By: B.

KANUNGO DGM (TMD), SIMHADRI

UNIT-2 DURING INITIAL COMMISSIONING

VIBRATIONS DURING INITIAL COMMISSIONING (2002-03) VIBRATION AT BEARING NO.1 & 2 AT THE LEVEL AT ABOUT 240 MICRONS PK-PK IN BEARING NO.1 AND 160 MICRONS PK-PK IN BEARING NO.2 AGAINST THE PERMISSIBLE ALARM LIMIT OF 200 MICRONS PEAK TO PEAK

DURING THE COURSE OF RUNNING THESE VIBRATION LEVELS HAVE PROGRESSIVELY INCREASED TO 280-300 MICRONS PK-PK AT BEARING NO.1 AND 260-280 MICRONS PK-PK AT BEARING NO. 2 JUST BELOW THE TRIPPING LIMIT OF 320 MICRONS PK-PK. .THE VIBRATIONS WERE INCREASING DURING HIGH FREQUENCY REGIME NECESSITATING REDUCTION IN LOAD TO 400 MW AT FREQUENCY > 50.5 HZ.

ACTION TAKEN BY SITE DURING OVERHAUL-2007

THE MAJOR JOBS CARRIED OUT DURING OH (JULY-AUG2007):

Overhauling of LP Turbine Overhauling of IP Turbine All Bearings inspection Alignment & centenary corrections
OBSERVATION AFTER OVERHAUL:

During subsequent rolling after overhaul, the shaft vibrations reached high levels which necessitated trim balancing. With trim balancing through M/s BHEL & M/s GE helped in achieving the shaft vibration levels of 320 micron pk-pk & 290 micron pk-pk at bearing no. 1 & 2 respectively.

ACTION TAKEN BY SITE DURING OVERHAUL-2007

ACTION TAKEN DURING OH (SEPT-OCT2007): It was then decided jointly by site, SRHQ-OS and CC-OS along with BHEL to open HP & LP turbine for carrying out slow speed balancing of HP rotor and to check for any facial imperfections on the rotor coupling faces at HPIP & IP-LP couplings and correct the same manually to the extent POSSIBLE. Accordingly, Turbine overhaul was taken through BHEL from 11/09/2007 to 18/10/2007. THE MAJOR WORKS CARRIED OUT WERE: HP Turbine overhauling including slow speed balancing of HP rotor. LP Turbine overhauling. IP-LP Coupling face correction. All bearings inspection.

ACTION TAKEN BY SITE DURING OVERHAUL-2007

MAJOR OBSERVATIONS DURING OVERHAUL-2007
Catenary deviation observed to be high with pedestal No. 3 moved down by

nearly 3.5 mm w.r.t Pedestal No.4

High axial misalignment at HP-IP coupling with top open by 0.75 mm w.r.t

bottom opening.
IP rotor rear shaft glands (4 Nos. + 4 Nos. + 1 no) in three different places

have been found pressed due to rub. The fins got rubbed, as well as got bent and fused over its own caulking wire & adjacent fins & caulking wires. The same is observed in the stationary gland box fins also. Bearing No. 1, 2, 3 & 4 was replaced with new bearings. Bearing no.1 bottom support and spherical seat found having pitting type of impressions from the extreme right side of the support. Bearing no.2 Jacking oil port pocket edges damaged due to scoring and shaft lift was not adequate. Bearing No.3 & 4 Contact area between cylindrical support and torus has been found widened.

Condt...

ACTION TAKEN BY SITE DURING OVERHAUL-2007

MAJOR OBSERVATIONS DURING OVERHAUL-2007
Exciter fan front face rubbing mark was observed. In cold condition the gap

between exciter fan and pedestal oil guard bolts head was found very less.
HP rotor unbalance was observed to the extent of 210 grams at the front end

only.
With IP-LP Coupling, the maximum throw at IP front was observed to the

extent of 0.4 mm and Journal 1 & 2 run out was observed to the extent of 0.08 mm & 0.07 mm respectively and HP front swing check was 0.28 mm. The above problem of High Journal run-outs at bearing no. 1 & 2 and HP front Swings check values are corrected by manual scrapping of LP rotor front coupling face and IP rear coupling face for removing its convexity. Condt...

