PROJECT

KUTTALAM FRAME 6 FA GTG

PROBLEM

HIGH EXCITER VIBRATIONS

The Exciter rotor of Kuttalam frame 6 FA GTG experienced very high

vibrations which caused extensive damage to Permanent Magnet
Generator , Exciter bearing and Generator rear bearing . The cause
of failure is being investigated by BHEL Hyderabad. . The Exciter
rotor assembly
was sent to BHEL Hyderabad to rectify damages
occurred at site. The PMG assembly was reconstructed with new poles
, Exciter bearing and pedestal were replaced with new sets and the
rotor was balanced at works before dispatching back to site. A new
set of Generator rear bearing assembly was sent to site for
replacement of generator bearing.
During re- commissioning of unit the exciter rotor was smooth after
initial rolling at site but on reaching base load the exciter bearing
vibrations were increasing to trip values resulting in tripping of GTG.
The problem was referred to specialists at Hyderabad unit and PSSR.
It was observed that the exciter vibrations were increasing only in
horizontal direction and the vibrations were predominantly of running
speed . The bearing shell to pedestal clearances were measured and
found to be zero-zero. Based on previous experience at kuttalm site
this was given interference of 0.15 mm by scrapping at parting
planes. The GT was started and it was observed that at FSNL there
was no increasing behavior of exciter vibrations and the unit could be
sustained to run at FSNL. Since exciter vibrations were predominantly
of running speed and generator shaft vibrations were also high the
exciter rotor and generator rotor were trim balanced at site using
exciter diode wheel plane and generator rear plane. On rolling to FSNL
marked improvement was observed in Exciter and generator vibrations.

However the exciter horizontal vibration were oscillating between 100

microns peak-peak to 200 microns peak peak . The reason for this
can be supportive vibrations from nearby structures which come in
phase and go out of phase to exciter vibrations. It was observed that
the generator rear pedestal was connected to exciter support frame
by cooling air pipes - inlet 8 inches and outlet 10 inches both two in
numbers. It was decided to isolate exciter support frame from
generator rear pedestal . The pipes were cut and the gap created was
connected using rubber sheet material for providing air sealing. The
exciter vibration on rolling were found steady and satisfactory. The
exciter horizontal vibrations were measured at 70 microns and vertical
at 15 microns pk-pk at FSNL . The unit was synchronized and brought
to base load. The vibration behavior of the unit is found satisfactory
and the unit has been cleared for continuous full load operation.