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Bharat Heavy Electricals Limited
BHEL PSWR

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Powering progress, Brightening Life

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TAKNIKI DARPAN
Reflection of the achievements…..

ISSUE SPECIAL: SITE FEEDBACKS

 lekeâveerkeâer ohe&Ce
Reflection of the achievements…..
EDITORIAL COMMITTEE ISSUE NO. 18, JANUARY : 2015

Sh. B. Swain
Sh. S.Mandal INSIDE
Sh. Rajib Chakraborty
TITLE PAGE
EDITOR
MESSAGE FROM HEAD (TSX) 01
Sh. B. Swain

ISSUE SPECIAL - SITE FEEDBACKS 02

CONTACTS & FEEDBACKS

Sh. Dinesh Jawade

Email: djawade@bhelpswr.co.in

Phone: 0712 3048660

Mobile: 09423680639

The statements and views expressed in this Magazine

are entirely those of authors and not necessarily that of
the Organization.

Cover photograph: NTPC Mauda

PUBLISHED BY TSX/PSWR FOR INTERNAL CIRCULATION ONLY

T ECHNICAL SERVICES, BHEL-PSWR
January - 15

MESSAGE FROM HEAD (TSX)…………

Dear Colleagues,
Wish you and your family members a very happy and
prosperous new year. We have entered into the last quarter of
financial year 2014-15 and when we look at the achievements
and targets for the year, it is very clear that the path ahead is
going to be tough and challenging.
We have nearly 3500MW to be synchronized and around
4000MW capacity addition is to be achieved. Additionally, some
old projects such as GPPC Pipavav, GSEG Hazira and IEPL Belais
going to be re-started. In totality, the asking rate (to use a popular
cricketing parlance) has already become very high and we will
have to give really more than hundred percent to achieve our
targets.
This issue of TaknikiDarpan is an excellent compendium of
feedbacks received from various sites of PSWR. The feedbacks
are a nice collage of experiences and innovations from Power
Sector, Industry Sector as well as IO projects. It is also heartening
to observe that the contributions are from a wide spectrum of
employees ranging from General Managers to Engineer Trainees
who have spared time to write down the feedabacks so that it is
shared with others for betterment of our working. We sincerely
hope, these feedbacks will be useful in problem solving and
reducing time cycle during project execution.
Please give us feedback about this issue and also share with
us your innovations and experiences at site so that others will be
benefited from it.
Once again, best wishes and enjoy working.

B. Swain
AGM, TSX,
BHEL, PSWR, NAGPUR.

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LPH 1 & DRAIN COOLER LEVEL HIGH PROBLEM IN TROMBAY-8

Sadanand Mandal
AGM, TSX
PSWR-Nagpur
PROBLEM:
While commissioning of Trombay-8 after revival, post LP blade failure in Jan 2014, it was reported that the
level control of LHP1 & Drain Cooler is not operating properly.
Both LPH 1 & DC used to remain bypassed due to very high level up to load more than 200MW. The
correctness of remote indicator with the local level gauge also confirmed that the level in LPH 1 increased
to very high level (>200mm) and caused LPH 1 & DC to get bypassed from condensate side.
It was also reported that after carrying out the modification (the height of inverted U-loop was reduced in
the LPH1 to DC drip line) earlier to the failure, the level control became effective but only after a load of
greater than 170MW. While commissioning the set during restart on 16.11.14, the same was also observed
by BHEL commissioning team at site.
ACTION TAKEN:
The process of unit restart had already been started after a gap of ten months and observations made only
after restart of unit. So following actions were carried out while unit is in operation.
1. Erected drip line layout was cross checked with the layout. It was observed, even after correcting the
layout of LPH 1 to DC drip line, there was still an inverted U-loop of 300-400 mm in the same line. This
loop was due to crossing of LPH2 drip line to LPH1 on the operating floor at 8.5 mtr. (see attached fig).
2. There seemedto be no vent orifice in the LPH1 vent line (2” size) to condenser. The vent valve was found
fully opened with heater in service. The same was closed and kept crack open to have orifice effect.
3. The isolating valve in drip line of DC to condenser was closed and allowed the level to build up keeping
constant watch on LPH1 level both from remote and local. As soon as the level started building locally
as well as at remote, the same drain valve was opened at a load of 210 MW. Then the load was started
reducing. It was observed that the level in LPH1 was within normal level even when the load was
reduced to less than 100 MW.
4. Under the same condition as soon as the vent valve was opened full, level started increasing. But unit
also tripped at the same instant. Hence not further observation could not be done.
However from the above observations, it became clear that there might be problem of air lock in the
inverted U-loop in the drip line of LPH1 to DC. High venting of LPH1 through the 2“vent line might be
causing low DP in the LPH1 to condenser drip line via DC.
For carrying out trim balancing, there was outage of unit on 20.11.12, without vacuum in condenser. By
using the opportunity, following temporary arrangement was made.
1. One temporary 1 inch line was erected from the top of the inverted U-loop to LHP 1 shell side through
the stand pipe vent (ref fig).
2. The vent valve was kept crack open to have orifice effect. The DC drip line valve to condenser was kept
full open.
With that arrangement unit was restarted on 22.11.14 early morning after adding balancing weight inLP
turbine front and rear plane. Both LPH-1 & DC was kept charged from condensate side from start of the

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unit. It was observed that there was no level built up problem from no load to full load. Max level in LPH1
was +35 mm (min level was -125mm as per remote level transmitter) throughout the operation.
From the above it may be concluded that
1. There was air lock in the inverted U-loop in the drip line of LPH 1 to DC. By providing the continuous air
vent from the top of inverted U-loop, the air locking problem was overcome.
2. Due to high venting of LPH1 to condenser there used to be low DP between LPH1 & DC combination at
low load condition. Once the steam flow to LPH1 increased beyond the threshold limit (> 170MW), the
DP becomes more and the resistance of air locking in the inverted U-loop got overcome and heater
comes to service. By keeping the vent valve in the throttled condition also helps to maintaining
sufficient DP to make the drip flow from start of unit to full load.
NOTE:
As per the heater level control logic, there is no level control valve in the drip line of LPH1 to DC and from DC
to condenser. There is only one level control valve in the cascading drip line from LPH2 to LPH1. Under
condition of high level in LPH1, the same control valve will get close command diverting the drip from LPH2
to condenser directly isolating the LPH 1 from drip side. Condensate line inlet valve to DC will close and
outlet valve of LPH-1 to LPH-2 will close & bypass valve will be opened bypassing the heater from
condensate side. As per the layout and logic there should not be any level built up in LPH1 under any
condition from no load to full load if the isolating valve in the drip line of DC to condenser is kept full open.
Even with the temporary arrangement made at site there is level build up in LPH1 (from -125 to +35 mm).
This is because of the inverted U-loop which still exists because of site condition. This is also not the
intended operation of LPH 1.
SUGGESTION:
To correct the same, it is highly recommended to modify the LPH1 drip line suitably based on site condition
so that there the drain line will always have negative slope towards DC. Otherwise it will have an
unexpected effect of LP turbine last stage blades for which it is not intended or designed.

