A PRESENTATION ON HP TURBINE BLADE FAILURE RAMAGUNDAM UNIT-6

UNIT-6 OVERHAUL HISTORY

Sl NO 1 YEAR 1989 TYPE OF OVERHAUL UNIT FIRST SYNCRONISED LPT HPT & IPT LPT 1R-06 No Root crack IL-03, 2L- 01 & 1R06 No NFT HPT inner casing refinning at RC puram 1R- 06,1L-04 Root crack. IR-02 NFT REMARKS UNIT FIRST SYNCRONISED ON 26.03.1989 2R blads(02 No) replaced

2 3 4

1992 1996 2001

5 6

2004 2006

HPT & IPT LPT

2004 HP/IP OVERHAUL OBSERVATIONS

Sl No
1 2

INSPECTION
HPT INNER CASING REFINNING BLADE LOOSENESS/SHROUD GAP

OBSERVATIONS
PARTIAL REFINNING AT BHEL RC PURAM NIL

3
4

BLADE DEPOSITS
TG BEARING INSPECTION

NORMAL
UT&DPT , OK

LPT OVERHAUL 2006 OBSERVATIONS

Sl No
1 2 3 4

INSPECTION
LPT ROTOR AND BLADES MPI FREE STANDING BLADES NFT BLADE DEPOSITS BEARING INSPECTION

OBSERVATIONS
LP-1R 08 BLADES REPLACED (6 ROOT CRACKS & 2 NFT) LP-IL 04 BLADES REPLACED DUE TO ROOT CRACKS NORMAL UT&DPT , OK

HPT EVACUATION SYSTEM

HPT EVACUATION SYSTEM ORIGINALLY NOT ENVISAGED. INSTALLED AND COMMISSIONED IN 2006. SYSTEM IN SERVICE. LOGIC OF VALVE CLOSING ON TURBINE START UP TO BE REVIEWED.

UNIT-6 TG REPAIR WORKS 2009

ON 10.08.2009 FROM 16:30 HRS, TURBINE SHAFTS & BEARINGS VIBRATIONS STARTED INCREASING & FLUCTUATING. BEARING NO.1 VIBRATION REACHED 45 MICRONS FROM 13 MICRONS AND SHAFT VIBRATION AT BRG No.1 REACHED 125 MICRONS FROM 75 MICRONS. BEARING NO.1 TOP RIGHT SIDE TEMPERATURE INREASED FROM 79 TO 100 DEG. UNIT WAS STOPPED AT 08:03 HRS ON 11.08.2009 FOR INSPECTION AND RECTIFICATION. TG CAME ON BARRING GEAR. CONTROLLED COOLING OF TURBINE CARRIED OUT AS PER LMI. BARRING GEAR STOPPED AT 16:00 HRS ON 14.08.2009. OIL PUMPS STOPPED AT 09:00 HRS ON 15.08.2009.

UNIT-6 TG REPAIR WORKS 2009

AFTER TURBINE COOLING, HAND BARRING WAS NOT FREE AND RUBBING SOUNDS OBSERVED AT HPT REAR SIDE.

AFTER DECOUPLING LPT ROTOR ALSO, HP-IP ROTOR SYSTEM HAND BARRING WAS NOT FREE. AFTER DECOUPLING IP ROTOR FROM HP ROTOR, IP ROTOR WAS FREELY ROTATING, BUT HP ROTOR NOT ROTATING.

UNIT-6 TG REPAIR WORKS 2009

AS HPT ROTOR WAS NOT FREE, HPT EXHAUST (CRH/HRH) CIRCUIT WAS CHECKED FOR ANY BLADE/FIN DEBRIS. METALIC DEBRIS (FIN MATERIAL) FOUND AT HPT EXHAUST WHEN INSPECTED THROUGH EXHAUST PIPE STEAM WASH CONNECTION FLANGE. HRH STEAM CIRCUIT WAS INSPECTED. METALIC DEBRIS FOUND COLLECTED AT HRH STRAINERS,HRH DRAIN POT, HRH HEADER AT BOILER . THE ABOVE OBSERVATIONS INDICATED HPT MOVING/STATIONARY BLADES FAILURE.

