FEED BACK No.

9
PROJECT : IX 10 MW STG AT HARIHAR POLYFIBRES (GRASIM INDUSTRIES) GOVERNING SYSTEM CHARACTERISTICS

SUBJECT :

OBSERVATION Hunting of control valves observed during commissioning trials on 10 MW STG at 4 to 5 MW loads was reported to BHEL Ramachandrapuram to obtain the assistance of a testing engineer for the governing system. A Testing Engineer from Steam Turbines/BHEL, Hyderabad was deputed to site immediately. Soon after his arrival the HP, IP and LP valve characteristics were checked, and valve lifts were carefully set against secondary oil pressures. Then when the values obtained were analyzed and compared with test reports of checks done at the test bed in BHEL Hyderabad, it was found that lifts obtained at site of the IP valves were matching with the test report values of the LP valves and vice-versa. The following steps were taken in the course of analysis: 1. 2. The three HP, IP and LP secondary oil pressure gauges were calibrated. The characteristics of HP, IP and LP valves were set to secondary oil pressures (1.5 - 4.1 Ksc) i.e from start of opening to full open, in each of the valves. The lift values of the HP valves obtained at site were exactly same as the test report values.

3.

24

4.

The lift values of IP valves obtained at site were NOT MATCHING with test report. So IP valve lifts obtained at site were compared with LP valve test report values. The values were matching. This indicated the interchanged assembly of IP and LP servomotors. To confirm. Aluminium paint was scraped off from the metal surfaces of the servomotors. Handwritten marker pen markings were seen which confirmed that the IP servomotor was assembled with the UP Control valve and vice-versa. The erection of servomotors is done based on DES No. DESCRIPTION. The parts are identified in the packing list completion schedule as listed below: and and

5.

6.

7.

DES NO. T 1000 A T 1000 B T 1000 C T 1000 D

ITEM DESCRIPTION STOP VALVE HP SERVO MOTOR UP SERVO MOTOR IP SERVO MOTOR PGMA 30607 PGMA 30609

Actually the punch marks are same (30607) on all IP and UP servo motors. The IP and LP servomotors are identical and hence there were no other visible identification except DES Nos.

25
The erected status of the governing valves servomotors looked as below on 6.10.01.

09.

Since the turbine is packed and dispatched after testing with control valves assembled and only servomotors were dismounted, and the servomotors are separately packed and assigned unique DES Nos. for despatch. It appears that the numbers were wrongly assigned at this point. The scale was assembled after the number was assigned, which is why the LP scale and IP scale also got interchanged.

26
10. At site now the following has been done.

(The corrected assemblies were interchanged as shown above because of the need to include a dampener rod, which matched only when this is done.)
CONCLUSION:

Hyderabad representative has taken the details back to works for necessary system correction in future. The hunting which was present during the next rolling was resolved by adjusting the damping devices in the HP, IP and LP secondary oil lines. The machine has run problem free since then under all required load conditions.