Dec 2010

1 DECEMBER 2010 TS TIDINGS
WISHING A VERY HAPPY AND PROSPEROUS NEW YEAR
Published by Technical Services / PSSR

For internal circulation
NAGARJUNASAGAR HEP DECEMBER : 2010

VOLUME : 14.07
HIGHLIGHTS
NALCO UNIT 10:
ESP PG TEST COMPLETED.
RAICHUR – UNIT 8 :
UNIT FULL LOAD TRIAL OPERATION AND COD COMPLETED.
RAYALASEEMA UNIT 5 :
UNIT REACHED FULL LOAD FOR THE FIRST TIME.
VIJAYAWADA - 1 X 500 MW.
TG PG TEST COMPLETED.
SIMHADRI UNIT 3:
FIRST STAGE STEAM BLOWING COMPLETED.
TECHNICAL SERVICES / PSSR

INSIDE
1. STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2009 - 2011.
2. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER CONTRACT

CLOSING/ CUSTOMER TRAINING.
3. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.
4. FEED BACK ON EQUIPMENTS FROM SITES.
5. LET US KNOW - UNIT PROTECTIONS
Feed backs and suggestions from all departments of BHEL for improvement of TS
TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER
(TSX)/BHEL-PSSR/CHENNAI

STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2009 – 2011:
AMARKANTAK – UNIT 5 :
Unit is running around 195 – 219 MW.
KAKATIYA UNIT 1 :
Unit is running around 300 - 490 MW. Load reduction due to ash handling
problem. ESP Hoppers open de-ashing is being carried out.
ESP C pass was isolated due to dislocation of collecting electrodes 5th and 6th
fields
Mill A Gear Box shaft got sheared. The damaged shaft was dismantled and sent
to BHEL/Hyderabad for repair.
Mill G Oil leak through gear box seal was resolved.

KOTHAGUDAM 500 MW, UNIT 11:
Trial run of Mill motors A, B, C and D was completed.
Steam blowing CD & EF corners was completed.
Mill – A & B lube oil flushing is in progress. PA Fan –B, ID Fan A second stage
oil flushing is in progress. APH –A seal setting is in progress.
PA fan A oil pressure setting was completed and blade pitch operation was
checked.
APH –B air motor trial was completed after attending the choking problem.
Boiler and Feed water system Hydro test was completed,
TG DMCW B trial run completed.
TG DMCW Pump C got jammed after running for 4 hours. The pump was run
after attending the jamming by M/s Flowserve vendor rep.
HFO pumps A & B trial run in recirculation was completed.
ACJOP, DC JOP, DC EOP motor trial run was completed.

Main oil tank oil vapour extractor A&B trial run was completed.
Turbine Lube oil lines air blasting, MOT Oil filling was completed; oil flushing
was started and is in progress.
TG Lube oil AOP-1&2 trial run was completed.
KRL KOCHI:
GT was running at 10- 20 MW.
34 KW water wash heater 3 No’s was commissioned. Process-I/C 2 cable

termination and hi-pot test was completed.
33KV GIS side Tie-3 transformer, Bus coupler-2 SCAP panel checking was
completed.
Faulty flow divider was replaced with spare flow divider.
TDBFP saddle pump was replaced with new pump.
TDBFP turbine solo run was completed.
KUTTIYADI UNIT 1:
MIV OPU problem was rectified.
Hydro mechanical cabinet and Electro Hydraulic Controller overhauling was

carried out by BHEL/Bhopal Engineer.
Unit was running as per customer requirement for peak load demand. Unit is
under shutdown from 29.12.2010 due to LGB shaft vibration high.
KUTTIYADI UNIT 2:
Unit is running as per customer requirement for peak load demand.
Erection of coupling capacitors inside stator frame for Partial Discharge

monitoring system was completed.

NALCO - UNIT 9:
Unit was under shut down for annual overhaul from 07:20 hours on 25/11/2010.
TG PG Test flow nozzle erection was completed.
Condenser On-Load Tube cleaning system erection is in progress.
Erection of Boiler Steam Leak Detector is in progress.
BHEL/Jhansi rep. is at site to attend to B phase generator transformer bushing

oil leak problem.
NALCO – UNIT 10:
Unit was running around 85-120 MW.
ESP PG Test was completed.
Presently unit is running around 110 MW.
NALCO – DAMANJODI UNIT 5:
BFP A Lube oil line flushing was completed
BFP A motor trial run was completed.
BFP A voith coupling scoop control was commissioned.
BFP A, B, DM makeup pump suction, discharge and recirculation lines steam

blowing was completed.
BFP A and B to Hydraulic coupling alignment was completed.
Deaerator and BFP discharge line hydro test was completed
BFP voith coupling was inspected in the presence of vendor rep. and found shaft
mounted MOP got damaged. Pump has to be sent to Hyderabad for repair.
Feeder A and B outlet gates were commissioned.
Mill CD LP lines oil flushing is in progress.
Mill AB ball loading and mill AB trial was completed.