PROPOSED TO ROUTE THE LPH 1 DRIPLINE BELOW THE FLOOR TO GET

CONNECTED DOWNSTREAM THUS AVOIDING INVERTED U -LOOP AND
AIRLOCKING PROBLEM

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ACTUAL ARRANGEMENT AT SITE

Mr. Sadanand Mandal is presently posted at Technical Services, Nagpur

having vast experience in commissioning of Steam Turbines & Gas
Turbines and its auxiliaries.

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January - 15

HPCV1 & 2 NOT OPENING AS PER CHARACTERISTICS

Sadanand Mandal
AGM, TSX
PSWR-Nagpur
PROBLEM:
While taking readings of HPCV 1 & 2 opening with HP secondary oil pressure in Hydraulic governing mode,
it was observed that even though the start of opening of the valves were set correctly, opening of the valves
was more than design in the midrange of HP secondary oil pressure (see table).However, final opening was
matching.
ACTION PLAN:
The front washer of respective feedback cam was removed and their thicknesses were reduced. The
existing cam thickness of HPCV1 was reduced from 18 mm to 13 mm and that of HPCV2 was reduced from
17 mm to 13 mm. Accordingly the locking washers thickness at the back of the cam of respective valve was
increased by 5mm for HPCV1 & 4 mm for HPCV2 respectively for proper locking of the cam. With that HPCV
1 & 2 opening with HP secondary oil pressure was taken and found in order (see table )

Before changing feed back cam After changing feed back cam
Sl no HP sec oil HPCV 1 HPCV 2 HP sec oil HPCV 1 HPCV 2
Press opening opening Press opening opening
ksc mm mm (ksc) mm mm
1 2.4 2 2 2.4 1 1
2 2.78 5.5 6 2.5 2 2
3 2.9 7.5 7.5 2.8 6 6
4 3.4 21 16 3.o 9.5 9
5 3.6 30 26 3.4 21 16
6 3.75 33 29 3.58 25 21
7 4.63 62 64 3.7 30 27
8 5.1 62 64 3.9 37 35
9 4.2 44 44
10 4.6 50 51
11 5.0 51 52
12 5.1 55 55

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EHC PROBLEMS
Sadanand Mandal
AGM, TSX
PSWR- Nagpur
PROBLEM 1:
After adjusting the balance voltage at -1.6 V, it was observed that the balanced voltage was drifting towards
positive side causing disturbance in EHC operation. On investigation it was observed that the amplifier
piston as well as the EHC pilot assembly were not free. So both the assemblies were dismantled and
cleaned thoroughly. Even after that the problem did not get resolved. It was then noticed that-
1. There was leakage at the bottom of the EHC pilot through the threaded cap.
2. There was low trip oil pressure to the EHC block. It was less than 4.5 kg/cm2 instead of 5.0 +0.5 kg/cm2
as per design even after full tightening of pressure converter in the trip oil line.
ACTION TAKEN:
1. A new pilot from spare was assembled. Before assembly no leakage through the thread was ensured.
2. The trip oil supply line orifice size was increased from 3.0 mm dia to 4.0 mm dia. The orifice to EHC pilot
valve was increased from 1.5 mm dia to 1.8 mm dia. With that oil pressure in the trip oil line to EHC
improved to 5.0 kg/cm2.
3. Since there was lot of adjustment trial taken with the old moving coil assembly, a new moving coil
assembly was installed in place of the old one.
With the above changes, the EHC balanced voltage drifting problem got stabilised.
PROBLEM2:
While taking HP & IP secondary oil pressure readings with EHC voltage, it was found that the IP secondary
oil pressure was dropping immediately from 5.3 kg/cm2 to 0 kg/cm2 with EHC opening more than 90 %. It
was also observed that two follow up pistons out of three in the IP secondary oil follow up piston battery
was not responding properly with the adjustment screws. By blocking the oil supply to those two suspected
follow up pistons, IP secondary oil pressure became stable even beyond 90% EHC opening. It increased to
5.6 kg/cm2 with 100 % EHC opening. Repeatability was also found to be matching.
Though no apparent abnormalities were noticed with these two follow up pistons, they were replaced with
new ones. Still the problem of IP secondary oil dropping did not get resolved. So the EHC with follow up
pistons battery and linkages was removed from location for through checking. It was observed that there
was fouling of power piston linkage with IP secondary oil follow up piston battery sleeve. Further it was
noticed that the power piston linkage was of short length than the design. It was 102 mm against 127mm as
per drawing (fig-1). The length of the old linkage was increased at site by adding an extra piece and EHC
block was assembled (fig- 2). The functioning of the block was found to be alright and there was no
dropping of IP secondary oil pressure beyond 90 % opening of EHC even with all three IP follow up pistons in
service. Max IP secondary oil pressure was 5.6 kg/cm2 with 100 % EHC opening.

