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    Report On Oil Ingress Problem in Generator

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    Parmar Bhavesh
    1. Oil ingress was observed in the generator of Unit-3 at NTPC Mouda project during electrical testing, which was determined to be caused by a malfunctioning vacuum oil tank (VOT) make-up float valve and insufficient line size of the hydrogen drain line from the generator. 2. Modifications were made to increase the size of the hydrogen drain lines from the generator and the VOT make-up float valve was repaired. 3. Additional actions taken included servicing flow meters, installing a temporary filter, and cleaning the modified drain lines to address the root causes and prevent future oil ingress issues.

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    Report On Oil Ingress Problem in Generator

    Uploaded by

    Parmar Bhavesh
    13 views4 pages
    1. Oil ingress was observed in the generator of Unit-3 at NTPC Mouda project during electrical testing, which was determined to be caused by a malfunctioning vacuum oil tank (VOT) make-up float valve and insufficient line size of the hydrogen drain line from the generator. 2. Modifications were made to increase the size of the hydrogen drain lines from the generator and the VOT make-up float valve was repaired. 3. Additional actions taken included servicing flow meters, installing a temporary filter, and cleaning the modified drain lines to address the root causes and prevent future oil ingress issues.

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    Report on Oil Ingress Problem in Generator(1)

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    1. Oil ingress was observed in the generator of Unit-3 at NTPC Mouda project during electrical testing, which was determined to be caused by a malfunctioning vacuum oil tank (VOT) make-up float valve and insufficient line size of the hydrogen drain line from the generator. 2. Modifications were made to increase the size of the hydrogen drain lines from the generator and the VOT make-up float valve was repaired. 3. Additional actions taken included servicing flow meters, installing a temporary filter, and cleaning the modified drain lines to address the root causes and prevent future oil ingress issues.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    13 views4 pages

    Report On Oil Ingress Problem in Generator

    Uploaded by

    Parmar Bhavesh
    1. Oil ingress was observed in the generator of Unit-3 at NTPC Mouda project during electrical testing, which was determined to be caused by a malfunctioning vacuum oil tank (VOT) make-up float valve and insufficient line size of the hydrogen drain line from the generator. 2. Modifications were made to increase the size of the hydrogen drain lines from the generator and the VOT make-up float valve was repaired. 3. Additional actions taken included servicing flow meters, installing a temporary filter, and cleaning the modified drain lines to address the root causes and prevent future oil ingress issues.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 4

    Report on Oil Ingress Problem in Generator at Unit-3 2X660

    MW NTPC Mouda Project


    Jitendra Kumar
    Sr Engineer/TSX
    Introduction:
    BHEL PSWR first super-critical turbo generator set first rolling was done on 25/03/2016 to
    achieve synchronization milestone. However turbine got tripped on separator level
    protection during electrical testing and oil ingress was observed in generator during
    coasting down period of turbine. Oil ingress in generator was so quickly that within time
    period of 5-10 minute the MOT level goes down by more than 100 mm. Therefore, it was
    decided to release the H2 gas from Generator immediately to safeguard the set and finding
    root cause of oil ingress in generator.

    Observations and findings:


    Following observations and findings were noted during and after the oil ingress problem:

    1. Signal of Liquid in generator at TE First appeared in DCS by liquid level detector


    switch mounted in liquid level detector rack (LLDR) and then after TE pre chamber
    oil level high alarm triggered in DCS.
    2. After few minutes same has appeared for EE also in same manner.
    3. Seal oil DP at both TE and EE was found normal i.e.1.3 bar with one SOP in operation
    till the problem occurred. However during coasting down of turbine after its
    tripping, DC SOP was found running with AC SOP.
    4. DC SOP got auto start during coasting down of turbine due to malfunctioning of VOT
    level low switch and same was found in trends/SOE.
    5. Seal oil DP at both TE and EE were found 2.9 and 3.1 respectively during the period
    of oil ingress. When DC SOP made off, seal oil DP of TE and EE came down to its
    normal value.
    6. Vacuum oil tank (VOT) level found full with oil which was maintaining earlier 150
    mm before the oil ingress to Generator. When tried to maintain the VOT level
    manually by evacuating oil from VOT by slightly opening dump valve of SOP’s
    discharge line but attempts goes in vain as same could not possible. Therefore it is
    being suspected that make up float valve of VOT malfunctioned at that moment.
    7. Intermediate oil tank (IOT) level was found maintained 250 mm till the H2 pressure
    reaches below 1.4 bar and afterwards level found full.
    8. 04 nos. metal type flow meters installed in seal oil skid for measuring air side and
    ring relief seal oil flow in TE and EE was found stuck up, therefore not reflecting the
    actual seal oil flow in the lines. However physically seal oil flow was experienced in
    each lines of TE and EE.
    9. H2 drain line U-loop height and DPRV impulse line was found as per drawing.
    10. Bearing Chamber vapor exhaust system checked and same found ok.
    11. VOT top cover opened for inspection for make-up float valve assembly and its valve
    sheet.
    12. During inspection of VOT make up float valve it was observed that valve is not
    getting closed completely and heavy passing of oil was observed even when float
    valve was in closed condition due to float valve stuck up at top position of guide
    sleeve during its travel to upper position (fig01).

    Fig-01
    13. Slope of H2 side oil drain line from generator TE and EE pre chamber to IOT was found
    more than sufficient. As per drawing it should be 40 mm per meter.
    14. The line size of H2 side oil drain line from pre chamber to U-loop was found NB 50
    which is as per drawing no. 0-150-00-01648 (sheet1/5) and also as per BOM (TGE-3256,
    Rev 02 dtd 04.05.2015) the material supplied is of size NB 50 and after U-loop to IOT the
    line size was found NB 80.

    On enquiry for the line size of H2 drain line from Generator pre chamber to U-loop
    with same rating set like Lalitpur and Bara, it was found that their having H2 drain
    line size NB 80 and our H2 side drain line size NB50,which was found different.
    Therefore it was concluded that due to H2 side drain line size NB 50 oil got ingress
    in Generator as DC SOP also got picked up due to malfunction of VOT level switch
    and due to running of both AC & DC SOP seal oil flow got high as seal oil DP
    maintained high which could not be accommodated in H2 side drain line size NB 50
    causing oil ingress in generator.

    As Generator TE H2 side drain line length up to U-loop was much more than that of
    EE as compared therefore LLDR first alarm triggered in TE during oil ingress and
    then EE.

    Action taken:
    1. Problem reported to the Hardwar unit for their concurrence for modification of TE
    and EE H2 side drain lines up to U-loop. Unit has given concurrence for the same.
    After obtaining concurrence from Unit both TE and EE H2 side drain line size from
    generator pre chamber to U-loop has been modified from NB 50 to NB 80.
    2. Both generator TE and EE H2 side modified drain lines from pre chamber to U-loop,
    cleaning was done by air blowing/blasting method as flushing was not possible.
    3. VOT make up float valve stuck problem was attended by increasing the length of
    guide sleeve by 30 mm (Fig02). Make up float valve re-assembled after its siting
    surface proper cleaning/servicing and kerosene test. After re-assembly of float valve
    checked for its operation by charging oil to VOT. Afterwards no oil passing was
    observed in VOT through float valve and also oil level in VOT gets maintained at 160
    mm.

    Fig02
    4. All the 04 nos. metal type flow-meters installed in seal oil skid rack for measuring
    seal oil flow to Generator in TE and EE lines were serviced and calibrated.
    5. A temporary mesh put in H2 side drain to IOT inlet line near IOT, to arrest any
    foreign particles during initial operation of seal oil system and to be remove before
    system put in regular operation.

    --------

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