ESP B pass: all seven panels dummy load test was completed.
ESP A pass fields were charged and found normal.
Feed water system MOVs commissioning is in progress.
Six no. of valves of piping gallery was commissioned.
Control room ac system was commissioned by M/s. Thermax representative.
NEYVELI TS II EXP CFBC, 2 X 250 MW, UNIT 1:
TG Oil flushing was declared completed on 31/01/2011 & Seal oil system first
stage flushing with hot oil circulation is in progress. Seal oil Pump-1B motor
trial run was completed
RAPH 1A Lube oil motors 4 nos trial run was completed.
DMCW Pump-1B trial run was completed.
BFP 1A Motor 8hrs trial run was completed.
SA Fan 1A run for 10 min and found normal.
ESP Pass A1 & A2 total 7 nos of CERM coupled trial run was completed.
ESP 1B balance 3 nos. motors (RAPPING), ESP 1A 8 nos. motors (RAPPING)

coupled trial run completed.
APH A support & Guide bearing oil flushing is in progress.
ID FAN 1A & 1B motor 8hrs trial run was completed.
ESP 1B, Electronic Controller Panel (3Nos) dummy load test was completed
Seal pot blower motor (LT) - 5 nos trial run was completed.
Purge &seal air-Blower motor (HT) and Ash cooler -Blower motor (HT) both
(1A&1B) trial run was completed.
FBHE Empty and Exit chamber- blower motor (LT) 1A & 1B trial run was
completed.
APH-1B lube oil flushing of guide and support bearing was completed.
BFP 1C lube oil flushing was started and is in progress.

RAICHUR – UNIT 8:
Unit was running around 100-120MW due to BFP B&C Booster pump NDE
mechanical seal leakage.
BFP B&C Booster Pump NDE mechanical seals were replaced.
Unit full load trial operation was completed and commercial operation was
declared.
Unit was tripped on 22.12.2010 at 2300 hrs due to FD Fan A lube oil pump
tripping and FD fan B blade pitch control problem.
Unit was synchronized on 28.12.2010 at 1245 hrs and presently running at

215-220 MW.
TG PG test preparatory works in progress.
BFP B booster pump thrust bearing metal temp high problem was being attended
by BHEL/Bhopal and Hyderabad. Engineers at site.
Turbine seal steam leak off control valve problem was being attended by Vendor
representative at site.
RAYALASEEMA TPP - UNIT 5:
Mill F oil flushing was completed.
Feeder E tracking was completed.
Vacuum trip device was serviced, Overspeed trip device no. 2 testing line were
made ready.
LPBP limit pressure controller was replaced and problem in LPBP rack problem
was attended.
HP dosing pumps two nos. were commissioned from remote.
Boiler Safety valve floating was completed.
Balance insulation works is in progress.
LP Heaters were charged first time.
MDBFP B motor failed on earth fault and motor was replaced from the customer
spare motor.

Unit reached full load first time on 31.12.2010 at 2038 hrs. Unit under
shutdown due to boiler tube leak.
SIMHADRI STAGE II, 2 X 500 MW, UNIT 3:
LDO line steam blowing was completed.
MAX DNA FOPH panels were charged.
MS line and Boiler Hydro test was completed.
MDBFP Trial run was completed.
SGECW pump B trial run was completed.
Stage 1A and 1B Steam Blowing was completed.
LP dosing system hydrazine and ammonia pumps trial run was completed.
SAPH 3B main motor and Lube oil pump motor trial run was completed.
SAPH 3B support and guide bearing oil flushing is in progress.
TG AOP1&2, AC JOP, DC EOP motors trial run was completed
TG Lube oil line air blasting, MOT oil filling were completed, oil flushing was
started on 27.12.2010 and oil flushing is in progress.
TG Batteries load test was completed.
VIJAYAWADA UNIT 7:
Unit is running around 450 – 500 MW.
TG PG test was completed successfully on 18.12.2010.

