Professional Documents
Culture Documents
Aug 2011
Aug 2011
Aug 2011
HIGHLIGHTS
NALCO DAMANJODI UNIT 5:
INSIDE
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
Air blasting of TG lub oil lines and lines connecting to central lub oil system
was completed. Lub oil centrifuge was commissioned. Trial run of AOP 1 & 2
motor was completed. AC JOP motor trial run was carried out
SG-DMCW & TG- DMCW pumps A & B motors trial run was carried out.
TG- DMCW pump A - 8 hours trial run was completed.
Boiler : Steam blowing of HT & LTPRDS lines from unit -1 to unit 2 was
completed.
HIPOT test of UAT- 1 incomer bus duct, MDBFP cable,ST3: LV2 bus, FD
fan A cable and OBE to 2 KA board bus bar HIPOT test was completed.
TDBFP A & B feed water discharge lines steam flushing was completed.
HPH 5B & 6B and interconnecting pipe lines steam flushing was carried out.
MDBFP oil flushing was declared completed. MDBFP motor was bumped and
direction of rotation was found to be alright.
6.6 KV switch gear bus bar differential protection SEC - A & B GT was
completed.
UPS battery bank -2 initial charging and discharging cycle was completed.
Load gear compartment vent fans 1 & 2 trial run was completed.
Lube oil mist eliminator fans 1 & 2 trial run was carried out.
Unit was shut down on 31/07/11 due to economizer tube leakage. After
attending the tube leakage, unit was synchronized on 05.08.11 and
loaded to 360 MW. Load reduction was due to coal feeding problem and poor
quality of coal.
KUTTIYADI 2 x 50 MW UNIT 1:
KUTTIYADI 2 x 50 MW UNIT 2:
Unit was shut down on 08.08.11 for attending to mills problem and
HPBP C & I work.
Seal air fan B: Shaft replacement and bearing re-alignment work was
completed.
Punch points observed during initial trial and scavenging assembly fixing was
completed and after this, no load trial of feeder-C was completed.
Unit was synchronized on 05.08.11 and the load was maintained around 25 MW.
Unit was boxed up on 08.08.11 due to problems faced in lignite air lock
feeders.
Air lock feeder vendor representative was called for attending the problems.
Boiler was drained and leakages observed in combustor wall near SUB Start Up
Burner) 3 was attended.
FBHE 3&4 bundle chamber and empty chamber blowers were run and identified
leakages attend are being attended.
4 hours no load trial run of Extraction feeders (10 nos. ) was completed on
26.08.11.
Bunker A SS lining work was completed and cleared for lignite filling.
HP Heaters Group Protection Devices system was checked and found O.K
TG PG test was completed successfully on 05.08.11 and MOM signed with the
customer.
Unit tripped on 30/08/2011. TG did not come on barring gear. Hydromotor was
found jammed and clutch was found damaged. Problem was referred with BHEL,
Hardwar and PSTS, Noida. Spare awaited from BHEL, Hardwar.
Air tightness test of duct from ESP outlet to ID inlet was carried out.
CC pump B filter and thrust bearing was inspected, found to be alright and
boxed up.
Mill F: 4 hours trial run & ring roll setting was completed.
Works for PA duct interconnection and seal air lines for LHS mills are
completed.
SAPH B: Guide bearing and support bearing lube oil flushing is in progress.
CC pumps cooling water lines flushing and over head flushing was
completed.
The unit could not be taken into EHTC mode due to hunting. The EHTC position feed
back (Collin feed back) was not exactly following the position set point. The trends
are attached for reference. When there was decreasing command of EHTC position
set point steadily, the actual EHTC position was seen decreasing more than required
value and raises back to match with position set point. This continuous behavior causes
hunting. Hence the unit was in service on hydraulic governing mode of operation.
Analysis:
Initially, suspecting the problem was due to electronic system the following have been
replaced:
Plunger coil, Collins feedback transmitters, Collins transmitter modules (AKC), TBs in
CJJ02 panel and in field JB. The cable from field JB to CJJ02 was re-laid.