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Fig.1

Fig.2

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New linkage (fig-3) with correct dimension was brought from BHEL/Hardwar and again assembled in the
EHC block by replacing the old fabricated one. With that calibration of EHC was taken and found to be
satisfactory

Fig.3

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January - 15

FURNACE AIR TIGHTNESS TEST USING 2 BLOWERS METHOD

ENGAGED AT 2X150 MW OPGS KUTCH SITE
Tarsem Lal
GM (Project-VII)
Madhur Jain
Sr. Engineer
OPG Kutch
INTRODUCTION:
Furnace Air Tightness Test conducted in Boiler requires following points to be completed:
1. Completion of FD Duct to APH
2. Completion of Secondary Air Duct
3. Completion of Economizer to APH Duct
4. Readiness of FD Fan with commissioning
5. Bottom Ash Hopper Sealing
At 2X150 MW OPGS Kutch Site, erection of Ducts has been completed and FD Fan was kept ready for
Commissioning. But, because of the unavailability of Startup power from the customer, the commissioning
of the FD fan was getting delayed. Considering the delay in commissioning of FD Fan, Furnace Air Tightness
Test was getting delayed. Since the Air Tightness Test of the furnace is a continuous process and involves a
time period for completion, an alternate solution was required for avoiding the delay.
THINKING BEHIND THE METHOD:
Brainstorming was done by all persons involved in presence of Construction Manager as to how the delay
can be avoided by alternate means. On in depth brainstorming, it was thought that Air Tightness Test in ESP
is being done with the help of Blowers of 37 KW motors. At OPGS Kutch Site, the approximate volume of the
Furnace including the Ducting circuit required for Furnace Air Tightness Test is 3 times the volume of ESP. If
the tightness test of ESP can be completed with 1 number of blower, Furnace Air Tightness Test can be done
by engaging 2 Blowers of 37 KW motors running simultaneously. Though time for building the required
pressure of 100 mm of water column will be more but certainly the process can be used for finding the leaks
and the time required after commissioning of FD Fan can certainly be reduced.
ARRANGEMENT:
The very next step was how and where the Blower discharge is to be connected. On detail study and intense
discussion ideas ranging from Bottom S Panel to Water Cooled Access Door at 9mm were discussed.
Ultimately it was decided that Discharge Pipe is to be connected to Vertical section of Coal Pipes at Corner 2
and Corner 4. The Blowers were suitably strengthened so that vibration is minimized.

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Also, the work on Bottom Ash Hopper (Customer Scope) was not even started. On Discussion along with
the customer it was decided to seal the S Panels temporarily by Castable refractory.
IMPLEMENTATION:
The arrangement is in process and continuously leaks are identified and are being repaired simultaneously.
CONCLUSION:
Since being a continuous process, the leaks are being identified and regularly attended. Also, the blowers
are readily available for ESP Air Tightness Test and the same blowers can be used for the same. The process
has removed the dependency on external factors such as Foundation readiness for Fans, Startup Power,
etc. which are usually in Customers Scope as is the case at OPGS Kutch site. The process has helped in
reducing the time for Furnace Air Tightness Test once the FD Fan is commissioned on receipt of startup
power from the customer. At OPGS Kutch site, instead of cribbing about the non-availability of the fronts,
team has successfully found the alternate solution which has saved approximately 25 days.

Mr. Tarsem Lal is presently working as GM-Projects (I, VII and

Amravati) at Amravati site.

Mr. Madhur Jain is presently working as Sr. Engineer at OPG

Kutch site looking after Boiler erection.

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CASE STUDIES
Tapas Saha
AGM,
Hindalco Mahan Site
1.0 FAILURE OF BFP IN UNIT-1 AT HINDALCO MAHAN SITE
DESCRIPTION:
On 16/08/2013, when U#1 TG was running on load, BFP 1A suddenly developed very high vibration leading
to shut down of the pump. Prior to the high vibration, there was heavy shaking of suction and discharge
lines of BFP.
ACTION:
It was decided to decouple the BFP shaft and check alignment. While checking alignment it was found that
shaft is very tight in rotation. After much effort it was possible to rotate and alignment was checked. Radial
alignment was found disturbed by about 3mm. It was then decided to open the pump. After opening the
pump, the cartridge was sent to BHEL, Hyderabad for inspection and repair.
ANALYSIS:
It is concluded that the damage in the pump has occurred due to high vibration which was caused by
misalignment of Hydraulic coupling assly. It was also found that Hydraulic Coupling is disturbed from its
original position by several mm as few of the foundation bolts which were assembled during erection were
missing . There is no provision of locating pin in hydraulic coupling assly supplied by Voith.
REMEDIAL ACTION:
It is suggested to provide at least two locating pins in the Hydralic coupling assly. This will prevent physical
movement of the body in case foundation bolts are not in order.

2.0 HIGH VIBRATION AND LP ROTOR BENDING OF U#3 TG AT ADITYA BIRLA PROJECT ATLAPANGA,
ODISSA.
DESCRIPTION:
The Unit was commissioned and was running at 80MW load. Suddenly there was high shaft vibration in brg
no. 4. The vibration exceeded more than 400 micron. Machine was hand tripped but it could not return to
Barring Gear operation. After 3-4 days when machine was cooled , inspection of brg was carried out. During
inspection it was found that journal and coupling run out was on the higher side at 0.10mm.However there
was no damage in the bearing. Heavy rubbing marks were observed in the LP gland area.
ACTION:
LP gland was replaced with a new gland . Since LP rotor run out value was high, it was replaced with a new
rotor as per direction from customer. After replacement of the rotor m/c was rolled again and loaded. All
parameters were found normal.
ANALYSIS:
During first commissioning, the gland steam temperature controller were not commissioned. The gland
steam temperature was being controlled from PRDS. During operation once gland steam temperature shot
up to 370 deg C. During that time high vibration of the rotor was observed. Due to sudden over-heating of
the gland box, the body of the glad box, which is a fabricated one , got deformed and resulted in total loss of
clearance between shaft and seals and led to rubbing of the shaft.
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REMARKS:
i) The gland steam controller should be in service before charging steam to shaft glands. The temperature
of initial gland steam should be kept as low as possible.
ii) The bow in the shaft was probably a temporary phenomenon. An attempt of salvaging the situation
could be attempted by putting the rotor on Barring Gear operation for a prolonged time and then low
temperature soaking could have been carried out at 500-600 rpm. But this was not attempted due to
pressure from customer to replace the rotor.