SERVICES RENDERED TO CUSTOMER /SAS/MUs:
Shri. S Elangovan, Asst Engineer was deputed to North Chennai thermal power project
for study of abnormal noise in Unit 2 bearing number 7 and advised customer on
course of action for resolving the problem.
CUSTOMER TRAINING & TECHNICAL PAPER PRESENTED:
--- NIL ---
APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED :
--- NIL ---

FEED BACK NO.1
Project: Rayalaseema Thermal Power Project, unit 5, 210 MW
Problem: Malfunctioning of Hydraulic low vacuum trip device in the governing rack.
Problem details:
During first commissioning of unit number 5 of Rayalaseema Thermal Power project,

Muddanur, the hydraulic low vacuum trip device was malfunctioning. The setting for
trip value of vacuum could not be done to -0.7 ksc. Adustment could be done to the
value around -0.55 ksc. The first synchronization milestone activity was completed
with this value as electrical low vacuum protection was also available. During
subsequent start ups for coal firing also, it was not resetting sometimes. By manual
assistance to the device it resets sometimes, but not consistent.
Analysis and resolution:

The hydraulic low vacuum trip device was serviced at site by technicians from BHEL,
Hardwar. There was no deviation observed during servicing. Even after servicing, the
device resetting behaviour was not satisfactory and consistent. The trip value was
also not consistent.
Description of the device:

The purpose of the low vacuum trip is to operate the main trip valve by draining the
aux trip oil circuit when the condenser vacuum drops below the trip value.
Refer attached figure, the condenser vacuum was connected to the top side of the
diaphragm (7). The space below the diaphragm is at atmospheric pressure. The drop
in vacuum above diaphragm will cause movement of the diaphragm and the auxiliary
pilot valve (8) downwards. This establishes the connection between auxiliary trip oil
circuit ‘X1’ to drain chamber ‘c’ so that the auxiliary trip oil circuit was depressurized
and the main trip valve closes. The value of vacuum at which the device operates can
be adjusted by adjusting initial tension of spring (6) by means of adjusting screw (5).
The adjustment is to be done when turbine is at rated speed so that the initial
compression of spring from primary oil circuit through the piston (2) is established.

On thorough inspection of the device, it was observed that one hole in the chamber
below the bellow was not available. Due to non availability of hole, the space below
diaphragm was not exposed to atmosphere and causing malfunction of the device. The
hole was drilled at site and subsequently the performance of the device was found
normal.
Conclusion:
The problem of missed hole in the device at manufacturing unit was reported to them
and necessary checks shall be included in the quality checks to avoid such problems at
site.

Missed
hole in
the device

FEED BACK NO. 2

Project: Kakatiya TPS
Problem: Problem faced in the planetary gear box of pulveriser
1. Introduction
BHEL Kakatiya TPS Stage-I 1x500MW project reported on 12-07-2010

suspected thrust pad bearing damage of Planetary Gearbox installed in Mill-B. Mill
was running smoothly from the date of "No Load Trial Run" in March 2010 as shown in
Annexure – I, clocking about 300 hours load run. The damaged Gearbox was replaced
with spare gearbox and mill was put back into operation. Later, the Gearbox was sent
to BHEL/Hyderabad works for carrying out inspection and necessary repairs, test run
and dispatch back to site.
2. Receipt & Inspection
Preliminary inspection was carried out and the report is as follows:

* All external pipe lines damaged. To be replaced.
* Ball valves for bottom drain missing
* RTD Guards damaged.
* Table heavily rusted.
The Gearbox was further opened for internal inspection on 22.10.2010 and the
observations made are as follows:
. a) The thrust pad bearing was found damaged (total babbit material is worn out).
This was in conformance to what was reported by site. b) The table lower surface
visually looked OK.
The thrust pad bearing was replaced with new set. The Table lower surface was
re-ground and assembled. The Gearbox was made ready for test run. However,
during assembly and checking, excess play on the pinion was observed and bearing
damage of the bevel-helical stage of gears was suspected. Hence, the Planetary
Gearbox was again dismantled to check/inspect all the internals thoroughly.
The following major damages were noticed further to the Gearbox components:
Bevel Pinion shaft teeth are broken. The inner side bearing of Pinion shaft
damaged and rollers found lying on the bevel gear. From the extent of damages

noticed it is suspected that broken bearing parts have come between the Bevel-
helical gear set and damaged the Pinion shaft teeth.
The photo taken on the damaged parts is as shown in Annexure - II.
3. Failure mode - analysis
From the extent of damage occurred, it is concluded that severe shock/ thrust
loads have been transmitted to the Gearbox internals, due to hard to grind foreign
materials entering the mill along with coal, like stones, steel parts etc. Site had
also informed that during such foreign materials entry into mill very severe
vibrations were noticed in the mill. The heavy thrust loads not only resulted in
damages to the thrust pad bearings, but also lead to the Bevel pinion shaft inner
side bearing and the shaft teeth.
The failure mode of the bevel pinion shaft inner bearing was analysed in detail.
The experts of bearing suppliers (other than the original supplier of the failed
bearing) were consulted as well as damaged bearing parts were sent to BHEL
Corporate R&D for study purpose too. The reports conclude the following:
(i) The heavy shock/thrust loads that came up on the mill, has resulted in the
bevel gear exerting an abnormal axial movement to the bevel pinion shaft.
(ii) The axial movement of bevel pinion shaft has heavily loaded DE side of the
Non- Drive End bearing, which would have caused a) possible lubrication failure, b)
the solid cast brass cage was now driven by the DE side rollers where as the NDE
side rollers started slowing down, which tried to skew the cage and eventually led
to its failure.
(iii) Once the cage is broken, the rollers became free and escaped through the
assembly slot on the cone and into the bevel helical gear set damaging the bevel
shaft teeth.
(iv) On analysing the further damages that occurred to the bearing assembly
parts, it confirms the mode of failure explained above, whereby it can be
concluded that the bearing failure is not the prime suspect.
.The pictorial representation of the above is given in Annexure-III.
4. Repair procedure - test run