As the problem remained, the pilot valve of EHTC was cleaned. One vent was
provided to the EHG plunger coil chamber to eliminate doubt of vapour pressurization
in the chamber.
With all the above activities carried out, the problem remained same. Further
following checks were carried out as per the advice of BHEL PSSR during annual
overhaul:
The trip oil pressure inlet to EHTC was reduced from 5.8 KSC to 4.6 KSC.
Steady value without any pulsation was observed in the newly introduced trip oil
pressure gauge.
EHTC pilot valve and follow up pistons were serviced again. No abnormality was
observed during servicing.
The orifices in the trip oil line to EHTC were cleaned and the trip oil pipe line
was also air blown.
The balancing voltage of the plunger coil was re-adjusted to -1.10 Volts after
reassembly.
The EHTC characteristics were taken and the behavior was smooth. The trends of
position set point and feedbacks are attached for reference. The behavior was normal
during raising and also during lowering of position set points.
The Unit was rolled and synchronized with EHTC. No problem was observed and EHTC
Collins feedbacks are following to the position set point.
Conclusion:
The root cause of the problem is suspected to be higher trip oil inlet pressure to
EHTC. This has caused the pilot response faster and more than required and made
the EHTC convertor movement and again corrected to the required position during
internal draining in pilot valve. The recommended pressure of trip oil pressure at
EHTC inlet is 4.5 ksc to 5.0 ksc for smooth operation of EHTC.
Courtesy :
During the first commissioning trial of this Unit, the HP Stop valve (left) was tripping
randomly after unit was run on load. This happened a couple of times at different
loads and parameters but it did not cause any turbine tripping. It was having
potential for Turbine tripping so it needed to be attended.
Analysis:
Following pages contain images of the HP stop valve coupling with details. When the
stop valve is closed the status of the coupling parts is as shown in schematic Drg.2,
Fig.1. When the valve is opening under hydraulic forces, the status is as in Drg.2,
Fig.2. When this valve is fully opened, the status is as in Drg.2, Fig.3. The coupling
gaps indicated in the design drawing shown in Drg.1 ensure there is provision for
thermal growth of the valve stem when hot steam is passing through the valve. If the
assembly of the coupling does not follow the gap dimensions recommended, then
tripping can occur, when thermal expansion of the valve stem pulls down on the
servomotor stem and causes release of trip fluid pressure. This will happen every
time, when the turbine is on load.
For analyzing this,
1. The coupling gap was checked in valve close condition and found to be only
6mm instead of 7mm. Then a 1.0 mm shim washer was inserted between
parts 35.1 & 35.2 at AA as shown in Drg.1 No tripping was observed at any
load.
2. As a permanent correction, the coupling part 35.1 was machined by 1 mm at
the location BB shown in Drg.1.
Conclusion:
The problem was resolved as explained above but some improvement is suggested
for future sets. The machining that was done was a necessary correction because
the provision for thermal expansion of the valve stem was found inadequate. It is
better to have the dimensional tolerance for individual components ensured at unit
so that the product manufactured does not require any rework, as indicated in
blueprint, at site, and further, does not lead to any operational problems.
Courtesy :
Shri. M.V. Baskaran / DGM Technical Services / BHEL-PSSR, Chennai
Shri. Bikas Mishra / Manager TG-Erection / BHEL-PSSR / Simhadri site
Drawing 2
The three phase transformer windings can be connected in several ways. Based on the
windings connection, the vector group of the transformer is determined.
The transformer vector group is indicated on the Name Plate of transformer by the
manufacturer. The vector group indicates the phase difference between the primary
and secondary sides, introduced due to that particular configuration of transformer
windings connection.
The three phase transformer primary and secondary windings are mainly connected in
the following ways
WYE - WYE (ALSO CALLED STAR-STAR)
DELTA - DELTA
The Star connection is also called Wye as it resembles the English letter 'Y'. As both
the names Star and Wye are equally used we have the freedom to use them
interchangeably. Of course some people also use the term 'Mesh' in place of 'Delta'.