3.0 RECTIFICATION OF DIFFUSER OF LPT IN UNIT-4 AT HINDALCO, MAHAN SITE.

DESCRIPTION:
The total calculated length of diffuser in LP inner-outer casing from Turbine End to Exciter end as per drg is
3558.4 mm. While lowering the outer casing the guide of diffuser fitted in the outer casing passes by the
diffuser with a clearance of about 5 mm each side. This dimension of diffuser was found more at about
3575 mm. This caused obstruction in lowering the casing and the outer casing box-up was held up.
SITE ACTION:
This dimension was not maintained at works causing this problem. It was not feasible to send back the
diffuser to works or any other machine shop for rectification. It was decided at site level to first push the
diffuser edge with jack but it did not yield any result. Site had then proposed the following;
a) Cut and remove the stiffening members from behind the diffuser (T/H)
b) Create small incision in the diffuser edge upto a length of about 150 mm. About 8-10 such incisions
were reqd.
c) Bend these pieces backwards by localised heating and pushing.
d) Join the incisions by welding after the above exercise.
Site proposal was accepted by Engineering and accordingly work was carried out and LP box-up was done
successfully within three days.
REMARKS:
Due to affirmative action by site , time and money could be saved in huge amount.

4.0 OIL LEAKAGE IN LPBP CONTROL VALVE ACTUATOR OF UNIT-1 AND UNIT-2 AT HINDALCO, MAHAN
SITE
DESCRIPTION:
The high pr. (150Kg/cm2) LPBP system for 150 MW TG was supplied by M/s HORA, Germany. All the
actuators were supplied in assembled condition to site. In Unit #1 and Unit#2 control valve actuators were
leaking out oil through the spindle. This problem was reported in March 2013 and was conveyed to BHEL,
Hyderabad. Since BHEL,Hyderabad had no expertise on the servo-motors, the specialist from M/s HORA,
Germany was called. The German specialist refused to attend the problem citing scouring marks which
developed at site due to welding splatter, causing the leakage. M/s HORA refused to take any responsibility
for this problem and their representative left site without attending the problem.

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ACTION TAKEN:
It was decided at site level to open one servomotor and to inspect the internals. On inspection it was
found that the spindle had some rough surface which caused slight rubbing of the end gaskets ( see
attached drg.). The spindle was polished with fine emery paper (200 gr) and the gaskets were replaced
with new spare. The actuator was put into service in June 2013 and till now there was no leakage found.
Same exercise was carried out for the second actuator in U#2 and was successful.
REMARKS:
The problem which was disowned by the OEM, was resolved by site erection group. In addition, time and
costly foreign exchange also could be saved for the organisation due to affirmative action taken by the site.

Mr. Tapas Saha is presently working as Construction Manager at

Hindalco Mahan site

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PROBLEM OF LOW OIL LEVEL IN SEAL OIL VACUUM TANK

SUMAN KUMAR MISHRA
DGM/TSX
MPPGCL SATPURA
INTRODUCTION:
Satpura Unit#11 was continuously running at various load demands from 160 MW to 200 MW load.
Parameters of Generator Seal Oil System were normal as below:

Parameter Value
Seal Oil DP Turbine End 1.41 kg/cm2
Seal Oil DP Exciter End 1.41 kg/cm2
Seal Oil drain temperature H2 TE side 50.26 Deg C
Seal Oil drain temperature H2 EE side 54.30 Deg C
Seal Oil Drain Temp Air TE side 57.02 Deg C
Seal Oil Drain Temp Air EE side 61.0 Deg C

Oil level in Seal Oil Vacuum Tank was normal.

Vacuum pumps of seal oil vacuum tank were being commissioned to maintain vacuum inside the vacuum
tank. During commissioning of vacuum pumps, slight heating of vacuum pump body was observed. For
checking, vacuum pump was stopped and the pump remained stopped for one day.

PROBLEM OBSERVED:
After two days, oil level in seal oil vacuum tank started decreasing below minimum level. Level was not
improving.
ACTION TAKEN:
Level in Intermediate Oil Tank was observed for any anomaly. It was found in order. Operation of float in
Intermediate Oil tank and Seal Oil Vacuum tank was observed. For checking, bypass valve of float in
Intermediate Oil Tank was opened for maintaining oil level in seal oil vacuum tank. But still level was not
being maintained. Observation was done from sight glass in seal oil vacuum tank. Very small amount of oil
was seen flowing in the tank.After confirming proper operation of float in Intermediate Oil tank, position of
bypass valve of vacuum pumps was checked. Bypass valve was found in closed condition and vacuum
pumps were also in stopped condition. Bypass valve was opened. After opening of bypass valve, oil level in
vacuum tank started increasing.
Probably by opening of bypass valve, there was release in slight pressurization of vacuum tank.
SUGGESTION:
In seal oil vacuum tank, only level switch is envisaged for indication of level low condition. Seal Oil level not
low condition in vacuum tank is used for start permissive of AC seal oil pump.Continuous monitoring of oil
level of seal oil vacuum tank is not provided. Level transmitter should be provided in seal oil vacuum tank
for continuous monitoring of oil level in seal oil in vacuum tank. Emergency in seal oil system can be
avoided.

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Ref: Scheme for Seal Oil System presented below:

Suman Kumar Mishra is presently posted at 2X 250 MW MPPGCL

Satpura site working as Unit Commissioning Manager.

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REPORT ON TDBFP DRIVE TURBINE OVER SPEED GOVERNOR PROBLEM

AND ITS TRIPPING SPEED ADJUSTMENT
Jitendra Kumar
Sr. Engineer/TSX
NTPC Mauda site
INTRODUCTION:
BHEL make 500 MW rating thermal sets are having 01 no Motor Driven Boiler Feed Pump (MDBFP) and 02
nos. Turbine Driven Boiler Feed Pump(TDBFP).During continuous full load operation both the TDBFPs cater
to feed water to boiler for steam generation.
PROBLEM FACED:
During no load mechanical run (solo run) of drive turbine, over speed governor pin did not operate even at
maximum test oil pressure of 3.5ksc.Subsequently, drive turbine did not trip by Over Speed Governor(OSG)
during actual over speed test and oil injection test failed. Due to non-operational of OSG pin, drive turbine
no load mechanical run test was not accepted by customer.
OBSERVATIONS AND FINDINGS:
1. Test oil line was checked for leakage inside the pedestal and same was found OK.
2. OSG tester 8mm dia. ball was missing from its bottom position. This ball controls the holding oil flow in
trip device and will cause continuous oil leakage from top of trip device during remote device
engagement.

Fig-01
3. Over speed tester valve body was found in damaged condition near bottom (Fig-02).