The list of activities to be done and components identified to be replaced

for making the gearbox good is given in the Annexure-IV.
On 01-01-2011 the Gearbox assembly was completed and released for test run.
The test run of the Gearbox was carried out 02-01-2011 & 03-01-2011 and
concluded successfully. The test results are attached to this report as Annexure-
V.
A brief description of the Planetary Gearbox is given as Annexure-VI. The

repaired gearbox is declared fit and run worthy and cleared for dispatch to
Kakatiya site on 04-01-2011.
5.Conclusion
Entry of foreign materials like steels, stones, wooden blocks and larger size coal is
to be avoided for better availability and smooth functioning of pulveriser. Customer
may be advised to supply the recommended size coal and without foreign materials.
Annexure – I
Following are the brief history details of Mill-B and its Planetary
Gearbox till the Failure date:12-07-2010:
1) No Load Trial Run was carried out on 23.03.10 and Ring-Roll gap setting
carried out.
2) Mill Has run for 300 Hours at various intermittent stages - 238 Hours in the
month of July'10 itself.
3) Failure of the PGB on 12/07/10 Parameters are as below

Mill Motor Current 108.5 Amps
Thrust bearing Temp 80.0 deg cent
Oil Temperature (Tank) 40.0 deg cent
The Oil inside the tank was found to be black in colour with frequent chocking of
filters.
4) There has been few incidences of foreign material entry like stones, wooden
logs etc. During this period Gear Box has got disturbed and realignment
had to be carried out. Considering the situation locking arrangement of the
Mill Gear Box was done for all the mills.

5) During the Erection & Pre-commissioning period following activities were carried
out:
The Pipe lines after erection were acid cleaned as per the Erection manual &
Technical Services, Chennai guide lines.
The lube oil flushing were carried out as per the recommended procedure.
The Oil flushing was declared completed after ensuring the oil filters are clean for
24 hours.
6) The parameters of Lube oil system for the Mill-B before the failure date is as
follows:
, - Flow is maintained at the maximum of 150 LPM and minimum of 120 LPM.
- Lube oil temperature in the tank is around 36 to 38 deg.C.
- Lube oil temperature after the cooler is at 33 to 35 Deg.C.
- Lube oil pressure is maintained at 2.9 Kg/ Sq.Cm to 3.7 Kg/ Sq.Cm.
- No leakage of Hot air is observed from the seals to Gearbox thrust pad
bearing.
- During frequent filter cleaning, site observed silver coloured material
from the filters.
- Due to frequent chocking of the filters of Mill-B, site replaced these filters,
one from Mill-D and another from Mill-G. Then also this chocking of filter is
observed was observed to be happening frequently.
7) The vibrations of the Mill-B during No Load trial run are as follows:
SI. Motor Drive Motor Non-Drive Gearbox bearing drive

Pick Up
No End end end
Location D V
D V D V
1. Horizontal 8 2.3 13 4.8 6 2.7 .
2. Vertical 7 2.6 8 4.3 2 2.0
3. Axial 5 2.4 6 2.9 9 1.4
D - Displacement in microns; V - Velocity in mm/ sec.

Annexure – II
Gearbox as received from Kakatiya TPS
Gearbox as received from Kakatiya TPS

Thrust Pad bearing -Babbit- material washed out – PGB
Bevel pinion shaft damage - PGB Kakatiya TPS

Bevel pinion shaft DE Side bearing - PGB Kakatiya TPS

Bevel pinion shaft inner bearing damaged parts - PGB Kakatiya TPS
Bevel pinion shaft inner bearing damaged parts - PGB Kakatiya TPS

Bevel pinion shaft, inner bearing broken pieces lying at the bottom of housing- PGB ,
Kakatiya TPS
Bevel pinion shaft damage - PGB Kakatiya TPS

Bevel pinion shaft, damaged - PGB Kakatiya TPS
Annexure-III
The sequence of Events leading to the bevel pinion shaft NDE side bearing failure-
1.There was a shock load / Over load on the drive.
2.Due to which, the spiral bevel has exerted a force in the direction.

