Project:

North Chennai Thermal Power Station- 210 MW, unit # 2 Problem: Oil leakage from hydraulic actuator of Emergency shut off valve. In North Chennai unit #2, total oil piping (lube oil, jacking oil and control oil) was replaced after the fire accident, which has happened in December 2004. The Emergency Shut off valve actuator was fully damaged and could not be used. Customer has arranged an Emergency Shut off valve with actuator from IB, Valley project, as BHEL could not supply it readily. During commissioning, oil leakages were observed in valve open position. Leakage points and analysis: Emergency shut off valve actuator consists of two pistons arranged, one behind the other. During opening of the valve both pistons are subjected to control oil via connection a. (Refer figure) and the pistons move against the force of the compression spring. The axial movement of the piston is converted into a rotary movement via a cog rack and toothed wheel, thus rotating the ball cock of the shut off valve through a coupling. The valve is erected upside down due to space restrictions. The oil leakages occurred in the following locations were attended as described below: 1. The oil leakage observed from the actuator spindle at the bottom: The actuator was removed, dismantled and the sealing rings were replaced at all locations. Thus the leakage at this location stopped. 2. Leakage observed between the two power piston cylinders from the first piston leak off chamber:

The sealing surface in the leak off chamber is observed to be rough, which was causing the leakage. The two pistons leaks off lines are connected to the drain header along with the fire protection solenoid drains. The leak off drain point orientation made at bottom by rotating the cylinder assembly as shown in the figure. This ensures no collection of oil in the leak off chamber. However during opening again, oil leakage was observed. To check the leak off quantity, the leak off pipes were disconnected and the shut off valve was opened. The leak off quantity from actuator was observed to be nil, whereas oil was coming out from drain header. This has caused backpressure in actuator leak off chamber. The leak off lines were separately routed to Main Oil Tank (MOT) by disconnecting it from other drains. Subsequently no leakage was observed during operation of the actuator. 3. Leakage from spindle of the shut off valve in open position: After reassembly of the actuator, this leakage was observed. As the actuator is assembled from bottom, misalignment has caused this leakage. It was carefully mounted with proper alignment and found the leakage has stopped from the spindle of the shut off valve. Conclusion and Suggestion: Customer is advised to replace the actuator as and when they receive new actuator, since the sealing surface was found rough. While erecting the leak off drain piping, it is to be routed properly, so that no back up oil build up in the leak off chamber occurs. It is desirable to erect the valve with actuator at the top and proper alignment to be ensured between valve and actuator.

Leak off connection Reoriented to bottom