REPORT ON BLADE FAILURE OF LP LAST STAGES IN UNIT-2, 210 MW, IB TPS.

1. BRIEF HISTORY TWO SECOND UNIT OF 210 MW, 3 CYLINDER, REACTION TYPE, TANDEM COMPOUNDED, SIEMENS DESIGN, BHEL MAKE, STEAM TURBINE WITH 6 EXTRACTIONS, SINGLE REHEAT, 535 DEG AND 150 BAR INLET STEAM CONDITIONS. 22.10.1 5 55,000 HOURS !APROX" NONE, HOWE#ER COMPLETE O#ERHAULING OF ONLY LP TURBINE AND ALIGNMENT OF HP, IP LP AND GENERATOR ROTORS DONE ON 01.11.1 $ TO 23.12.1 $ 2 %06.2003 &ULY 200', INCLUDING GENERATOR ROTOR THREAD OUT AND MISC. WORKS DUAL FLOW, $ STAGES, 5 STAGES BLADING WITH SHROUDING AND LAST 3 STAGES ARE FREE STANDING WITH FREE TREE GROO#E ROOTS. THE TURBINE IS TRIPLE CASING, WITH FIRST 5 STAGES CONTAINED IN INNER INNER CASING AND LAST 3 FREE STANDING STAGES IN INNER OUTER CASING. (20 MM TOTAL INSTALLED UNITS UNIT DETAILS

DATE OF COMMISSIONING TOTAL OPERATING HOURS AS ON DATE OF FAILURE HISTORY OF ANY CAPITAL O#ERHAULS DATE OF FAILURE DUE DATE PLANNED FOR CAPITAL O#ERHAUL OF THE TURBINE !ALL 3 MODULES" DETAIL OF LP TURBINE HEIGHT OF LAST STAGE LPT MO#ING BLADE 2. SL. NO. 01

SEQUENCE OF EVENTS DURING FAILURE DATE 2$.06.2003 TIME in HRS 0(.55 DESCRIPTION TOTAL GRID FAILURE OCCURRED WHERE BOTH THE UNITS WERE DISCONNECTED FROM THE GRID AND SUBSE)UENTLY TRIPPED FROM FULL LOAD. NO ABNORMALITIES OBSER#ED DURING COASTING DOWN OF THE UNIT. EMERGENCY SUPPLY RESUMED WITH RUNNING OF DG SET. AUX. OIL PUMP STARTED IN TIME ENSURING OIL SUPPLY TO BEARINGS. COASTING DOWN TIME OBSER#ED TO BE 12 MINS FROM FULL SPEED OF 3000 RPM TO BARRING GEAR SPEED OF 120 RPM TURBINE ROLLED TO FULL SPEED AFTER RESUMPTION IN START UP POWER AND NORMALISATION OF GRID FOR SYNCHRONISATION. BEARING NO 5 PEDESTAL #IBRATIONS OBSER#ED TO BE ABO#E NORMAL OF 'O MICRONS !0 TO PEAK". AFTER SYNCHRONISATION AND AT 30 MW LOAD THE #IBRATION INCREASED TO '$ MICRONS. THE UNIT WAS HAND TRIPPED. PRESUMING WATER INGRESS TO GLANDS AND LP GLAND RUBBING IT WAS DECIDED AFTER INLINE CONSULTATION WITH BHEL EXPERTS FROM HARADWAR, DELHI AND CALCUTTA, TO ROLL THE UNIT AFTER. FEW HOURS ON BARRING GEAR AND PROPER SOAKING OF THE UNIT AT 600 RPM. THE UNIT WAS RE ROLLED AND SIMILAR #IBRATIONS OBSER#ED AS SEEN EARLIER. THE UNIT WAS HAND TRIPPED THE UNIT WAS RE RUN AFTER MORE DISCUSSIONS WITH BHEL PERSONNEL AND CHECKS FOR GLAND BOXES OIL )UALITY ETC. HOWE#ER THE #IBRATION LE#ELS REMAINED HIGH AS BEFORE. IT WAS THEN DECIDED FOR CHECKING OF BEARINGS GLAND BOXES AND LAST STAGE BLADES OF TURBINE. THE UNIT WAS HAND TRIPPED. BY THE TIME BEARINGS 3, ' AND FI#E INSPECTED AND BEARING 5 FOUND TO HA#E MINOR ABNORMALITIES, AND WAS REPLACED, GLAND BOX CLEARANCES CHECKED AND DURING OPENING OF LPT OUTER CASING OBSER#ED BLADE FAILURE OF LAST STAGE OF LPT !FRONT AND REAR"

02

2$.06.2003

0(.56

03

2$.06.2003

13.00

0'

2$.06.2003

1'.00

05 06

2$.06.2003 2 .06.2003

1 .20 10.00

0(

10.0(.2003

3.