3. This Loaded the bearing (NDE side)
a. Due to this loading, the rollers on the DE end of the bearing were overloaded
which caused Possible Lubrication failure to the bearing.
b. The cage is made of solid cast.
c. The bearing cage (brass) was now driven by the DE end rollers and the NDE
end were slowing down, which tried to skew the cage and eventually lead to
its failure.

d. The Rollers now free, a few escaped through the assembly slot on the cone
e. This further damaged the cage and the rollers, now unguided, skewed
inside and completely damaged the bearing.
f. This is-obvious from Heavier scoring on the NDE portion of the cup and
Blackening of the Outer diameter and face of the cup.


UNIT PROTECTIONS
Introduction
The Unit Protection scheme as discussed in this article mainly relates to

the three major equipments of a power plant – i.e. Boiler, Turbine and Generator.
Generator protection system is provided with three master protective trip relays, ie
CLASS A, CLASS B and CLASS C protection which is named as 86A, 86B and 86C
respectively which will be located in the Generator Relay Panel. Boiler Trip will be due
to master Fuel trip issued by DCS. Turbine Protection system isolates the steam inlet
valves through electrical solenoids and hydraulic devices.
CLASS A Protecton Trip
Class A Protection will initiate trip to both Generator and Turbine. The
faults leading to the CLASS A Trip are of severe nature which not only requires the
isolation of generator but also turbine to prevent further damage to the equipments
mainly generator and generator transformer. The major protections as listed out in
the single line diagram are Earth Faults of Generator stator and Rotor, Differential
Protection for Generator, Generator transformers and Unit Transformers, mechanical
Protections of generator transformers, Negative phase sequence Stage-2 and
Overfluxing Protn. Stage 2 , which require serious attention.
CLASS A protection will lead to the tripping of Both Generator and

turbine along with UAT incomer breaker trip with initiation of Bus transfer from Unit
load bus to Station bus. Turbine trip will make its stop valves and control valves close
and HP / LP bypass valves to fast open. If HP/LP bypass valves have not opened,
system will initiate Boiler trip on Reheater Protection to avoid the reheater coils going
devoid of steam. But however on boiler trip on this protection ID fan and FD fan will
not trip and it has to be ensured that atleast one of the fans are running. Generator
Protection trip will cause the opening of Generator Circuit breaker along with its Field
Breaker.

CLASS B Protection Trip
Class B protection trip mainly deals with Turbine and Boiler Trips which
initiates only turbine trip and not generator trip. But however generator will trip on
low forward or reverse power. It is also initiated by Generator Mechanical Protections
which includes seal oil Liquid level High Inside Generator, Primary water main winding
and bushing flow low, PW conductivity high, gen cold gas temp high and main exciter
hot air temp high.
Turbine Protection System
Turbine protection system is provided to ensure safety for plant and

personnel and for longer equipment life. Normal operation of the turbine is checked by
supervisory devices such as analog controller, binary control elements and monitoring
equipment. The limiting Devices detect deviations from normal operation and initiate
counter measures like starting standby equipment etc., to return the turbine to
normal conditions. Protective equipment shuts off the turbine or parts of the
equipment in case of circumstances endangering persons or the turbine which cannot
be maintained anymore within safe limits.
The turbine trip is actuated by any of the following protection systems:
• Electrical protection system
• Hydraulic protection system
Both the protection systems, when initiated, act on the hydraulic control system and
cause trip oil pressure to collapse which in turn closes the Emergency stop Valves,
Interceptor valves and control valves. The electrical protection system is normally
provided with two separate channels. The field inputs will give signal to both the
channels and these two channels actuate two separate remote trip solenoids
individually for redundancy. The hydraulic protection system drains the auxiliary trip
oil circuit and closes the main trip valve which in turn drains trip oil circuit to close all
the valves.

