PROJECT : NEYVELI THERMAL POWER STATION II, UNIT NUMBER 6, 210 MW. PROBLEM : 1.

Starting device not operating from control room. 2. EHTC hunting when changed over to load control at load of 40 MW.

1. Starting device not operating from control room.

Problem: The servicing of all the governing system components was carried out during overhaul. There were no problems during checking and setting of governing characteristics. While checking the operation of starting device from control room, it was observed that the device was not operating. The power supply module was checked and found to be healthy. The power supply was getting extended whenever command was given from control desk. But it was noticed that the power supply module was tripping on overload protection within few seconds of command. While giving command, observation was made at local and found that motor was not rotating. Analysis: The starting device motor is provided with magnetic brake and hence it is not possible to check the freeness of motor by rotating manually. The brake will get released on giving command. The cable terminations of brake system was checked and found healthy. The motor was decoupled and operation of the motor was checked by giving command at control room. It was found that the motor was rotating freely in both directions of commands in decoupled condition. Also, the adjusting gear was rotating freely by hand and starting device was free to operate by hand wheel.

The coupling (part number 25 and 26 in the figure) is within the housing and not visible after assembly of motor. The extended shaft of the motor with coupling hub was rotated during assembly and proper coupling was ensured. The motor is bolted to the housing of the adjusting gear and after tightening the coupling gap (gap between part numbers 25 and 26 in the enclosed figure) should be 0.5 mm. Measurements of length of extended shaft with coupling hub and depth of the other part of coupling in adjusting gear were made and found that there were no gap in coupling. Also, while tightening the motor, the shaft was forcing against the worm wheel of adjusting gear (as the measurements indicated interference at coupling) and motor shaft was getting jammed and unable to rotate by motor, causing the motor to trip on overload. Conclusion: For maintaining coupling gap, 1 mm shim was introduced between motor and the housing of adjusting gear. After assembly it was found that the starting device was operating from control room and the current was normal during operation. It was advised to check the coupling gap, whenever motor was replaced for starting device or speeder gear.

Figure .1 Adjusting gear for starting device

2. EHTC hunting when changed over to load control at load of 40 MW. Problem: The unit was rolled and synchronized with EHTC in service. During rolling, at warm up speed, rated speed and during synchronization, the behavior of EHTC was smooth. While changing over to load control and loading beyond 40 MW, severe hunting of EHTC and control valves was noticed. The machine was immediately changed over to hydraulic governing and further loading was done. Analysis: The behavior of EHTC and control valves at rolling and speed control mode at low load was smooth. Also, during checking of characteristics the behavior was smooth. Hence it is suspected that the load controller settings might have got disturbed and is to be tuned. But as per C & I engineer, the settings are same as pre-overhaul values. The balance voltage was checked and found to be 3.5 volts, instead of 1 volt. The same was readjusted to 1 volt. With EHTC in isolated position, the speed control loop was checked and found that the feedback was not smooth even after adjustment of balance voltage. It was decided to check the freeness of the pilot valve. The moving coil with sleeve was removed. The pilot valve was observed for its rotation by admitting and isolating the control oil many times. It was found that at times, the pilot valve does not rotate. The pilot valve was removed and serviced again. The holes of oil jet for rotation in the disc of the pilot were thoroughly cleaned and assembled back. The rotation of pilot with admission of control valve was checked many times and the pilot was rotating smoothly. The behavior of the EHTC in isolated condition was checked and found to be smooth. The machine was changed over to EHTC control at load of 150 MW and the behavior was smooth.

Conclusion: While checking the characteristics of EHTC, the behavior was smooth. It is necessary to check the rotation of pilot and its consistency by admitting and isolating control oil many times.