DETAILS OF FAILED BLADES

BLADE NO. GS *LP+IIIL

OBSERVATION

PHOTOGRAPH

D+02050

BLADE WAS BROKEN AT A HEIGHT OF '00 MM FROM THE ROOT.

D+020'

CRACK OF 15 MM LENGTH AT THE LOCATION OF 250 MM FROM TIP OBSER#ED AT THE INLET EDGE. IMPACT MARK AT THE TIP OF THE PROFILE AS WELL AS RUBBING MARK AT INLET EDGE OF TIP OF PROFILE OBSER#ED. A DEEP CUT OF LENGTH 12 MM AT OUTLET EDGE 23 MM FROM TIP OBSER#ED. PROFILE GOT TWISTED INWARDS.

D+02056

IMPACT MARK AT THE TIP OF THE PROFILE AS WELL AS RUBBING MARK AT INLET EDGE TIP OF BLADE PROFILE OBSER#ED. PROFILE GOT TWISTED INWARDS.

TS LP-IIIR

D+0206$

IMPACT MARK AT 2 PLACES AND CUT OF 20 MM LENGTH AT TIP OF BLADE PROFILE OBSER#ED. ONE CONNECTING PIECE GOT SHEARED FROM UPPER HALF GUIDE BLADE CARRIER 3R AND IMPINGED IIIR MO#ING BLADES. PROFILE GOT TWISTED INWARDS DUE TO THE IMPACT OF THIS BROKEN PIECE.

D+0210'3

CRACK OF 1$ MM LENGTH AT THE LOCATION OF 2'5 MM FROM TIP WAS FOUND AT THE INLET EDGE. IMPACT MARK AND CUT OF 1$ MM LENGTH AT TIP OF BLADE PROFILE OBSER#ED. PROFILE GOT TWISTED INWARDS DUE TO THE IMPACT OF BROKEN CONNECTING PIECE.

D+02006

15 MM LENGTH CHIPPED+OFF MATERIAL AT THE INLET EDGE AND 10 MM FROM TIP OBSER#ED. DAMAGE IS DUE TO SUBSE)UENT IMPACT OF BROKEN CONNECTING PIECE.

4.

MAINTENANCE WOR

DONE

It was decided to replace the 6 nos. da a!ed "# nos. on either side$ %lades with new ones. &hel Hardwar was contacted 'or a(aila%ilit) o' spare %lades. A'ter pers*asion+ &HEL Hardwar identi'ied a(aila%ilit) o' so e %lades %*t in'or ed the) a) not atch the o ent %alance o' the e,istin! da a!ed %lades. Hence+ the n* %ers p*nched on the roots o' the da a!ed %lades were sent to &HEL+ Hardwar and accordin! to the ori!inal Mo ent &alancin! Chart si, %lades + three each 'or %oth the sides were identi'ied and dispatched to the site %) &HEL+ Hardwar alon! with re-*ired nos. o' cla pin! pieces and loc.in! pieces.

Moment Moment New Moment Old/damaged offset new weight Blade weight Blade no. vs. old in in gm-m no. in gm-m gm-m ,ur(ine %nd -"- ... $ #
D 0206$ D 02006 D0210'3 '1 $ '22' '222 BA 6220 BA 6112 BA 6221 BA 611( BA 612( BA 6115 '1$1 '2'3 '1 1 +1( ,1 +31

Frequency Measured in Hz. !t "ress#

(1 !F1", 166!F2" (1!F1", 166!F2" (1! F1",166 !F2" (0 !F1", 16 !F2" (0 !F1", 16 !F2" (0 !F1", 165!F2"