ELECTRICAL TRIP SYSTEM
1. Lube oil pressure very Low
The Lube oil pressure very low protection is provided to protect bearings from oil
starvation. This trip signal is initiated from pressure switches 2/3 which are set to
1.2 kg/cm2. The value varies for different design of turbines. These values normally
referred to pressures at centre line of Turbine and hence suitable head correction
was to be made while calibrating the pressure switches.
2. Condenser Vacuum very Low
The condenser vacuum low protection is provided to protect the condenser against a
non-permissible pressure increase and the deterioration of vacuum. The trip signal is
initiated from the 2/3 condenser pressure transmitters. This protection was given to
avoid overheating of turbine exhaust area and to reduce oscillations of LP Blading due
to reduced mass flow.
3. HP Turbine Exhaust Temperature very High
The HP exhaust steam temperature protection is provided to protect the exhaust

section of the Turbine, the blading & extraction points against overheating. During
startup/shutdown or load rejections, there can be long period during which steam
turbines are operated at very low volumetric flows and relatively high back pressure
i.e. the mech. Energy transmitted by the turbine shaft is Converted to thermal
energy, which in turn result in an increase in the temp. of both the exhaust steam
and turbine components. The trip signal is initiated from 2/3 thermocouples.
4. Axial Shift very High
A too high axial displacement of the turbine shaft may cause damage to the turbine
blades. This protection trips the turbine in case the axial shift of the shaft exceeds
the limits set during erection. The axial shift is measured in both directions (±) using
three proximity probes. The trip signal is initiated from 2/3 proximity probes.

5. Top Bottom Differential Temp very High
Excessive large temp differentials within turbine components cause heat stresses. The
temp differential between upper & lower parts of the turbine casing (HP and IP
sections- front and rear) is a measure of casing distortion. It may reduce the life/
failure of the turbine components.
The casing temperatures of turbine are measured using thermocouples. This

Protection is enabled when turbine load is more than 25 % of full load. The trip is
initiated from the calculated differential temperature (2/3) between top and bottom
temperature. This protection is provided for both HP and IP turbines.
6. TG Bearing Metal Temperature very High
The excessive temperature rise of bearings during operation can cause wear to
bearing shells. Bearing temperature high trip protects the thrust and journal bearings
of the Turbine and Generator against excessive temperatures rise. The temperature
of the Babbitt metal temp is measured by means of four thermocouples in the each
bearing.
7. LP Cylinder Outer Casing Temperature very High
The LP turbine outer casing temperature high direct trip is not available, when
temperature increased beyond 110°C the machine should be manually tripped. LP
Exhaust hood spray shall be switched on during no load operation when temperature
reaches 90°C. The excessive temperature raise may cause failure of diaphragm,
distortion of end stage blades.
8. Vibration very High
The direct trip is not initiated from high shaft / bearing vibration. The machine
should be manually tripped when crossing the trip level. The shaft vibration trip level
is 320 micron (pk-pk) and bearing vibration trip level is 106 micron (pk-pk).
Continuous operation of the unit with excessive vibration may cause the fatigue failure
of the components and operation beyond trip limits may cause damages to the
internals.

9. Fire Protection
The protection acts in the event of any of the following conditions:

i) Fire protection switch either in control room or in machine hall operated.
ii) Level in main oil tank falls to a very low value indicating substantial leakage of oil
from the system. Trip signal is initiated from the 2/3 level transmitters.
When Fire protection 1 acted the control fluid pumps will go for shutdown/ Emergency
shutoff valve closed which in turn close the HPT and IPT stop and control valve.
When Fire Protection 2 acted, initiates the fire protection 1 first, SLC of JOP and
AOP switched off, Jacking oil pump started, DC EOP SLC switched on, Turning gear
valve closed, and Vacuum breaker also opened to reduce the coasting down time.
10. Electrical overspeed trip
Electrical overspeed trip protection is provided in addition to the hydraulic

protection from the electrical speed signal.
11. Remote manual trip from control room
For enabling the tripping of the turbine during abnormalities for which
automatic tripping is not provided ( for the parameters like inlet steam temperature
very low/very high, vibration etc.,) and for manual shut down of the machine remote
manual trip from control room was provided.
12. Boiler trip
Boiler trip will initiate turbine trip as there is no steam generation.
13. Boiler drum level very high
Operation of the turbine with Boiler drum water level very high can cause
carryover of wetness of steam to turbine and in turn damage the turbine. Hence
boiler drum water level very high protection was given to the turbine.

HYDRAULIC TRIP SYSTEM:
1. Over speed trip 1 and 2
When speed of the turbine increased beyond the preset value due to
centrifugal force the eccentric bolts will actuate over speed trip levers, the auxiliary
trip fluid is drained and main trip valve closes, which in turn drains the trip fluid from
the system. The stop and control valves will be closed immediately
2. Emergency Trip Valve
The emergency trip valve (Manual trip lever) enables the machine to be
manually tripped. When emergency trip valve lever is pressed, the auxiliary trip oil is
drained which in turn drains the trip fluid from the system. The stop and control
valves will be closed immediately
3. Low Vacuum Trip
When vacuum falls below the initial set value, the auxiliary trip fluid is drained
which in turn drains the trip fluid from the system. The stop and control valves will
be closed immediately.
CLASS C Protection Trip
Class C protection Trips Generator circuit breaker alone and generator will
continue delivering the house load in islanded mode. The major protections leading to
the trip will involve the disturbances coming from the grid and hence isolation from
the grid alone will solve the problem.
Boiler Master Fuel Trip
Boiler Master fuel trip will trip the boiler in the cases as mentioned in the
single line diagram. Upon Boiler trip, Turbine will trip. In addition to that, Coal
Feeders and PA fans will trip together with closing all the Oil trip valves and nozzle
valves.





