PROJECT : VISAHAKAPATNAM STEEL PLANT (VSP) PROBLEM: LOW VACUUM FOR 7 YEARS IN TG -2,TPP TG-2, TPP, VSP is a controlled

extraction condensing steam turbine of 60 MW rating supplied by BHEL and installed around 1990. A problem of low vacuum has been troubling this unit for last 7 years i.e. vacuum was maintaining at - 0.72 ksc with both main ejectors and one starting ejector in service, at full load and extraction as per design. Actions taken: Earlier VSP has done all regular checks to resolve the problem since its existence i.e. they have done, at different times, 1. Condenser tubes cleaning (by acid cleaning and bullet cleaning). 2. Water tightness test of steam space (by filling water to turbine rotor axis). 3. Replacing all ejectors with new ones. In spite of all such efforts condenser vacuum was always low. VSP requested BHEL to find air ingress points to resolve the low vacuum problem, using our Helium detection kit. During February 2006 BHEL deputed a commissioning engineer from PSSR with a Helium leak detection kit to locate as yet unidentified air ingress points in VSP TG-2. A special cooling provision was made in a sampling line taken from the main ejector air vent (i.e. the sampled air/vapor was cooled with a temporary arrangement and taken up straight to turbine floor) to prevent moisture entry into the kit. Water vapor from air exhaust in the ejector can hamper Helium detection by wetting the special purpose membrane of the detection kit.

With this, the total system was checked with Helium detection kit. The complete results list is annexed in a separate table. Major leaks measured were: 1. Vertical parting plane (i.e joint between HP top casing and LP top casing: see annexed figure for detail). ---- 20,000 ppm. (major air ingress point indicated in sketch enclosed). 2. HP flash tank vent bellow near flash tank. ---- 500ppm 3. Starting ejector air isolation valve gland and valve flange.--- 200ppm. VSP took a unit shut down to attend the leak points along with generator pedestal vibration problem. All identified points were attended. When VSP brought back the unit to full load with extraction, vacuum was significantly improved to -0.83 ksc. TURBO GENERATOR NO.2 HELIUM LEAKAGE DETECTION TEST
S. NO. 501 02 03 04 05 LOCATION Turbine rear gland bellow Horizontal parting plane (MER side) Vertical parting plane (MER side) Both Bursting Diaphragms Vertical parting plane (ECR side) (Leakage is from Horizontal flange to valve block near rib) Horizontal plane (ECR side) Rear bellow (ECR side) Vacuum breaker HP flash tank bellow near condenser LP1 extraction valve bonnet HP flash tank bellow near flash tank Condenser box Hot well manhole cover Surge pipe, stand pipe flanges HPH-4 Safety valve LEAKAGE VALUE (ppm) 1-4 1 50 (Max.) 0 20,000

06 07 08 09 10 11 12 13 14 15

0 0 0 0 30 500 0 0 0 0

VACUUM LEAK DETECTION WITH HELIUM DETECTION KIT Integral top casing of 60 MW Turbine of Vishakapatnam Steel TPS

LP Top Casing

Major Air Ingress point (900 portion out of 3600 joint)

HP Top Casing

Shown Portion 20,000 ppm detected.