$%M!$&' allowa(le diff. of moment (alance )/*+ gm-m#

MOMENT BALANCE DIFF WITHIN LIMITS MOMENT BALANCE DIFF WITHIN LIMITS MOMENT BALANCE DIFF BEYOND LIMITS BUT ACCEPTED MOMENT BALANCE DIFF WITHIN LIMITS MOMENT BALANCE DIFF BEYOND LIMITS BUT ACCEPTED MOMENT BALANCE DIFF WITHIN LIMITS

/enerator %nd -"- ... - #

D02050 D020' D02056 '313 '2 ' '1 6 '2 2 '2'0 '203 +21 ,'6 ,0(

Three persons 'ro &HEL+ Hardwar incl*din! a /*alit) Control an reached I& TPS site on 01.23.422# and Mr. T. 5. 6hosh+ D6M+ STE+ Hardawar reached on 07.23.422# ornin!. The spare %lades8 're-*enc) was eas*red and the se-*ence n* %ers were con'ir ed o(er telephone 'ro Shri &. Das+ D6M "T&M$+ &HEL Hardwar 07.23.422#. The details are as a%o(e. Ma!netic Particle test was carried o*t on all the last 4 sta!es o' the LP Rotor %lades %) a tea 'ro Corporate R9D+ &HEL+ H)dera%ad a'ter thoro*!h sand %lastin! in sit*. No a%nor alities or crac. reported %) the a'ter the tests. All the rotors were deco*pled and reali!n ent o' HP+ IP LP and 6enerator Rotor were done with corrections whate(er re-*ired. The HP IP casin! centerin! done a'ter 'inali:ation o' the rotors. LP T*r%ine was %o,ed *p with corrections o' all internal clearances where(er re-*ired. LP !land %o,es reali!ned with chan!e o' new .e)s. All &earin!s were DP and ;ltrasonic tested. Two nos. o' Thr*st pads replaced as it was re<ected %) ;ltrasonic testin!. The *nit was rolled and the (i%ration anal)sis was done %) e,pert 'ro Ta al &anner<ee. He opined the (i%rations are well within li its. !. ROOT CAUSE AND FUTURE ANALYSES SAS &HEL Calc*tta+ %) Mr.

Mr. N. 5. &ansal+ A6M "T*r%ine$ 'ro TS=+ H/ &HEL (isited I& TPS 'or anal)sis and ca*se o' 'ail*re. He re(iewed all operatin! para eters histor)+ asse %l) protocols and s*% itted a report and reco endations as %rie'ed %elow.

I" #$$%#&' "(#" )*#+%' (#' ',--%&%+ "(% -.**./012 1. O-- F&%3,%145 .$%&#"0.1 2. O6%&*.#+012 3. F&%3,%1" G&0+ F#0*,&% 4. P..& /#"%& 4(%70'"&5

I" (#' )%%1 #+60'%+ ". "(% 4,'".7%& ". '%1+ "(% )*#+%' ". BHEL C.&$.&#"% R8D 9 BHEL H#&+/#& -.& -,&"(%& 4.1-0&7#"0.1 .- "(% $&.4%'' .- -#0*,&% 7%4(#10'7. R%4.77%1+#"0.1. T. %%$ .1% 4.7$*%"% '%" .- LP *#'" "/. '"#2%' -&%% '"#1+012 )*#+%' #' '$#&% T. 4*%#1 )*#+% #1+ &.".& &.." ". &%7.6% '#*" +%$.'0" R%$*#4% #** 4*#7$012 $0%4%' #1+ *.4: $*#"%' MPI .- #** "(% )*#+%' #-"%& &%7.6#* -&.7 "(% &.".& R%7.6% $0$% $,**' ". LP -&.1" 2*#1+ ).; C(%4: #1+ 01',&% IR 6#*,% .- )%#&012 N. < P%+%'"#* I1',&% $&.$%& /.&:012 .- %#&"( )&,'( P.''0)0*0"0%' .- )*#+% -#0*,&% 01 U10"-1 .1 '070*#& *01%' .- U10"-2 %;0'"'. S. 1%4%''#&5 $&%4#,"0.1 .1 "(% *01% .- U10"-2 ". )% ,1+%& "#:%1.
&ased on the reco endations the 'ailed %lade has %een send to &HEL+ H)dera%ad and another set will %e send to Haradwar 'or anal)sis+ and tests to con'ir e,act reason o' 'ail*re. The report is e,pected to %e a(aila%le %) the end o' No(e %er 422#.