turbine issues resolution

34
SESSION-1 STEAM TURBINE & AUXILIARIES

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Page 1: Turbine Issues Resolution

SESSION-1

STEAM TURBINE & AUXILIARIES

Page 2: Turbine Issues Resolution

Problem Measures Taken

1. A lot of matching is required at site at mating surfaces like wall-girder, packer to module etc, due to lack of surface finish during manufacturing stage. This increases overall cycle time for assembly at site and wastage of man power. The same is to be ensured during manufacturing stage to minimize site matching. .

Birsinghpur and other sites.

At site, girder to endwall blue matching can be avoided, 0.2mm feeler gaps can be allowed. Tightening of bolts and seal welding will suffice. Anchor plates matching will have to be done at site. For maintaining catenary of machine, packers seating surfaces may have to be blue matched at sites.

2. LP inner outer and LP inner inner casing axial keys thickness finalized during shop assembly not matching during erection due to permissible site adjustments. Hence it is suggested that the axial key are also to be finalized at site i.e. over size keys are to be supplied along with set temporary keys.

Birsinghpur and other sites.

Minor adjustments can be done at sites. Oversize supply of keys is not required.

However, sites can give more detailed feedback in this regard.

Page 3: Turbine Issues Resolution

Problem Measures Taken

3. The auxiliary coupling bolts for HP/IP and IP/LP couplings are supplied 08 nos. and 09 nos. respectively. During swing check at HP front after stretching of supplied aux. coupling bolts and rechecking the same after tightening of all the coupling bolts (after reaming/honing and final alignment), deviation observed from initial values achieved. This leads to re-opening of IP casing and face matching of IP coupling. Hence it is suggested that total no of auxiliary coupling bolts(16 nos. for HP/IP and 18 nos. for IP/LP couplings) are to be supplied to check the swing values at HP front with stretching of all the coupling bolts to avoid this problem.(this problem leads to delay in turbine box-up by one month)

Rihand, Birsinghpur

Already implemented for all future sets.100% auxiliary coupling bolts

will be supplied

Page 4: Turbine Issues Resolution

Problem Measures Taken

4. STG deck inserts (Mechanical Embedment), Drawing No.2-13100-87156 Rev 01: Part nos.05 to 118 have been shown as customer scope. This being an EPC contract it is in the scope of the region. Part no.95 (Quantity 5 nos.) plate 100X250X600 & part no.96 (Quantity 4 nos.) plate 100X200X300 is not so easily available and are difficult to fabricate.

Birsinghpur, Sipat, Bellary

Unit has agreed to include 100 mm size plates in their scope of supply. Such special plates generally not available will henceforth be supplied from unit.

5. Implementation of BOI such as Insulation of Turbine and associated piping needs to be improved. In fact the type of insulation may be changed from present spray type to castable or ready to assemble insulation pads in order to avoid environmental / health issues.

Ramagundam and other sites

Can be implemented on customer demand against cost differential. Ceramic type blanket insulation for turbine has already been offered for 2x250 MW Neyvelli project as per customer requirement at additional price.

Page 5: Turbine Issues Resolution

Problem Measures Taken

6. Special Auxiliary Bearing for No-1 journal for SWING CHECK for 500MW set may be designed & supplied by mfg. unit.

Talcher and other sites

Use of device made by PSWR, as an alternative to aux. bearing under trial at Rihand & Vindhyachal. On successful feedback from site, PS & STE will review and decide for future

7.Site suggested that the thermal insulation (Glass Wool) supplied for turbine and turbine piping etc. should be of the same density. It is very difficult for site to store the glass wool density wise separately & during actual use of the wool it is difficult to ascertain the erector’s people for taking the wool of required density. Also site should be able to pick up the wool as and when required from the vendor.

TDL Panipat

Isolated case.

For all other projects, supply, storage and application are in vendor’s scope.

Suggestion of workshop participants for using common density instead of 100 & 150 kg/m3 at present has also been deliberated with PEM representative attending workshop and participants were conveyed various constraints against this suggestion.