UNITS WHICH HAVE ACHIEVED 100% OA
THERMAL
500 MW
RAMAGUNDAM UNITS – 4, 5 & 7
TALCHER UNIT – 3,4 & 5
SIMHADRI UNIT – 1 & 2
SIPAT UNIT – 4
VTPS UNIT - 7
210 MW
VIJAYAWADA UNIT – 1 & 5
RAICHUR UNIT – 4 & 5
METTUR UNIT – 1 & 3
NEYVELI UNIT – 7
125 MW
JSL, DUBURI UNIT - 2
UNITS WHICH HAVE ACHIEVED PLF MORE THAN 100%
500 MW
SIPAT UNIT – 4 & 5

UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100%
THERMAL
500 MW
RAMAGUNDAM UNITS – 4, 5 & 7
TALCHER UNIT – 1 & 2
SIMHADRI UNIT – 1 & 2
VTPS UNIT - 7
250 MW
KOTHAGUDAM UNIT – 9
210 MW
VIJAYAWADA UNITS – 2,3,4 & 5

RAICHUR UNIT – 4 & 5
METTUR UNIT – 1 & 3
NORTH CHENNAI UNIT – 1 & 2
AMARKANTAK UNIT – 5

PERFORMANCE OF BHEL THERMAL SETS IN SR (210 MW AND ABOVE)

FOR THE PERIOD FROM 01/04/2010 TO 31/12/2010 COMPARED WITH THE
CORRESPONDING PERIOD IN THE PREVIOUS YEAR.
( PLF IN PERCENTAGE )
STATION 2009 - 10 2010 - 11

North Chennai 88.03 76.79
Neyveli 82.65 79.05
Raichur 78.04 58.41
Tuticorin 77.21 74.40
Ramagundam 91.74 90.60
Muddanur 83.14 77.58
Kothagudam 90.45 71.12
Vijayawada 90.83 73.28
VTPS - 7 - 71.41
Mettur 88.11 78.88
Talcher 87.30 85.91
Simhadri 95.35 93.17
Sipat 93.18 93.91
120.00 2009 - 10 2010 - 11
100.00
80.00
60.00
40.00
20.00
0.00
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1 DECEMBER 2010 TS TIDINGS

WISHING A VERY HAPPY AND PROSPEROUS NEW YEAR

Published by Technical Services / PSSR

NAGARJUNASAGAR HEP DECEMBER : 2010

TECHNICAL SERVICES / PSSR

1. STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER CONTRACT

3. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.

4. FEED BACK ON EQUIPMENTS FROM SITES.

5. LET US KNOW - UNIT PROTECTIONS

TECHNICAL SERVICES / PSSR

STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

 Unit is running around 195 – 219 MW.

 Mill G Oil leak through gear box seal was resolved.

KOTHAGUDAM 500 MW, UNIT 11:

 Trial run of Mill motors A, B, C and D was completed.

 Steam blowing CD & EF corners was completed.

 Boiler and Feed water system Hydro test was completed,

 TG DMCW B trial run completed.

 HFO pumps A & B trial run in recirculation was completed.

 ACJOP, DC JOP, DC EOP motor trial run was completed.

TECHNICAL SERVICES / PSSR

 TG Lube oil AOP-1&2 trial run was completed.

 GT was running at 10- 20 MW.

 34 KW water wash heater 3 No’s was commissioned. Process-I/C 2 cable

 Faulty flow divider was replaced with spare flow divider.

 TDBFP saddle pump was replaced with new pump.

 TDBFP turbine solo run was completed.

 MIV OPU problem was rectified.

 Hydro mechanical cabinet and Electro Hydraulic Controller overhauling was

 Unit is running as per customer requirement for peak load demand.

 Erection of coupling capacitors inside stator frame for Partial Discharge

TECHNICAL SERVICES / PSSR

 TG PG Test flow nozzle erection was completed.

 Condenser On-Load Tube cleaning system erection is in progress.

 Erection of Boiler Steam Leak Detector is in progress.

 BHEL/Jhansi rep. is at site to attend to B phase generator transformer bushing

NALCO – UNIT 10:

 Unit was running around 85-120 MW.

 ESP PG Test was completed.

 Presently unit is running around 110 MW.

