STARTING OIL PUMP IN SERVICE PROBLEM AT NTPC,TTPS UNIT#5 , 110 MW UNIT

Objective To study the Main oil pump discharge pressure not sustaining when unit is running on load

Brief Description of TG Lub oil System

When the Turbine Generator is on Barring Gear and on Full speed No load ( FSNL ) , Starting oil pump ( SOP ) supplies Lub oil to all bearings , Governing system , Airside seal oil system, MOP suction . When the machine is rolled to 3000 rpm , Main oil pump ( MOP ) takes over the duty of supplying Lub oil to TG Bearings , Governing system , Airside seal oil system .

Observations :
As we switch off the SOP after unit is synchronized to Grid , MOP discharge pressure is taking a dip of 4-5 Kgf/cm2 from 10.5 Kgf/cm2 to 5.5 6.5 Kgf/cm2 which is resulting in Auto start of SOP . If the SOP is not coming into service , Turbine is getting tripped and the unit # 5 has tripped 2 times so far because of this account.

Problem faced :
When the SOP is switched off either at FSNL ( 3000 rpm ) or when the unit is on load , MOP Discharge pressure is not holding at a constant value , but it is varying by 4-5 Kgf/cm2 resulting in dip of discharge pressure . Hence the Turbine Generator is getting tripped .

Major jobs carried out during Annual OH 2009 of Unit # 5

No Turbine cylinders were overhauled 6 Nos of TG Lub oil system NRV's serviced 2 Nos of SOP Discharge valves , MOP Suction isol. valve , MOP Disch. to Lub oil coolers isol. valve serviced TG Lub oil cooler bundles replaced with New design ( Finned tubes ) bundles of M/s Laxmi Engineering Industries ,( Bhopal ) Pvt Ltd make Air side and Gas side Seal oil pumps replaced with New pumps of M/s Tushaco make Gear pumps 2 out of 3 Logic has been introduced in this overhaul by C&I in DDCMIS Generator Rotor , Seal Rings replaced during Gen. Rotor thread out operation

Post Overhauling works

2 Nos of NRVs one in MOP suction line from SOP Discharge , SOP Discharge to Gov. system oil line were replaced with New ones
No change in SOP running status while unit is on Load

ONE no. of SOP replaced with overhauled pump

No change in SOP running status while unit is on Load

Brain storming /Recommendations

Oil Injector which is providing MOP suction needs inspection All NRV s in TG Lub oil system servicing MOP Inspection & Seal rings replacement if required Governing system inspection Lub oil Orifices inspection/rectification

Suggestions to solve the above problem by the Esteemed members

We welcome your valuable suggestions

REPEATED FAILURE OF OMEGA PIPE GASKET AT NTPC , TTPS STAGE 2 UNITS ( 2*110 MW )
Brief Introduction of the Problem : What is OMEGA pipe ?
It is nothing but an IP Turbine Steam Inlet pipe in the form of symbol OMEGA . Omega pipe is having LHS & RHS Steam inlet pipes and a common inlet on the IP cylinder facing Steam leakage was observed from LHS Flange of Omega pipe in Dec ,2008 & Jul , 2009 in Unit # 5 Resulting in Unit # 5 Outage on 2 occasions

Observation of the Problem :

Steam leakage from LHS Flange of Omega pipe of Unit # 5 was due to the failure of Old Serrated Gasket of material SS 316 . May be due to thermal shocks during Load changes/Transient operating conditions.

Remedial measures :
A New modified Gasket with more outside diameter to hold between the Studs being used . Camprofile gasket with Graphite sheathing on both sides used with higher OD to arrest the leakage . Support system for the IP Steam chest LHS /RHS will be thoroughly inspected during next Annual Overhaul .

Suggestions by the Esteemed members

We welcome your valuable suggestions