PA FAN HIGH VIBRATIONS

BOILER
PA FAN
Knowledge Management System
SIMHADRI
Document Submitted by:
D.S.G.S.S.Babji, DGM (BMD),
Emp. No.003937,
1
Emp. No.003937,
Mobile: 09440918484
E-mail: dsgssbabji@ntpc.co.in
Date of submission: 11/08/2009
1.ABSTRACT OF THE CASE STUDY
1. Equipment Type: Axial Profile Fan
2. Equipment Specification: AP-2 20/12
3. Type of failure : High Vibrations in Axial direction
4. Summary of Failure Analysis: Power Point Presentation enclosed
PA fan of Unit#2 at NTPC-Simhadri was having high axial vibration
problem since commissioning i.e. year 2002.
Since, opportunity to repair comes only during unit overhauls,
repeated attempts were made jointly by BHEL and NTPC during
annual overhauls.
PAFan-2A High Vibrations problem
2
Finally problem could be solved during overhaul of 2007.
The presentation covers various activities carried at in chronological
order.
Commissioned on 04.09.02:Vibrations on
trial run at 50%B.P. / 77 A. at Table-1
Fan vibrations increased
19.02.2003: M/s BHEL Suspected looseness
or misalignment. Total rotor assembly
and blades were replaced. Vibrations at
Table-1 H V A
M-DE 1.0 1.4 2.1
M-NDE 1.3 1.3 1.9
FAN DE 3.6 2.3 5.5
FAN NDE 2.6 3.0 5.3
Table-2 H V A
M-DE 2.96 3.01 5.11
PAFan-2A High Vibrations problem
and blades were replaced. Vibrations at
32% B.P. & 62 A - Table-2
27.04.2003: To reduce unbalance, BHEL
carried out alignment and dynamic
balancing at site No improvement in
vibrations - 52% B.P. Table-3
19.06.2003: Complete rotor assembly was
replaced .Vibrations at 65% B.P Table-4
F-DE 8.92 5.4 13.6
F-NDE 7.67 5.35 13.3
Table-3 H V A
F-DE 8.5 5.8 10.2
F-NDE 8.5 4.5 10.5
Table-4 H V A
F-DE 5.9 3.0 8.0
F-NDE 3.8 2.4 8.2
3
During Overhaul dt.20.05.2004:
Complete Rotor Dismantled. Trial Run Taken.
Vibrations in Fig-5 at 55% B.P.-Table-5
During overhaul dt.11.07.2005:
Complete servicing of rotor assembly done all
bearings, springs , INA ring and Rigiflex
coupling were replaced. No improvement.
Vibrations at 57% B.P. - Table-6
Table-5 H V A
F-DE 3.3 3.9 7.8
F-NDE 3.3 2.6 8.0
Table-6 H V A
F-DE 2.9 2.6 11.3
PAFan-2A High Vibrations problem
During Overhaul of 2006 :
BHEL sought for trail run and analyzed.
Readings at 49% B.P., 73 A- Table-7
BHEL Suggested the following:
Alignment of Diffuser With Uniform Axial Gap
Of 10 Mm W.R.T Impeller housing
Spring Back Check On The Impeller Housing
And Correction if required,
Alignment Of OGV Core Seal
Vibrations could be flow induced-check ducts
F-NDE 2.4 3.0 11.3
Table-7 H V A
F-DE 3.0 2.0 7.4
F-NDE 3.4 2.0 7.3
4
PAFan-2A High Vibrations problem
Work Done during Unit Overhaul of 2007 with BHEL supervision
Re-alignment of diffuser w.r.t. impeller housing by adjusting diffuser
soft foot. Spring back check done on impeller housing foot.
(Please refer to pic.-1 in the following slide)
5
Diffuser Assembly Soft Foot Adjustment (Pic.1)
Correction
6
Work Done during Unit Overhaul of 2007 with BHEL supervision
Metal interference observed between OGV core sealing ring and OGV
(Impeller Housing) transmitting strain up to rotor.
Trial run taken without OGV core sealing ring to confirmthe same.
The diameter of OGV core sealing ring reduced by 2 mm on outer
PAFan-2A High Vibrations problem
The diameter of OGV core sealing ring reduced by 2 mm on outer
circumference to relieve strain.
(Please refer to fig.-1, fig.-2 and pic.-2 in the following slides)
7
,17(5)(5(1&(2%6(59(' ,17(5)(5(1&(2%6(59(' ,17(5)(5(1&(2%6(59(' ,17(5)(5(1&(2%6(59('
,03(//(5+286,1* ,03(//(5+286,1* ,03(//(5+286,1* ,03(//(5+286,1*
',))86(5$66(0%/< ',))86(5$66(0%/< ',))86(5$66(0%/< ',))86(5$66(0%/<
Complete PA Fan Assembly (Fig.-1)
8
DIA REDUCED BY 4.0 MM
10 mm
'LIIXVHUFRUH 'LIIXVHUFRUH 'LIIXVHUFRUH 'LIIXVHUFRUH
100 mm
Interference observed
Arrangement of impeller housing/ OGV (Fig.-2)
DIA REDUCED BY 4.0 MM
'LIIXVHUFRUH 'LIIXVHUFRUH 'LIIXVHUFRUH 'LIIXVHUFRUH
2*9 2*9 2*9 2*9
Impeller Housing
9
OGv CORE SEAL!NG R!NG
OGV Core Sealing Ring (Pic.-2)
D!FFUSER
!NTERFERANCE ZONE
OGv
10
Work Done during Unit Overhaul of 2007 with BHEL supervision
PA fan Blades at Simhadri are showing symptoms of pitting/flaking and
subsequent metal loss.
The metal loss problem is referred to CC/OS and is under study by corporate
R&D to ascertain root cause and to provide a solution to the problem.
PAFan-2A High Vibrations problem
The pitted/corroded blades were replaced with new sets.
(Please refer to pic.-3 in the following slide)
Fan Motor Alignment Done.
11
PA Fan Blades Metal Loss Problem (Pic.-3)
12
Work Done during Unit Overhaul of 2007 with BHEL supervision
After completing all the works on PAFan-2A,
Vibration Readings were measured after overhaul at unit full load (i.e. 500
MW) and were found Within Permissible Limits as given at Table-8
Vibration measured at 60%B.P. and 97 Amps current.
PAFan-2A High Vibrations problem
Vibration measured at 60%B.P. and 97 Amps current.
Table-8 H V A
F-DE 3.1 0.9 2.5
F-NDE 3.1 0.8 2.5
13
14