NALCO – DAMANJODI UNIT 5:

 BFP A Lube oil line flushing was completed

 BFP A motor trial run was completed.

 BFP A voith coupling scoop control was commissioned.

 BFP A, B, DM makeup pump suction, discharge and recirculation lines steam

 BFP A and B to Hydraulic coupling alignment was completed.

 Deaerator and BFP discharge line hydro test was completed

 Feeder A and B outlet gates were commissioned.

 Mill CD LP lines oil flushing is in progress.

 Mill AB ball loading and mill AB trial was completed.

TECHNICAL SERVICES / PSSR

 ESP A pass fields were charged and found normal.

 Feed water system MOVs commissioning is in progress.

 Six no. of valves of piping gallery was commissioned.

 Control room ac system was commissioned by M/s. Thermax representative.

NEYVELI TS II EXP CFBC, 2 X 250 MW, UNIT 1:

 RAPH 1A Lube oil motors 4 nos trial run was completed.

 DMCW Pump-1B trial run was completed.

 BFP 1A Motor 8hrs trial run was completed.

 SA Fan 1A run for 10 min and found normal.

 ESP 1B balance 3 nos. motors (RAPPING), ESP 1A 8 nos. motors (RAPPING)

 APH A support & Guide bearing oil flushing is in progress.

 ID FAN 1A & 1B motor 8hrs trial run was completed.

Unit is running around 195 – 219 MW.

Mill G Oil leak through gear box seal was resolved.

Trial run of Mill motors A, B, C and D was completed.

Steam blowing CD & EF corners was completed.

Boiler and Feed water system Hydro test was completed,

TG DMCW B trial run completed.

HFO pumps A & B trial run in recirculation was completed.

ACJOP, DC JOP, DC EOP motor trial run was completed.

TG Lube oil AOP-1&2 trial run was completed.

GT was running at 10- 20 MW.

34 KW water wash heater 3 No’s was commissioned. Process-I/C 2 cable

Faulty flow divider was replaced with spare flow divider.

TDBFP saddle pump was replaced with new pump.

TDBFP turbine solo run was completed.

MIV OPU problem was rectified.

Hydro mechanical cabinet and Electro Hydraulic Controller overhauling was

Unit is running as per customer requirement for peak load demand.

Erection of coupling capacitors inside stator frame for Partial Discharge

TG PG Test flow nozzle erection was completed.

Condenser On-Load Tube cleaning system erection is in progress.

Erection of Boiler Steam Leak Detector is in progress.

BHEL/Jhansi rep. is at site to attend to B phase generator transformer bushing

Unit was running around 85-120 MW.

ESP PG Test was completed.

Presently unit is running around 110 MW.

BFP A Lube oil line flushing was completed

BFP A motor trial run was completed.

BFP A voith coupling scoop control was commissioned.

BFP A, B, DM makeup pump suction, discharge and recirculation lines steam

BFP A and B to Hydraulic coupling alignment was completed.

Deaerator and BFP discharge line hydro test was completed

Feeder A and B outlet gates were commissioned.

Mill CD LP lines oil flushing is in progress.

Mill AB ball loading and mill AB trial was completed.

ESP A pass fields were charged and found normal.

Feed water system MOVs commissioning is in progress.

Six no. of valves of piping gallery was commissioned.

Control room ac system was commissioned by M/s. Thermax representative.

RAPH 1A Lube oil motors 4 nos trial run was completed.

DMCW Pump-1B trial run was completed.

BFP 1A Motor 8hrs trial run was completed.

SA Fan 1A run for 10 min and found normal.

ESP 1B balance 3 nos. motors (RAPPING), ESP 1A 8 nos. motors (RAPPING)

APH A support & Guide bearing oil flushing is in progress.

ID FAN 1A & 1B motor 8hrs trial run was completed.

BFP 1C lube oil flushing was started and is in progress.

BFP B&C Booster Pump NDE mechanical seals were replaced.

Unit was synchronized on 28.12.2010 at 1245 hrs and presently running at

TG PG test preparatory works in progress.

Mill F oil flushing was completed.

Feeder E tracking was completed.

HP dosing pumps two nos. were commissioned from remote.

Boiler Safety valve floating was completed.

Balance insulation works is in progress.

LP Heaters were charged first time.

LDO line steam blowing was completed.

MAX DNA FOPH panels were charged.

MS line and Boiler Hydro test was completed.

MDBFP Trial run was completed.

SGECW pump B trial run was completed.

Stage 1A and 1B Steam Blowing was completed.

SAPH 3B support and guide bearing oil flushing is in progress.

TG AOP1&2, AC JOP, DC EOP motors trial run was completed

TG Batteries load test was completed.

Unit is running around 450 – 500 MW.

TG PG test was completed successfully on 18.12.2010.