Page 6: Turbine Issues Resolution

Problem Measures Taken

8.Radiographic test requirement shall be reduced from 100 % for all the piping in TG Integral piping. Instead 100% RT shall be for Jacking oil lines and other lines, only 10% shall be adopted. This will save lot of inspection time and thus to achieve Milestone readiness in advance

Bellary

Such requirement is as per NTPC tender document. Unit informed present FWS addresses 10% to 100% requirement.

Bellary site to provide specific details wherein they desire RT quantum reduction for consideration of the unit.

9.Governing system, hydraulic governing , view glass is provided to know the bellow condition during operation. In old units, toughened glass is provided compatible to CF system. Recent projects acrylic material is been supplied which is reacting with CF resulting in softening and leakage.

Site has now covered with metal sheet of 5mm thickness and Unit to provide quality glass.

Same type of problem is faced in CF 32bar filter vent glass. These vent glasses also need to be changed with toughened glass.

Talcher -3,4,5&6

Site participants informed that in 210/250MW sets, these are not being provided and unit can consider need of uniformity, whether blanking can be permitted for 500MW sets or toughened glasses compatible to CF system will be provided. Unit will deliberate on same and take suitable decision based on workshop feedback and intimate concerned sites accordingly.

Page 7: Turbine Issues Resolution

Problem Measures Taken

10. Package no. 75704/1 (LP casing assy.) which includes loose items of LP turbine usually got delayed leads to delay in LP casing assembly in turn causing over all delay of the project. Supply of the same is to be ensured during dispatch of pedestals itself.

Birsinghpur and other sites

Raw material receipt constraints, temporarily delayed supplies for a while and such situation is being avoided now.

11. LPBP rack fittings and EHTC block internal lock nuts found loose requiring readjustment of characteristics at site. Locally arranged at site.

Mejia

Feedback has been given to Shop and Quality for the needful. Improvement needed in Packing & dispatch

12. TG integral piping supplied by vendor of sizes 50mm Nb and below could not be bend at site with the conventional Hyd. bending machine. Crack found in the Jacking oil line during bending. The same bending machine has produced perfect bends for pipes supplied for seal oil system by HWR directly. ELBOWS were used and thus causing great increase in welding joints and delays.

Mejia

Elbows supplied by vendor M/s Bend joints, Bhopal. Bend test will be included in Quality Plan. Feedback is being given to CQS Bhopal to ensure bend ability requirement is being met.

Page 8: Turbine Issues Resolution

Problem Measures Taken

13. LPBP stop valve servomotor oil leak during first charging The 3 no bushes for servo bottom long studs was found protruded and the ‘O’ ring supplied found not endless and damaged. The bushes were machined and new ‘O’ ring from customer arranged. Services of HWR technicians (for unit-1 overhaul) were used. Repetitive for both valves and control valve also developed leakages during operation

Mejia

Input will be obtained from technicians who visited Mejia site and will be deliberated in RCA committee.

14. EHTC of Governor System found defective. The HWR technicians could not rectify the problem. The small spool rod ( between plunger coil to the piston top ) found bend. After making the same straight the EHTC could be made

operative. However problem reappeared again. Mejia

EHTC coil has been brought by site representative for inspection and rectification at Haridwar. Rectification done.

Site to give feedback to Unit and CQ whether problem is resolved and need further help, if any

Page 9: Turbine Issues Resolution

Problem Measures Taken

15. Leakages from governor components. The Trip valve bottom flange, all the test valves of ESV & IVs, Speeder gear etc is having oil leakage. The quality of sealing chords need to be checked. The leakages within a very short period of operation is causing concern

Mejia and other sites

This is being taken up in RCA committee. More care will be taken during assy. & testing.

Additional quantity of O-rings and chords will be given to sites as commissioning spares as requested by participants.

Sites to contact Haridwar unit for their requirements and CQ if required.

Page 10: Turbine Issues Resolution

Problem Measures Taken

16. IPCV &IV-1 problem of operation. IV-1 found closing after full opening during first commissioning The coupling end square nut length was increased by ~4mm to get the correct value and servomotor assy. IPCV –1 found having free actuator movement before opening of valve, The same was rectified by introducing a 3 mm washer in the coupling. Also the valve found mal functioning. The pilot top bearing found damaged ( with balls falling from race). A new equivalent bearing was procured locally.

