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 :- Excellent
>4 km/sec :- Very good to Excellent
3.5 to 4 Km/sec :-Good to very good
3.0 to 4.0 km/sec :- Satisfactory but integrity suspected
<3.0 Km/sec :- Poor and loss of integrity exist
COLUMNS 11 & 12 FELL BETWWEN POOR & SATISFACTORY BUT SUSPECTED INYEGRITY
AND REVEALED HONEYCOMBIMG
PEAK TO PEAK
NUMBER VIBRATION() NUMBER VIBRATION() pk-pk
1 32.20 10 53.10
2 30.00 11 45.80
3 31.00 12 41.60
4 34.70 13 32.40
5 42.80 14 55.00
6 41.80 15 32.10
7 46.10 16 46.10
8 47.10 17 65.4
9 54.70 18 63.4
15
2
1
3
4
5 6 7
8
9
10 11
12 13
14
16
A CRACK IS BEING NOTICED(PIC S ATACCHED)
17 18
METAL BASE PLATE
CIVIL FOUNDATION AREA
BEARING NO .06 PADESTAL MAPPING(v)

*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

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
U-3 LPT rear brg vibration
0
10
20
30
40
50
60
70
1
1
/
2
0
/
0
0
1
1
/
2
0
/
0
1
1
1
/
2
0
/
0
2
1
1
/
2
0
/
0
3
1
1
/
2
0
/
0
4
1
1
/
2
0
/
0
5
1
1
/
2
0
/
0
6
1
1
/
2
0
/
0
7
1
1
/
2
0
/
0
8
1
1
/
2
0
/
0
9
Measurement Samples
V
e
l
o
c
i
t
y
-
m
m
/
s
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
STRETCHING DETAILS U # 3 BRG NO
4,O/H 12
BOLT NO. DESIGN
VALUE
STRETCHI
NG VALUE
FRONT-L 1.83 2.30
FRONT-R 1.83 2.30
REAR-L 1.80 2.43
REAR-R 1.80 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

IR AND PI AFTER PLACEMENT OF STATOR AND
FINALISATION OF LEVELLING AND ALIGNMENT
DATE 15/1/2012
15 secs 60 secs 600 secs PI
R-E 1000 3500 9000 2.57
Y-E 1000 3500 9500 2.71
B-E 1000 3250 8500 2.62
RYB- E 200 1500
R-Y 2500 8500
B-Y 2500 8000
Y-B 2500 8000
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.


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