REPORT

PROJECT: NTPC Unchahar

UNIT NO. : 2

RATING : 210 MW( KWU)

STATEMENT OF PROBLEM

NTPC Unchahar reported high rise of vibration of Brg # 6 Unit 2 on 10 th June after
a shut down and repair work which was carried out by NTPC itself.The vibration
rose to the tune of 102 microns in vertical direction while horizontal vibration
remained in the range of 20-25 microns pk-pk Also NTPC reported that the unit has
been running under high vibration after overhaul in 2016 carried out by NTPC
through its vendors. NTPC requested BHEL RSC Varanasi for analysis and
resolution of the issue.

BHEL RSC Varanasi engineer visited the site and carried out the vibration mapping
of the pedestal 6 and also collected coast up readings along with vibration spectrum.
The vibration pattern did not change corresponding to speed but varied with load.
Significant rise of bearing vibration was observed with loading and also variation in
the front and rear footing of the pedestal and also across the parting plane was
observed. The above factors indicated towards bearing disturbances and
unloading/looseness.
BEARING NO. 6 PEDESTAL VIBRATION MAPPING
The matter was discussed with NTPC and they requested for some immediate action
plan for running of the unit before taking the Unit into shutdown and also to avoid
down time as NTPC had to place order on BHEL and BHEL also required time for
further procedure and mobilization.

As per request following was advised as temporary measure and final

recommendation with shutdown was also advised. Also it was decided that if during
the activities by any means the vibration crosses 102 microns the unit is to be
tripped.

Temporary Action Plan :

Curved fixture placement
area

Load of 100 kg
was placed

Fixture with curved surface for

Load of 100 kg placement of direct load on the top
was placed

1. All the foundation bolts specially the front ones are to be tightened online
with the use of spanner and long pipes. Use of hammer was prohibited.
2. Loading of weight on the base plate.
3. A fixture to be formed and placed on top and loaded with additional
weights

All the above activities were done in presence of BHEL and the vibration
came back to 81 microns and was observed for twenty four hours and
stability was observed.

Final Recommendations :

BHEL further advised that the problem needs to be permanently resolved and
the carried out measures are just temporary for gaining of time.

1. The bearings need to be replaced and as per previous experience and data of
pedestal ovality the pedestal also needs to be replaced.
 2. The foundation bolts have to be re-stretched along with replacement of metal
washers in all the pedestal bolts.
3. The matching of the foundation base plate has to be carried out with surface
plate and then transferred to Pedestal instead of matching the new pedestal to
the base plate.
4. The secondary grouting is to be strengthened through epoxy grouting.
5. Placement of order as early as possible.
6. Tripping of machine if vibration values increases above 100 microns.

Action Taken :

NTPC awarded BHEL for carrying out the overhauling of the Unit and
resolution of the problem and placed a PO :-4000207326-049-1006 dtd
21/07/18. Machine was debarred on 19/08/18 & BHEL team mobilized site on
dt 20/08/18 and following activities were carried out.

1. The bearing 6 pedestal was opened and all readings were recorded.
2. Bearing 6 inter clearance with pedestal top half is found to be 0.17-0.20 mm
which is above the permissible limits (0.10-0.17mm). The final inter-
clearance value with new bearing and pedestal corrected to 0.07 to 0.01 mm
3. Bearing 6 was found to be loose as there were black marks on bottom half
which is due to oil ingress in the bottom half sitting area and rubbing it
against pedestal.

Figure 1 Black Spotting On Bearing Bottom

 4. Pedestal was found oval . There was ovality of 1.6 mm in top-bottom and left
right readings. Top bottom reading was 1.6 mm lower than left right readings.
5. Difference between coupling bolt of LP-GEN and coupling hole was found
0.06-0.16 mm in all holes. Reaming and honing of holes were carried out and
coupling bolts were replaced with new ones.
6. Assembly was done with new bearing and new pedestal keeping the inter-
clearance in limit. Initially the base plate was matched with surface plate and
level cross checked through water level to the tune of 0.25 mm and blue
matched to more than 80 % .

Figure 2 Base Plate Blue Matched With Surface Plate

7. Blue matching of pedestal and bearing, pedestal with base plate etc. were also
done.
8. All pedestal bolt washers were replaced with new ones and matched with
bearing and base.
9. Foundation Bolts of Base plate of pedestal 6 was stretched to the stretch
values.
10.Epoxy grouting was carried out at pedestal 6 secondary grouting area.

RESULT

The machine was synchronized on 17/09/2018. After synchronization Bearing 6

vibrations were in permissible limits for continuous operation. Bearing 6 vibrations
were X 8.16microns and Y 21.98 microns at 191 MW. Vibration at Various Loads
were observed & found satisfactory.
Figure 3 Vibration @ 189 MW

Figure 4 Vibration @ 156.9 MW

Figure 5Vibration @ 200 MW as on 29/11/2018

Shobhan Kumar Malana (Dy. Manager,BHEL RSC Varanasi )

Amit Singhal (Sr. Engineer, BHEL RSC Varanasi)
Dharmendra Kumar(Sr. Engineer,BHEl RSC Varanasi)
Abhishek Kr. Singh (Sr. Engineer,BHEl RSC Varanasi)