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Fig-02
4. Radial clearances between OSG fly bolt and rotor shaft measured and found 1.0 mm which was within
limit as its design value is given from 0.8 mm to 1.0 mm.
5. Radial gap in both sides were measured and found 1.0 mm.
6. OSG fly bolt movement checked and found stuck up.
7. OSG dismantled for checking assembly discrepancies, fly bolt vent hole found choked with metal
debris. Trip device vent hole and drain hole found rusted.
8. OSG Tester test oil, control oil and holding oil lines checked for dummy and same found ok.
9. Trip device sliding pilot spindle found rusted and its movement inside liner of trip device was also found
stuck up (Fig-03)

Fig-03
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10. Trip device vent hole and drain hole found rusted.

CORRECTIVE ACTIONS TAKEN:

1. OSG dismantled for its thorough servicing /cleaning and re-fitted after lapping and blue matching. OSG
bolt free movement ensured by hand.
2. OSG pin length reduced by 2.0 mm to increase OSG tripping speed from 5875 rpm to 5968 rpm.
3. Trip device thorough cleaning/servicing done and re-assembled after lapping and blue matching to
ensure free movement of sliding pilot valve spindle inside trip device.
4. Trip device vent hole and drain hole cleaned by rustoline and air blowing.
5. OSG tester 8mmdiaball used from unit -2 TDBFP OSG testers.
After servicing and assembly of OSG and trip device in their position, drive turbine rolled for oil injection
test and actual over speed test. This time OSG bolt operated at test oil pressure of 1.5 ksc during oil
injection test.
During actual over speeding test, drive turbine tripping by OSG occurred at speed of 5968 rpm which is in
tripping range i. e. from 5965 to 6069 rpm.

RECOMMENDATIONS / CONCUSION:
1. Proper cleanliness of individual governing oil pipe to be ensured by air blowing and looping during
flushing.
2. Manufacturing unit should adhere correct assembly and testing of governing console and this should
be done with utmost care and due importance so that missing items can be identified during its testing
and site should not suffer for this.
3. 2 mm dia. orifice should be installed in holding oil line to avoid excessive holding oil leakage from top of
trip device during its remote engagement.
4. OSG servicing/checking must be completed prior to start of commissioning of governing system.

Jitendra Kumar joined BHEL PSWR in Feb 2008 and looking after Turbine-
Generator and aux. commissioning. Presently posted at 2X500 MW NTPC
Mauda having experience of commissioning of 125 MW KN series and
250 MW & 500 MW KWU turbines and aux. commissioning.

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REPORT ON BCW PUMP MOTOR CAVITY FILLING AND PURGING BY TEMPORARY

LINE FROM BOILER FILL LINE DURING BCW PUMP COMMISSIONING
NAVEEN KUMAR SONI
Sr.Engineer/TSX
KWPCL AVANTHA POWER SITE

INTRODUCTION:
Boiler Circulating Pump is a glandless (seal less) pump motor unit for boiler water circulation application
with pump and motor being integrated in a pressure-tight casing. The glandless design (no shaft seal)
makes this pump best suited for pumping of high temperature and high pressure liquids without any
leakage at all. The pump is driven by Torishima made high p erformance three phase induction motor filled
with water (wet motor).
In a controlled circulation Boiler, circulating pumps plays an important role in the performance of the
Boiler. For 500 MW/600 MW Units, 3 Nos of circulating pumps are given and these pumps are placed in the
down comer circuits to ensure proper circulation of water through the water walls.
Feed water entering the boiler drum via Economizer, flows from the drum through the down comers (6
Nos) to the pump suction manifold. The boiler circulating pumps takes water from the suction manifold
and discharges via the pump discharge lines in to the furnace lower front inlet header, furnace lower water
wall right and left side headers and rear headers.
In the water wall inlet header, the boiler water passes through strainers and then through orifices, which
feed the furnace wall tubes to drum.
Cooling water is required for BCW pump motor cavity water cooling and Heat barrier cooling.
Fill and purging line is required for motor cavity filling and purging before the BCW pump commissioning
and trial run. This line is taken from BFP common discharge and CEP discharge line as per BCW pump
erection and process and instrumentation drawing.
PROBLEM:
Problem is faced at erection and commissioning stage of systems for initial filling of BCW pump motor
cavity. As per BCW pump scheme motor cavity filling and purging line is given from BFP common discharge
header and CEP discharge line but initially these systemsare generally not ready.
SITE ACTION:
Following site action was done for BCW pump motor cavity filling and purging:
1. Boiler fill pump was commissioned.
2. 25 mm piping tapping was taken from boiler fill pump discharge line near boiler and piping erected up
to HP cooler and filter. Line diagram Scheme shown in figure and approval taken from customer.
3. One no of valve and NRV of 2500 Classwas introduced in the line.
4. Water flushing of temporary pipe line before the HP cooler and filter was carried out.
5. Water flushing of pipe line through HP cooler and filter was carried out.
6. Water flushing of permanent pipe line for CC pumps motor cavity filling line, up to motor inlet and LP
cooler inlet was carried out. Water flushing was declared as per procedure for commissioning of BCW
pump.
7. Filling and purging was done as per commissioning procedure.

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FIG.1

CONCLUSION AND SUGGESTION:

1. This arrangement may be mentioned in commissioning procedure itself so that customer will agree
and no further customer approval is required for this arrangement.
2. Drawing may b made to incorporate this arrangement with valves and piping lay out for initial filling
and purging of BCW pump motor cavity.
3. Contractor will be agreeing to do the job as regular work because it will be mentioned in drawing.
4. BCW pump commissioning will not be delayed due to BFP and CEP piping delay for normal fill and
purge line.

Naveen Soni is presently posted at 1X600 MW AvanthaBhandar TPP

having experience in commissioning of Boiler and its auxiliaries.

