POWER SECTOR- NORTHERN REGION

ACHIEVEMENT 2013-14 : AS ON 31.03.2014

Power Sector Northern Region
PARAMETER BUDGET RE ACTUAL % ACHIEVED
RSC-VARANASI
GROSS
TURNOVER
2000 1641
2011.12
100.56%
CASH
COLLECTION
1700 1873.50 110.20%
All Figures in Rs Lacs
ACHIEVEMENT 2013-14 : AS ON 31.03.2014
Power Sector Northern Region
PARAMETER BUDGET RE ACTUAL % ACHIEVED
OBRA R&M
GROSS TURNOVER
625 420
422.29 67.56%
CASH COLLECTION
361 356.62
92.98%
OBRA R&M [7&8]
GROSS TURNOVER 572 211 91.92 16.06%
CASH COLLECTION 270 0.00 0%
RIHAND R&M
GROSS TURNOVER
30 52 70.42
234.73%
CASH COLLECTION
14 50.80
362.86%
All Figures in Rs Lacs
PROJECTION FOR FY 2014-15

Power Sector Northern Region
PARAMETER BE FY-2014-15
RSC-VARANASI
GROSS TURNOVER 1000
OBRA R&M
GROSS TURNOVER 900
OBRA 7 & 8
GROSS TURNOVER 740
RIHAND R&M
GROSS TURNOVER 40
SINGRAULI ESP R&M
GROSS TURNOVER 350
TOTAL 3030
All Figures in Rs Lacs
BHEL, RSC-VARANASI
CURRENT YEAR PERFORMANCE AS ON 31.03.2014
Power Sector Northern Region
ORDER BOOKED (FY 2013-14)


Rs. LAKHS
CUSTOMER/PROJECT WORK AMOUNT
NTPC/SINGRAULI STPS Turbine & Generator
48.13
NTPC/TANDA Turbine & Generator
239.45
NTPC/UNCHAHAR TPS Turbine & Generator
98.87
NTPC/RIHAND STPS Turbine
222.52
UPRVUNL/ANPARA TPS Turbine & Boiler
635.39
UPRVUNL/PANKI TPS Turbine & Boiler
117.72
UPRVUNL/OBRA TPS Turbine & Boiler
452.70
PIPRI/UPJVUNL
60.00
TOTAL 1874.78
BHEL, RSC-VARANASI
Power Sector Northern Region
ORDER BOOK (FY 2014-15)


Rs. LAKHS
CUSTOMER/PROJECT WORK AMOUNT
PREVIOUS YEAR CARRY FORWARD
NTPC/UNCHAHAR TPS Turbine & Generator
24.00
NTPC/RIHAND STPS Turbine
105.0425
UPRVUNL/OBRA TPS Boiler
210.99635
TOTAL
340.03885
CURRENT YEAR
UPRVUNL/PANKI TPS Turbine & Boiler
1.93113
TOTAL
1.93113
EXPECTED ORDERS
500
GRAND TOTAL 841.96998
MILESTONE SCHEDULE : PLAN & ANTICIPATED
SL. PROJECT/
UNIT No.
MW Actual
Days
Contractual
Days
Advance /
On Time
Completio
n
Remarks
1 ANPARA # 1 210 11 15 4 27.04.13
Revisioning of
hydrogen seals
2 ANPARA # 1 210 135 33
Demoblisation and re
mobilisation due to civil
work done by customer

16.10.13
Restorationof
Unit # 1
3 ANPARA # 3 210 30 30 0 12.12.13 Boiler & TG
4 ANPARA # 5 500 31 35 4 07.03.14
Boiler &HP
Heater
5 OBRA # 9 200 32 25 Extra work done 21/12/13
Inspection of
Stator and Brgs
6 PANKI # 4 105 13 18 5 16.10.13
Replacement of
Exciter Armature &
Additional Testing
works
Power Sector Northern Region 1/6
MILESTONE SCHEDULE : PLAN & ANTICIPATED
SL. PROJECT/
UNIT No.
MW Actual
Days
Contractual
Days
Advance /
On Time
Completion Remarks
7 PIPRI # 4 50 29 55 26 14.06.13
Extra Work
8 RIHAND #3 500 31 40 9 11.10.13
O/H of Generator &
Additional work of
Rotor Replacement
9 SINGRAULI # 3 210 14 15 1 23.04.13
Servicing of
Governing System
10 SINGRAULI#6 500 6 15 9 26.04.13
Repairing of Gen
Exciter (Services &
supply Portion)
11 TANDA # 1 110 49 50 1 23.10.13
Cap. O/H of U#1 TG
and Aux
Power Sector Northern Region 3/6

OUR ESTEEMED CUSTOMERS
CUSTOMER /
PROJECT
100 MW 110MW 200 MW 210 MW 500 MW TOTAL
UNITS MW
ANPARA 3 2 5 1630
OBRA 3 5 8 1300
PANKI 2 2 220
UPRVUNL 3 2 5 3 2 15 3150
RIHAND 4 4 2000
SINGRAULI 5 2 7 2000
TANDA 4 4 440
UNCHAHAR 5 5 1050
NTPC 4 5 5 6 20 5490
THERMAL 3 6 10 8 6 33 8640
Power Sector Northern Region