Let us first consider the Wye - Delta type where three primary windings
are connected in Wye and the three secondary windings in Delta.
The windings in the primary are connected in Wye(Star) and the secondary windings
are connected in Delta. In the primary side the three windings are A1-A2, B1-B2 and
C1-C2. Similarly the three secondary windings are a1-a2, b1-b2 and c1-c2.
It should be noted that both the windings A1-A2 of primary and a1-a2 of secondary
are wound on the same limb of core. The naming of the terminals has been done
according to their polarity. Otherwise you can imagine that when A2 is positive with
respect to A1, then also a2 is positive with respect to a1. Think similarly for the
other windings. Fig A shows A2,B2,C2 and a2,b2,c2 are respectively the primary and
secondary side terminals taken out of transformer.
In the primary side the three windings are connected in star. So we have shorted A1,
B1 and C1. This is the primary side (star side) neutral 'N'. In the secondary side the
three windings are connected in delta. Here windings a1-a2 and A1-A2 are wound on
the same limb of the core, so the corresponding voltage waves are in phase. Hence we
have drawn a1-a2 parallel to A1-A2. similarly windings b1-b2 is drawn parallel to B1-
B2 and c1-c2 drawn parallel to C1-C2.
In the phasor diagrams we have drawn primary side voltage phasors A1A2, B1B2 and
C1C2. As usual for three phase system, these are the phasors displaced 120 degree
from each other. Similarly in the secondary side voltage phasors a1a2, b1b2 and c1c2
are drawn. Just observe that a1a2 is parallel to A1A2, b1b2 is parallel to B1B2 and
c1c2 is parallel to C1C2.
In the delta side we have so arranged that the phasors form the Delta. In the
winding connection diagram a2 is connected to b1 so in the phasor diagram a2 and b1
are joined. Similarly by joining other two phasors according to their winding
connection, we will automatically get the above phasor diagram.
The neutral (star point) physically exist in the star side. In the delta side physically
the neutral point does not exist so it cannot be brought out. The delta side neutral is
the imaginary point 'n' (geometrically found) which is equidistant from a2, b2 and c2.
c2a2, a2b2 and b2c2 are the line voltages in secondary delta side. So na2, nb2 and
nc2 are the phase voltages in secondary side.
Now compare the primary side vector diagram and secondary side vector diagram.
From the diagram it is clear that as if the secondary side phasor triad has been
rotated counterclockwise with respect to primary side. From the geometry it can be
confirmed that this angle is 30 degree. As the phasors are rotating counterclockwise,
so the secondary side phasor a2n (phase voltage) lead the primary side phasor A2N
(phase voltage) by 30 degree.
The transformers are classified into different Vector Groups depending on this phase
difference between the primary and secondary sides, obtained due to different
connection philosophy.
IEC has devised the standard code for determination of transformer vector group.
According to IEC the code for vector group consist of 2 or more letters followed by
one or two digits.
The first letter is Capital letter which may be Y, D or Z, which stands for High
voltage side Star, Delta or interconnected Star windings respectively.
The second letter is a small letter which may be y, d or z which stands for low
voltage side Star, Delta or interconnected Star windings respectively.
The third is the digits which stands for the phase difference between the high
voltage and low voltage sides.
From the above three points, the first two are quite straightforward. The third one
follows the clock convention as described below.
In this convention the transformer high voltage side phase voltage (line to
Neutral) represented by Minute hand fixed at 12 O'clock position and the low voltage
side phase voltage (line to neutral) is represented by the Hour hand which is free to
move. Clearly when the minute hand is fixed at 12 position, the hour hand can take
only twelve numbers of discrete positions 1, 2, 3 ... upto 12 . The angle between any
two consecutive numbers in a clock is 30 degrees (360/12). Hence the angle between
hour and minute hands can only be multiples of 30 degrees. See the figure.