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TECHNICAL FEEDBACK ON HPBP VALVE POSITION FEEDBACK TRANSMITTER ISSUES

Sandeep Kumar
Sr. Engineer (C&I)
BHEL Amravati Site

The HPBP (BP&BPE) Valves are fitted with RSG-10A resistive type Position Transmitter. During
commissioning at various sites, we have come across the following problems:-
PROBLEM:
These transmitters are supplied along with the valve assembly in assembled condition.
1. During the course of project execution, it takes considerable time between receipts of material at site
to actual E&C. During this period, valve assembly is kept at storage yards & these transmitters are
subjected to harsh environmental condition, causing defects.
2. During commissioning of the valves at most of the site, it is very difficult to set the zero position (5mA)
& span position (15mA) of RSG-10A position transmitter, due to improper fitting of position transmitter
on the valve body & associated linkages.
3. RSG-10 position transmitter has bolt & hexagonal nut type terminals for electrical connections. During
Commissioning & calibration of the valves, these connection needs to be removed & frequent
loosening & tightening of terminals make them prone to become loose. This looseness causes the
variation in the position transmitter output & malfunction of the valves.
SOLUTION TO THE PROBLEM:
1. It is advisable to send these transmitters as a separate package with the valve assembly with
appropriate storage instruction on the package, so that defects due to improper storage can be
avoided. During commissioning the same can be mountedat site after erection & necessary
adjustment can be done in situ.
2. To correct the problem of improper fitting of position transmitter on the valve body & associated
linkages, the whole position transmitter assembly needs to be removed & adjusted in situ.
3. It is advisable to provide push-in type or screwed terminals in RSG-10 position transmitter, which are
more reliable instead of bolt & hexagonal nut type.
PROBLEM:
Being a resistive type position transmitter RSG-10A Position transmitter is prone to loose contact
(Chattering), temperatures drift etc. which will ultimately cause the malfunction of the HPBP Valves.
SOLUTION TO THE PROBLEM:
Some Non-Contact type position transmitter can be used for HPBP Valves, like BALLUFF make position
transmitters which are used in EHA of Turbine Valves. Though using Non Contact type position transmitter
is a costly affair, but the HPBP system reliability & availability will be increased.
PROBLEM:
In the control system of HPBP Valves comprises of Valve Position controller module (PROMAX Module DSZ-
OM69229S908A, refer Fig. 2), Normally Auto Bit (P3A-3) is kept at high state for enabling the Blocking
Element & operation of the valve. It has been observed that in case of failure of position transmitter loop,
valve malfunctions.

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SOLUTION TO THE PROBLEM:

It is advised to continuously monitor the healthiness of position transmitter loop (SME Fault) & to build
logic so that Auto Bit (P3A-3) is automatically brought to low state for disabling the Blocking Element &
operation of the valve, in case of position transmitter loop fault (SME Fault) & an Alarm is generated to
indicate faulty position transmitter.

Figure1–RSG-10PositionTransmitter

Figure2–PROMAX Module DSZ-OM69229S908A

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January - 15

TECHNICAL FEEDBACK ON PARTIAL TRIP LOGIC MODIFICATION OF

TURBINE CONTROL VALVES FOR AVT (AUTOMATIC VALVE TESTER)
Sandeep Kumar
Sr. Engineer, C&I
BHEL Amravati Site
DESCRIPTION:
At Amravati 270 MW site, steam turbine is equipped with High Pressure EHA Governing system & software
base AVT Logic is implemented in max DNA DCS system. Partial Trip logic for HPCVs/ IPCVs, is built in max
DNA system & it is designed to partially close the turbine control valves momentarily (~0.5 Sec) in case of
abnormal condition to avoid the TSR (transient speed rise) of turbine. Partial trip acts only on turbine
control valves & stop valves remain open during partial trip. A schematic of position control module
(PROMAX Module)is shown below with partial trip in put.

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PROBLEM FACED:
During commissioning of AVT in Amravati U#1it was observed that during CV testing (Quick Opening &
Closing) steps arenot executed & AVT was going in Shutdown Steps. The partial trip logic for control valves
implemented was as follows:-
Partial trip bit will activate when any of this condition is satisfied:-
1. Any of the trip solenoid of that valve combination is OFF (e.g. for HPCV1 partial trip will be active when
any of the TSV of HPSV1/HPCV2 is OFF).
2. LSR Operated
3. Turbine trip operated
On further analysis it was observed that during AVT, stop valve is tested by TSV1 & then TSV2. TSV2 is kept in
OFF condition so that Stop Valve can remain close during Control Valve testing. Keeping TSV2 OFF was
causing partial trip of Control Valve.
MODIFICATION DONE:
Partial trip bit will activate when any of this condition is satisfied:-
1. (Any of the trip solenoid of that valve combination is OFF)A ND (Valve Combination is not selected for
AVT)
2. LSR Operated
3. Turbine trip operated
After this modification, input 1 of partial trip logic for control valve selected for AVT, is disabled during AVT.
After this modification AVT was demonstrated successfully OFFLINE as well as ONLINE.

Mr. Sandeep Kumar is presently posted at Amravati site and looking

after Control & Instrumentation.

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FAILURE REPORT FOR TURBINE AUXILIARY OIL PUMP#1

Sandeep Kumar
Sr. Engineer (C&I)
Hemant Nimje
Assistant Engineer-I
BHEL Amravati site
DESCRIPTION OF FAILURE:
Unit was started for Safety valve floating on 11.02.2014 &TG was in Barring Gear with AOP#1 in service,
steam dumping was in operation. On 12.02.2014 at 21:00 Hrs. it was observed that AOP discharge Header
Pressure& AOP1 current was hunting; after few seconds AOP#1 tripped on Overload & AOP#2 came in
service on Auto. During this changeover Lube Oil Header pressure dropped to 0.5 Kg/cm2 & after AOP#2
running it was normalized to 2.1 Kg/cm2.
OBSERVATION ON PUMP DISMANTLING:
AOP#1 was dismantled on 13.02.2014 for Inspection and it was found that ferrule joint of tubing which
supplies the lubrication Oil to the pump bearing is dislodged. Due to this, oil starvation of bearing has taken
place. Please refer photos below-

RECTIFICATION:
Pump Bearing was replaced.
ROOT CAUSE OF FAILURE:
Failure of ferrule joint of bearing lubrication line lead to failure of pump bearing.