OUR ESTEEMED CUSTOMERS
OTHER CUSTOMERS (INDUSTRIAL & HYDRO SETS)
CUSTOMER / PROJECT 12.5 MW 18 MW 22.4 MW 33 MW 50 MW TOTAL
UNITS MW
UPJVNL/RIHAND HYDRO 6 6 300
IFFCO / PHULPUR 2 1 3 43
KSFL/SHAHJAHANPUR 2 2 44.80
UPRVUNL/OBRA HYDRO 3 99.00
TOTAL 2 1 2 6 6 11 486.80
Power Sector Northern Region
SOME OF THE TROUBLE
SHOOTING JOBS
CARRIED OUT
HIGH CHRONIC VIBRATION AT ANPARA U#1

Severe Axial & Vertical vibration in Brg # 5 & Brg # 6 Pedestals.
High Vibrations were also noted in Stator Endshield and water
header and increased seal oil flow.
Vertical vibrations suddenly increased above 50 s and axial above
120 s & machine had to be debarred

Spectrum recorded showed sever 2x components and other
higher frequency components & mapping was carried out
CONCLUSION:
VI BRATI ON I NDUCED WERE FOUNDATI ON I NDUCED AND
ELECTRI CAL I N NATURE




CRACKS WITNESSED
IN COLUMN


CRACKS WITNESSED IN
BRG # 6 PEDESTAL






ACTION TAKEN
1. REPLACEMENT OF ROTOR AND BRG # 4&6
2. REGROUTING OF SECONDARY FOUNDATION OF
BRG 6 PEDESTAL AND STRENTHENING OF
COLUMN NO 11& 12

RESULTS : MACHINE SUCESSFULLY SYNCHRONISED
WITH VIBRATIONS OF SHAFT BELOW 60 MICRONS
PK-PK AND PEDESTAL BELOW 30 PK-PK IN ALL
BRGS




MOULDS PREPARED FOR TEST & ITS TESTING





HEAVY SPARKING AT EXCITER IN UNIT#4, PANKI (105MW)
Heavy Sparking in exciter commutator of Unit # 4 Panki TPS was
reported and soon the problem rose to alarming level and machine
had to be debarred on June 21 2013.
Vibrational analysis and electrical test were carried out by UPRVNL
and based on that following were suggested.
1)Undercutting of mica on the commutator
2)Carrying out the drop test on the commutator segments and on pole
pitch apart & grrove chamfering and maintaining geometric axis
3)Checking the commutator for non uniformity, all the brush holders for
their correct spring pressure and he usage of correct grade of carbon
brush.
Results : The sparking though reduced but still was not resolved
completely.





ACTION TAKEN BY RSC VARANASI
RSC ENGINEER VISITEDTHE SITE AND FOUND
THAT THE UNDERCUTTING & GOOVE
CHAMFERING WERE IMPROPER AND STILL
DEMANDED MORE BUT THE COMMUTATOR
BEING OLD AND REUSED CONTINOUSLY RAISED
SUSPICIONS OVER POSSIBILITY OF FURTHER
UNDERCUTTING DAMAGING THE INSUALTION.
THE EXCITER ARMATURE WAS SUGGESTED FOR
REPLACEMENT AND UNIT WAS BROUGHT BACK
TO BAR WITHIN 7 DAYS.














CHRONIC AXIAL VIBRATION PROBLEM AT NTPC
UNCHAHAR U#3 (210MW)
High axial vibration of LPT Rear Bearing in U# 3. with
values above 50s and velocity around 20 mm/sec
The spectrum analyses revealed unloading of Brg # 4.
ACTION TAKEN
1. CATENARY & DECK CORRECTION AND ALIGNMENT
2. DESTRETCHING & STRETCHING OF FOUNDATION BOLTS REAR
BOLT WAS STRETCHED TO 2.43 AND THE FRONT BOLTS TO 2.30
DEVI ATI NG FROM THR NORMAL APPROACH OF STRETCHI NG THE
FRONT TO A HI GHER AS COMPARED TO REAR TO ENSURE PROPER
LOADI NG AS PER SPECTRUM
RESULTS
The axial vibration reduce to below 25 microns & Velocity to less than 8 mm/sec.






LPT REAR BEARING VIBRATION IN U#3

70

60
50

40

30

20

10

0

Measurement Samples

Axial
Vertical

PEDESTAL 4 BOLT STRETCHING,U#3









SEVERE EARTH FAULT AT DEVIGHAT NEPAL
(MACHINE BROUGHT TO GRID WITHIN 20 DAYS)
NEA had reported about the earth fault of stator Unit # 2,
Devighat. BHEL RSC Varanasi engineer reported at site
for attending the earth fault.
Observations:Fault severe in nature resulting melting of
overhang portion of two coils of B phase & burning down
of insulation of the nearby three other coils.
Constraints : Space constraint on removal of poles & Time
constraint for removal of rotor
Solution: Stator Removal Causing Both Time, Cost and Work easier

Solution: Stator Removal Causing Both Time, Cost and Work
easier
Machine Re-levelled, aligned and Brought Back to Grid on
20
th
Day with better running parameters compared to
other running Units
After replacement of the individual coils HV of the new coils
were carried out at 14.2 KV for 1 minute.
After finalization of the stator the HV of all coils/phases was
carried out at 9Kv in two parts and IR and PI taken































SEVERE EARTH FAULT AT DEVIGHAT NEPAL
(MACHINE BROUGHT TO GRID WITHIN 20 DAYS)
U# 2 with better
vibration

parameters as

compared to U #
3