Note: Remember that in star and zig-zag connection the neutral point exist physically
and in delta connection the neutral does not exist physically and called virtual. But
the line to neutral voltage can always be calculated algebraically/geometrically.
From fig-A the low voltage secondary side phasor a2n leads the high voltage primary
side phasor A2N by 30 degree. (remember that the comparison is between the phase
voltages). According to the clock convention this specific case represent 11 O' clock.
So the above transformer connection can be represented by the symbol Yd11(or
YNd11). N or n may be used for a brought out neutral.
Let us change the connection slightly to get the Yd1 vector group. See Fig-B, here
the primary side is as before, but in the secondary side a1 is connected to b2 etc.
(compare with previous diagram).
In the above diagram the individual phasors are still the same as in Yd11 case. Here
we have only rearranged the phasors of delta side, only to satisfy the connection
changes in the secondary side. Here the clock face indicates one O' clock. As a result
we obtain the Yd1 vector symbol.
Here the primary windings are connected in Delta and the secondary windings are
connected in Star or Wye. The naming convention is similar to the Wye-Delta
transformer.
In the figure-C see how the windings of primary and secondary sides are connected in
Delta and Star respectively. Also see the corresponding phasors. In the Delta side
each winding is subjected to line voltage, but in Wye side each winding is subjected to
phase voltage (V/1.73).
As already told and shown although the neutral is not physically available in Delta
side, but neutral point 'n' can be found geometrically. The arrow NA2 is the phasor
representing phase voltage of high voltage side (primary). In the Star side(low voltage
side) arrow na2 is clearly the phasor representing the phase voltage of
From the diagram applying school geometry it is clear that na2 phasor lags NA2
phasor by 30 degrees.
Applying IEC coding: NA2 is minute hand fixed at 12 O' clock and na2 is hour hand at
1 O' clock (as the angle between the two is 30 degrees)
Similarly just slightly modifying the connection above we can get Dy11 notation. Here
we have rearranged the windings in the primary side for connection modification and
convenience. See Fig-D.
If you understand the above examples then identifying Star-Star and Delta-Delta
vector group are very easy. One can reasonably say that the phase difference
between the primary and secondary sides of both these cases is zero. The vector
group symbols will be Yy0 and Dd0. Remember the connections can be two different
ways. Consider the Wye-Wye connection. In Yy0 (zero phase displacement between
primary and secondary) secondary side neutral is obtained by shorting the terminals
a1, b1 & c1 and a2, b2 & c2 are brought out terminals. In Yy6 (180 degree phase
displaced) the neutral is obtained by shorting a2,b2 & c2 and a1,b1&c1 are brought
out terminals. See Fig-E and Fig-F.
Transformer connections are categorised into four main groups as tabulated below
Also transformers in group1 and group2 cannot be operated in parallel as there is 180
degree phase difference between the two secondary windings. This can only be
rectified by changing internal connection.
Similarly if group3 and group4 transformers will be connected in parallel then there
will be 60 degrees phase difference between their secondary windings. But with
transformer external connection modification the phase difference of secondaries can
be made zero. So group3 and group4 transformers can be operated in parallel with
some external modification.
THERMAL
500 MW
RAMAGUNDAM UNIT 7
TALCHER UNIT 2 & 5
SIMHADRI UNIT 1
VTPS UNIT - 7
250 MW
KOTHAGUDEM UNIT - 10
210 MW
VIJAYAWADA UNIT - 3
METTUR UNIT 3
TUTICORIN UNIT 1, 2 & 5
NEYVELI UNIT 4
UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100%
THERMAL
500 MW
250 MW
KOTHAGUDAM UNIT 10
210 MW
100.00
80.00
60.00
40.00
20.00
0.00
VTPS - 7
Tuticorin
Neyveli
Ramagundam
Kothagudam
Talcher
Vijayawada
Raichur
Mettur
Muddanur
Amarkantak
North Chennai
Sipat
Simhadri