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January - 15

SUGGESTION FOR MODIFICATION IN DYNAVANE FILTER DP CONTROLLER SCHEME

Sandeep Kumar
Sr. Engineer (C&I)
BHEL Amravati site
PRESENT SCHEME:
Dynavane filter scheme consist of following major parts (Schematic is shown in Annexure-1)
1. Dynavane Filter
2. Bleed Valve (pneumatically operated)
3. DP Measurement (Pneumatic DP Transmitter)
4. DP Controller (Pneumatic)&associatedcoppertubing
PROBLEMS IN PRESENT SCHEME:
1. As the material is supplied by MUs well before actual erection of equipment,
materialiskeptinstoreformorethan1year&whenitiserected&commissionedmanyproblemsoccursespeciall
yinDPController.
2. It can not be as certained, whether the system is working properly, because there is no monitoring
hooked upto the DCS (neither DPn or Valve Position)
3. As at the time of commissioning it self the warranty of Controller is over, system remains un-
commissioned & it appears in pending points.
SUGGESTED SCHEME:
It is suggested to change, Dynavane Filter scheme as per Annexure-2. This scheme consist of following
major parts
1. Dynavane Filter
2. Bleed Valve (Electro-Pneumatically operated)
3. DP Measurement (Electronic DP Transmitter Hooked upto DCS)
4. DP Controller (PID Controller env is aged in DCS Logic)
BENEFITS OF SUGGESTED SCHEME:
1. This scheme is simple than the pneum at ic controller & easier to commission.
2. It will ensure continuous monitoring of the system working.
ADDITIONAL REQUIREMENTS:
1. Cabling for DP Transmitter & Control Valve E/P Converter & feedback transmitter.
2. Electro-pneumatic Positioner required for valve.
3. Valve Position Feedback required for valve.
4. AnalogI/ Os required in DCS

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Annexure-1

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January - 15

REPORT ON OIL INGRESS IN GENERATOR

DURING PRESSURIZING AND DEPRESSURIZING OF AIR
Om Prakash Singh
Engineer/TSX
D.B. POWER
INTRODUCTION:
In 600 MW generator the rotor shaft ends are brought out of the gastight and pressure-resistant enclosure
through shaft seals. The shaft seals are supplied with pressurized seal oil to prevent hydrogen losses at the
shaft and air entry into the hydrogen-cooled generator. As long as the seal oil pressure in the annular gap
exceeds the gas pressure in the generator, no hydrogen escapes from the generator housing. The shaft seal
is supplied with seal oil from a separate system. The oil in the seal oil system is the same as that used in the
turbine generator journal bearings. The seal oil system consists of the seal oil unit and the connecting pipe
work to and from the generator. The arrangement chosen provides for easy and simple supervision of the
seal oil system.
DETAILS OF PROBLEM:
Seal oil pump was started for Air Tightness Test (ATT) of the generator and maintaining oil flow around
50m3/hr. While pressurizing the generator with service air, at 0.5 ksc oil started coming from the Liquid
Level Detector (LLD) exciter end and at around 2ksc oil stopped coming from the LLD line. Similarly during
depressurizing at 2ksc oil started coming from the LLD exciter end and stopped at 0.5ksc.
ANALYSIS OF PROBLEM:
Concerned documents and schemes are: Generator manual and Generator piping plan and section
drawing no.0-150-00-01424 sheet no.01
Oil ingress in Generator could be due to following reasons:
1. Flow of oil
Flow of seal oil should be less than 60 m3/hr. In case flow is higher than design value there is chance of
oil ingress in the generator.
2. Blockage in the Pre-chamber drain line of exciter end
If there is a blockage in the line, pre-chamber gets flooded resulting in oil ingress in the generator
3. Floats of IOT not properly working
If Floats of IOT are not working properly, it will block the drainage of oil of Pre chamber line and results
in oil ingress in the generator
4. Seal body assembly
If Seal Body assembly is not properly erected as per drawing, there is chance of oil ingress in the
Generator.
5. DP of seal oil system
DP of seal oil system is in the range of 0.8 to 1.5 ksc. In case DP is very high, then line and seal body get
pressurized and results in oil ingress in the generator.
6. Air lock in the Pre- chamber drain line of exciter end because of Slope and bends
If there are many bends in the drain line and slope of the drain line is not provided as per design, there is
chance of air lock which causes blockage of oil in the drain line
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7. Position of U loop of Pre- chamber drain line of turbine end

If position of U-Loop of pre-chamber drain line of turbine end is not provided as per scheme, there is
chance of restriction of flow of oil in exciter end causing oil ingress in generator.
CHECKS PERFORMED AND OBSERVATIONS:
In order to ascertain source of the problem, following checks were performed:
1) Flow of oil was reduced up to 30m3/hr by adjusting manual valve after the DPR valve. It was found that
oil from the LLD was still coming between the ranges of air pressure 0.5 to 2.0 ksc, but pressure of oil
coming from the LLD was very slow.
2) Pre-chamber drain line was checked for blockage by any foreign material by blowing air. Air was coming
from the other end of the pipe line.
3) Float of IOT was checked and found OK.
4) Seal body was checked and found as per erection drawing.
5) DP of seal oil system was maintained at the range of 1.0ksc to 1.5ksc.
6) Slope of pre chamber drain line was checked and it was found that the slope of less than 1:40(It should
be 1:50) at one stage and two bends continuously as shown in the fig no.01
7) Position of U-Loop was checked it was found 8.5m from zero meter, It should be 9.4m as per drawing
attached
After these initial observations, it was confirmed that oil ingress in the Generator during pressurizing
and depressurizing of air was occurring because of formation of air pockets in the slope and bends of the
line causing temporary blockages.
CORRECTIVE ACTION TAKEN:
1) Pre chamber drain line was modified and slope was increased and made as per design as shown in the
fig.02
2) Two continuous bend was removed as shown in the fig.02
3) U-Loop connection was corrected as per drawing. Refer fig no.03
Seal oil Pump was started and generator was pressurized with air up to 5 ksc. During this process we
observed that no oil was coming from LLD line exciter end. Similarly during depressurizing, no oil was
coming from the LLD line.
RECOMMENDATIONS / CONCLUSION:
1. Minimum bends should be provided in the pre chamber drain line.
2. Slope of the drain line should be provided as per drawing.
3. Position of U-Loop should be correct.

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FIG NO.01

FIG NO.02

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FIG.NO.03

Om Prakash Singh completed his B. Tech from BIT Sindri and joined BHEL
PSWR in Feb 2011. Presently posted at 2X600 MW DAINIK BHASKAR TPP
and looking after Turbine-Generator and aux. commissioning.

