12 R area - to be dressed by minor grinding.
5. Sealing fins found bent in stage 12R and 12 F stages to be straightened.
6. Rear gland last housing fins found badly rubbed and damaged to be replaced.
HP Turbine:
1. U seal ring of HPT below shaft seal cover to be replaced.

2. HPT dismantling is under progress. Action Plan will be decided based on the
observations.
Root Cause Analysis by BHEL of LP Casing shifting to right side needs to be clearly
brought out to prevent repetition with support of BHEL-Haridwar.
Observations and protocols handed over to BHEL.
SCHEDULE
BHEL gave a schedule of 4 weeks and NTPC insisted on completing the job in 3
weeks.
BHEL agreed to check back at works and confirm based on the availability of LPT
casing blades.
MEMBERS PRESENT
NTPC

BHEL

Sh. B. Basu GM (O&M)

Sh. E Balachandran GM BHEL Mouda

Sh. Pramod Kumar, GM/QA&I,EOCNoida

Sh. M Chandrashekhran,
GM/Inspection, EOC-Noida
Sh. A K Jain, AGM/Maintenance

Sh. A K Saxena, GM/Quality, Haridwar

Sh. C Siva Kumar, AGM/Mech

(Erection)
Sh. R K Sood, AGM/Turbine (Erection)

Sh. Veerapandi, DGM/PSWR, Nagpur

Sh. A K Sehgal, AGM/OS (Turbine)

Sh. Trijay Kumar Nim, Manager, PSTS,

Noida

Sh. Ajay Sehgal, AGM/Quality-Mouda

Sh. Jhamender Kumar, Engineer, FES,

Haridwar

Sh. R K Soni, AGM/TMD, Mouda

Sh. Chattopadhyay, AGM/OS, Noida

Sh. T K Ghosh, AGM (Engg.), Haridwar

Sh. Rajib Chakraborty, AGM-PSWR,
Mouda

Sh. Bharat Bhushan, Dy Mgr, Quality,

Haridwar

 Sh. B S Rao, DGM/Chemistry, Mouda

Sh. Aminder Singh, Sr Mgr/Quality,
Mouda
Sh. A P Samal, AGM/ PE-Mech, Noida