PHOTOS

CRH/HRH CIRCUIT INSPECTION

INSPECTION AREA OBSERVATION

HPT EXHAUST
HRH STRAINERS 1,2,3,4 HRH DRAIN POT CRH INLET HEADERS (BOILER) CRHNRVs MS STRAINERS 1-4 CONDENSER HOT WELL

METALLIC DEBRIS FOUND

METALLIC DEBRIS FOUND. DAMAGE TO STRAINERS. METALLIC DEBRIS FOUND METALLIC DEBRIS FOUND NO NO INSPECTED, FLOOD TEST DONE NO

HRH LINE STEAM BLOWING DONE WITH TARGET PLATE

UNIT-6 TG REPAIR WORKS 2009

BASED ON ANALYSIS OF MACHINE VIBRATIONS AND SUBSEQUENT INSPECTION/OBSERVATIONS , PLAN FOR UNIT RESTORATION UNDER BHEL SUPERVISION WAS MADE AS REPLACE HPT MODULE WITH SPARE MODULE WHICH WAS READILY AVAILABLE AT SINGRAULI. INSPECTION OF IPT AND LPT MODULES ALSO, AND CARRY OUT COMPONENTS INSPECTION AND NDT.

1.

2.

3. HRH STEAM BLOWING WHILE UNIT RESTORATION AFTER REPAIR WORKS.

UNIT-6 TG REPAIR WORKS 2009

SPARE HPT MODULE TRANSPORATED FROM SINGRAULI TO RAMAGUNDAM IN 10 DAYS. MODULE REACHED RAMAGUNDAM ON 05.09.2009. IPT BLAST CLEANING IPT CASINGS AND ROTOR MPI DONE, OK. TG BEARINGS DPT & UT ,OK.

UNIT-6 TG REPAIR WORKS 2009

LPT INSPECTION OBSERVATIONS ROTOR BLADE MPI : NORMAL

ROTOR BLADE GROOVE MPI : ONE BLADE ROOT CRACK IN 1R FREE STANDING BLADESNFT: NORMAL

TG BEARINGS INSPECTION

: DPT &UT

UNIT-6 TG REPAIR WORKS 2009

IN MPI OF LP ROTOR, A CRACK WAS DETECTED AT BLADE ATTACHMENT (STEEPLE) AREA AT STAGE 1R OF THE ROTOR. THIS IS FIRST OBSERVATION IN 500 MW LP ROTOR IN NTPC. LPT ROTOR WAS REPLACED WITH POOL SPARE ROTOR (FULLY BLADED ROTOR) WHICH WAS PARKED AT RAMAGUNDAM

UNIT-6 TG REPAIR WORKS 2009

HPT MODULE AND LPT ROTOR REPLACEMENT NECESSITATED REAMING AND HONING OF COUPLING HOLES IN HP-IP,IP-LP & LP-GEN COUPLING.

HRH STEAM LINE STEAM BLOWING SCHEME WAS FINALISED IN CONSULTATION WITH CC/OS . STEAM BLOWING WAS CARRIED OUT AT 25 KSC PRESSURE THROUGH 100NB PIPE WITH MOV AND TARGET PLATE.

UNIT-6 TG REPAIR WORKS 2009

UNIT WAS RESTORED ON 23.09.2009 IN 43.5 DAYS. MACHINE VIBRATIONS AND OTHER PARAMETERS ARE NORMAL

THANK YOU

UNIT-6 HP MODULE BLADE DEBRIS

UNIT-6 HP MODULE BLADE DEBRIS

UNIT-6 HP MODULE BLADE DEBRIS

UNIT-6 HP MODULE BLADE DEBRIS

UNIT-6 HP MODULE BLADE DEBRIS

UNIT-6 HP MODULE BLADE DEBRIS

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