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January - 15

LOW VACUUM PROBLEM AT TENDAHO U-1

Pawan Choudhary
Engineer/TSX
Avantha site

PROBLEM:
Tendaho U#1 20MW Turbine was running continuously, parameters were as follows.
· Turbine load between 2 MW to 5MW
· Aux. steam pressure 13.0 kg/cm2
· Gland steam header pressure between 200mmwc– 400mmwc,
· Condenser vacuum 0.170 ata.
After some time it was observed that condenser vacuum is deteriorating continuously from 0.170 ata to
0.390 ata. Aux. steam pressure was seen to be same as earlier but gland steam header pressure went to
negative side (-100 to -250mmwc).
All possibilities to improve the vacuum were checked as turbine tripping value on vacuum was 0.400 ata.
By increasing the aux. steam pressure to 15 kg/cm2 instead of 13 kg/cm2 unit was allowed to run. But
vacuum could not be improved and turbine tripped on low vacuum.
OBSERVATIONS:
After turbine shut down the strainers provided in the steam supply line of ejectors and steam supply line of
gland seal steam header were checked and all strainers were found in heavily choked condition. This was
the only reason for improper supply of steam to ejectors and low gland seal steam header. This strainer
choking was due to following reasons.
· Improper quality of steam supplied.
· Improper mixing of chemical into water at boiler end. Poor DM water quality
· Improper steam blowing of steam pipe line.
ACTION TAKEN:
As there are 2 no. of steam ejectors (one in service and one stand by) whenever one steam ejector's
strainer gets choked, 2nd steam ejector is taken in service and then the previous ejector is isolated for
cleaning its strainer.
But such provision is not available in gland seal steam header. Original scheme was as below.

G S Supply To Turbine
Y- strainer

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As shown above it has only one strainer before its supply header it cannot be isolated. The steam pipe line
for gland seal steam header was modified by providing 2 nos. of strainers - one in main supply line and
other in its bypass line as shown below.

G S Supply To Turbine

Y-strainer

This modification was very necessary because this strainer choking problem was coming frequently.
PRESENT STATUS & CONCLUSION:
Now whenever gland seal steam supply header pressure falls down, bypass line is taken in service and
main line strainer is cleaned and vice versa. With that there is no low vacuum problem.

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January - 15

BARRING GEAR STOPPING PROBLEM AT TENDAHO U-1

Pawan Choudhary
Engineer/TSX
Avantha site
SEQUENCE OF EVENTS:
· Tendaho Unit#1 (20 MW) tripped on 09/09/2014 3:40 PM. Turbine was continuously running on
barring gear till 11/09/2014 8:00 AM. At 8:00 AM, Customer Operator informed BHEL about Unit#1
Barring Motor Stopping. It was observed that Turning gear Motor was tripped on Overload. All other
drives like AOP, JOP were working satisfactory.
· MCC module was reset and barring gear motor restarted, but immediately tripped on overload.
· After this machine was checked by hand barring from provision at Turbine rear end and found OK.
· Hand Barring was also tried from Hand wheel on Turning Gear Motor but it was not rotating. From
further inspection it was also observed that there was leakage of oil in Turning Gear Box and due to this
leakage Turning Gear Box oil has emptied out.
· After top up of Gearbox Oil (approx. 8 liter) again it was attempted to rotate turning gear motor by
hand wheel but again it was found jammed and not moving in clock or anti clock wise direction even
though lube oil & Jacking oil Header pressures were adequate.
CAUSE OF FAILURE:
· To ascertain whether there was problem with gear box or Clutch assembly, Gear Box assembly was
removed and visual inspection was done for clutch parts and other parts. Clutch assembly was found
to be OK but hand wheel rotation was very sticky/hard.
· It was suspected that this phenomenon is due to either inadequate lube oil in gear box sump leading to
worm and wheel failure or inadequate grease in bearing leading to bearing failure.
· Though turning gear motor is supplied with one hand wheel at its Non Driving End, it was found that it
was slightly eccentric. When motor rotates at 3000 rpm this eccentricity causes failure of motor NDE
side bearing.
ACTION TAKEN:
· In consultation with concerned persons, it was decided to check possibility of using Gear Box assembly
from Unit#2. After confirmation from supplier, gear box assembly of unit-2 was shifted to Unit-1.
· Barring Gear operation checked through new installed gear box assembly and found to be satisfactory
for manual as well as through Motor operation. It was advised to routinely check the oil level in gear
box sump and do greasing as per recommended schedules.

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FURTHER ACTION PLAN:

· Dismantling of old gear box done and it was found that bearing of input shaft were in damaged
condition. It was also observed that oil seal of bearing were damaged which is indicating oil seal failure
due to oil leakage. Worm and worm wheel profiles are smooth and have no damages. In consultation
with manufacturer it was concluded to change bearing along with oil seal.
· Though turning gear motor is supplied with hand wheel mounted on it, but one should not allowto run
turning gear motor with the wheel. Otherwise it may be a cause to failure of turning gear bearings as
happened in this case.

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YOU ARE INVITED TO SHARE YOUR EXPERIENCE

Dear Reader,

Here is an opportunity to share your experience with us. If you have solved any problem, carried out any
modification or effected improvements in the past, on any power station equipment or system leading to its
improved performance, you can share your experience with others by contributing an article on it for
publication in the TAKNIKI DARPAN Journal. The article can pertain to design, engineering, commissioning,
operation, maintenance or R&M function.

While doing so, the following checklist may please be followed:-

1. The article is to be typed in MS Word.
2. Soft copies of all diagrams/ figures should be sent along with the article.
3. Scanned copy of photographs of author and a half page bio data (softcopy) are to be sent.
4. Author/ co-author's complete postal address, telephone numbers and email-id for further
communication is to be sent.
The article, after editing by the TAKNIKI DARPAN Editorial committee, will be sent back to you for your final
approval.

The articles may please be sent to the following address:-

SH. DINESH JAWADE

DGM-TECHNICAL SERVICES
POWER SECTOR-WESTERN REGION,
SHREEMOHINI COMPLEX,
TH TH
5 AND 6 FLOOR,
345, KINGSWAY
NAGPUR-440001

Your feedback, in the form of article, would certainly play a pivotal role in the perpetual endeavours of BHEL
and its customers towards effecting improvement in the performance of the equipment supplied by BHEL.

Thanking you,
Yourstruly,
Editorial Committee

ISSUE SPECIAL…… 37
 Designed & Printed at AQUA PROCESS Ph. : 9371162862

BHARAT HEAVY ELECTRICALS LIMITED

(A Govt. of India Undertaking)
POWER SECTOR WESTERN REGION
Shree Mohini Complex, 345, Kingsway, Nagpur-440001.
Visit our Website at : http://www.bhelpswr.co.in