ACTION TAKEN BY SITE DURING OVERHAUL-2007

CONVEXITY MEASUREMENT
COUPLING FACE CONVEXITY CAN BE MEASURED :
BY USING A STRAIGHT EDGE & SLIP GAUGES.

CONFIRMATION OF CONVEXITY
BLUE CHECK OF COUPLING FACE WITH SURFACE PLATE / CAST IRON PLATE. CAST IRON PLATE IS TO BE FIRST MATCHED WITH SURFACE PLATE AND THEN USED ON COULPING FACE.

ACTION TAKEN BY SITE DURING OVERHAUL-2007

MAJOR OBSERVATIONS DURING OVERHAUL-2007
Maximum swing check achieved at HP front end was 0.15 mm against a

limit value of 0.21 mm.

During the LPT flow path readings, the minimum negative axial clearances

between blades were found to be 0.7 mm and hence LP Inner outer casing along with LP inner casing was moved towards turbine side to obtain the negative clearance between blades to 4.7 mm.
The axial Reference between generator coupling and oil catcher face at end

shield TE of Generator Stator was found to be 813.70 mm against the erection value of 808 mm. To correct above Generator stator was shifted towards Turbine end by 5.7 mm to restore axial position of Generator stator. Accordingly Exciter bed also shifted towards turbine side by 7.5 mm to maintain the Clarence between exciter fan and bearing no. 7 rear oil guard. Condt...

ACTION TAKEN BY SITE DURING OVERHAUL-2007

OBSERVATIONS AFER OVERHAUL-2007

Again on bringing the machine on operation, the vibration levels were brought down with in alarm limits of 200 microns pk-pk but problem did not get resolved completely as vibration levels at bearing No.1 & 2 were sometimes crossing the alarm limit of 200 Microns pk-pk in running and during start ups.

ACTION TAKEN BY SITE DURING OVERHAUL-2009

ACTION TAKEN DURING OH (2009): Again in the year 2009, it was decided to utilize the planned outage of Unit # 2 Boiler to resolve the above high shaft vibration problem at bearing no. 1 and 2. Accordingly as jointly decided by Site, Regional OS and CC-OS, M/s. Siemens has been awarded the contract.

THE MAJOR JOBS CARRIED OUT DURING OH (SEPT-OCT2009):

IPT overhaul including slow speed balancing of IP rotor. LPT overhaul

All bearings inspections, alignment corrections etc.

The contract had also included the visit of a) Fact Finder during dismantling assessing and b) Commissioning expert during post overhaul both from Siemens SAG, Germany.

ACTION TAKEN BY SITE DURING OVERHAUL-2009

MAJOR OBSERVATIONS DURING OVERHAUL-2009
IP rotor unbalance was observed to the extent of 1 KG each at the front and

Rear end and the same was corrected by slow speed balancing.
IP rotor radial run out was observed to the extent of 0.14 mm at the centre

(steam admission area).

No rubbing marks were observed in Shaft gland seals or inter stage seal

fins.
MOP thrust bearing was found in damaged condition. Speed sensing gear

was found in loose condition.

Bearing No. 4 was replaced with new bearing. Bearing No.4 Contact area

between cylindrical support and torus has been found widened. The tappernes of bearing support saddle was removed by manual scrapping to avoid the bearing front rear temperature differences. Condt...

ACTION TAKEN BY SITE DURING OVERHAUL-2009

MAJOR OBSERVATIONS DURING OVERHAUL-2009
LPT INLET BELLOW PROBLEM:

LP turbine negative axial clearances between blades was

observed only 0.7 mm against the drawing value of 5 mm. LP turbine steam inlet bellows welding were cut on the adaptor plates on either sides based on the Engineering clearance from Siemens SAG, Germany as they were in stress due to shifting of LP casing to get the minimum negative axial clearance between blades and LP inner casing was shifted towards turbine side to get the minimum negative axial clearance between blades to design value of 5.0 mm.
Condt...

ACTION TAKEN BY SITE DURING OVERHAUL-2009

LPT INLET BELLOW PROBLEM:

ACTION TAKEN BY SITE DURING OVERHAUL-2009

MAJOR OBSERVATIONS DURING OVERHAUL-2009
Exciter cooling fan keyways and locking screws were found in

loose condition. Heavy rubbing marks were observed on the front face of the cooling fan. Severe pitting marks were observed on the Generator Exciter coupling faces which were removed by manual scrapping to the extent possible. The complete exciter was replaced with a repaired Unit from TSTPS. The exciter frame was moved towards generator by 2.5 mm to maintain the Clarence between exciter fan and bearing no. 7 rear oil guard.
All coupling faces convexity checked and found ok and no

manual scrapping of coupling faces were carried out.

Condt...

ACTION TAKEN BY SITE DURING OVERHAUL-2009

OBSERVATIONS AFER OVERHAUL-2009

On bringing the machine on operation, at full load after achieving full parameters the vibration levels at bearing no.1 and 2 were at 130 & 110 microns pk-pk .

During the course of running these vibration levels have progressively increased to 190-200 microns pkpk at bearing no.1 and 150 microns pk-pk at bearing no. 2.

THE FINAL READINGS / CORRECTIONS / OBSERVATIONS AFTER ABOVE OVERHAULS

HP-IP, IP-LP, LP-GEN, GEN-EXCITER Coupling alignments are corrected with in 0.02 mm and necessary preloading is given in bearing no. 1 & 7.

Slow speed balancing of HP & IP Rotor was carried out (HP rotor in 2007 and IP rotor in 2009). The Hp front end swing check is 0.1 mm against design limit of 0.21 mm and Exciter end swing check is 0.23 mm against design limit of 0.29 mm.
Condt...

THE FINAL READINGS / CORRECTIONS / OBSERVATIONS AFTER ABOVE OVERHAULS

Rotor Final coupled run out readings are given below: HP-IP Coupling CRO (Journal-1 / J2 / HPC / IPC): 0.02 / 0.025 / 0.035 / 0.015 MM.
IP- LP Coupling CRO (Journal-3 / IPC / LPC): 0.01 / 0.05 /

0.03 MM.
LP- GEN Coupling CRO (Journal-4 / LPC / GEN C /J5): 0.02 /

0.025 / 0.055 /0.025 MM.

Gen - Exciter Coupling CRO (GENC / EXC C /J7): 0.03 / 0.04

/0.04 MM.
Condt...

THE FINAL READINGS / CORRECTIONS / OBSERVATIONS AFTER ABOVE OVERHAULS

Final Catenary readings are given below [ in mm ] :

Bearing no. BRG-1 BRG-2 BRG-3 BRG-4

Actual 7.12 5.01 3.51 0

Design 6.70 5.14 3.46 0

Condt...

THE FINAL READINGS / CORRECTIONS / OBSERVATIONS AFTER ABOVE OVERHAULS

ALL COUPLING FACE RUN OUTS:

HP Rotor rear coupling face run out (Inner / outer) : 0.0325 / 0.025

mm IP Rotor front coupling face run out (Inner / outer) : 0.0175 / 0.015 mm IP Rotor rear coupling face run out (Inner / outer) : 0.0125 / 0.02 mm LP Rotor front coupling face run out (Inner / outer) : 0.035 / 0.075 mm ( LP front coupling face manual scrapping [tapper cutting] done during overhaul in 2007 to correct the IP front throw and high journal run out at bearing no. 1 & 2 ). LP Rotor rear coupling face run out (Inner / outer) : 0.02 / 0.04 mm All coupling face Convexity checked and found within limits.

SIMHADRI UNIT-2 HIGH VIBRATION PROBLEM

CONCLUSION :

Now the machine is running with vibration levels at bearing no. 1 & 2 are 190-200 Microns and 150 microns pk-pk respectively and under raising trend. You are requested to give your valuable suggestions to bring down the vibration levels to the extent of 100 microns peak to peak at bearing no. 1 & 2.

THANK YOU