Mejia and other sites

Shop record of coupling dimension to be sent to site.

Cap nut sizes and coupling logsheet will be provided to site prior to erection commencement.

Identification will be more clear from unit i.e. Left, Right, Nos. etc.

Page 11: Turbine Issues Resolution

Problem Measures Taken

17. Seal steam fouling with pedestal casing guide key block. The Key block was ground to accommodate the seal steam pipe also the additional bends/elbows were used to reroute the seal steam pipe to gland.

Mejia, Ib Valley

Drawing modified.

18. In ST front bearing pedestal, each of the four nos. holes provided in the yoke (itemno.32) for fixing parting plane bolts (itemno.33) are offset with respect to the respective threaded holes provided in the pedestal parting plane by 7-8mm. Due to this, the process of assembly /disassembly of the yoke is cumbersome/ complicated & time consuming for site. This is related to a vital component and hence total inspection and quality control should be exercised prior to dispatch.

New Parli

This appears to be error at site since the cap is being sent assembled at works. After dismantling at site, the bearing cap might have been assembled in reverse orientation. 

However, unit shall obtain further feedback from site in this regard. CQ will also facilitate the same.

Page 12: Turbine Issues Resolution

Problem Measures Taken

19. Foundation bolt (M64x1580mm) of drg. no. 0124-04-11000, threads of one no. bolt not turned properly and hence threaded properly and hence nut could not be threaded up to required depth. Haridwar representative visited site & grinded locally

Parichha

Protection of threads was inadequate. Matter discussed with Dispatch section to ensure use of plastic net and buffer between bolts to avoid collision during movement.

20. Outer face of inlet insert of HP insert assembly (Drg no. 1-10514-14000) outside the sealing ring area is uneven up to 1mm due to damage in its outer periphery all around its circumference. Haridwar representative visited site & rectified threads

Parichha

Adequate protection to the surface shall be ensured from unit.

21.The axial clearance between the groove given in the bearing pedestal and the casing protruding portion is 10mm.(zone 9&10L of drg no. 0-11801-01000). Due to casing protruded portion not being chamfered, the clearance is less than that is required. Casing area grinded to achieve the required clearances

Parichha, Unchahar, Rihand

Feedback shared with CFFP to take care of additional material in future.

During discussions, this was agreed to be taken up in RCA committee with involvement of GM(Q), CFFP, Haridwar.

Page 13: Turbine Issues Resolution

Problem Measures Taken

22. Radial clearance of 3 mm between casing & pedestal (section-AA of drg 0-11801-01000) was to be maintained but when casing was aligned the radial clearance was 0mm on one side and 5 mm on the other side. Pedestal grinded to achieve the required clearances

Parichha

During discussion, it has been agreed to be deliberated in RCA committee.

23. The 6th, 7th & 8th stages of LPT blades of LP inner-outer casing (Drg No. 9-10304-12000), bottom half on both rear and front sides, have dents on its surfaces. Total blades were 27 nos. Haridwar team visited site & rectified blade dents.

Parichha

Feedback will be obtained from technicians who visited site.

At Unchahar site the problem has not been repeated.

24. The taper hole diameter of 20mm (section-EE of drg no. 0-10612-01000) of IP inlet insert was drilled but the hole for leak off is not provided in lower IP inlet insert Haridwar team visited site & drilled the required holes

Parichha, Unchahar

Human error.

QC checks introduced in route card.

Page 14: Turbine Issues Resolution

Problem Measures Taken

25. Item 48 LP front wall of drg no. 0-10739-01000 is fouling with LP radial key block assembly. The assembly of key block has been done as per drg no. 0-10744-01000 of LP casing assembly. The stiffener plate were cut down suitably so that side wall could be assembled with LP girders

Parichha

Isolated case.

Sites to provide additional details like sketch, photographs in such cases for better understanding and resolution from unit.

26. In section-QQ of LP casing assembly (Drg no. 0-107-4401000), axial keyway width for (one key out of 4 keys) after assembly of girder and front wall is 49.98mm but key supplied are of width 43 mm. 1 no Key of 52mm was supplied by BHEL Haridwar

Parichha, Unchahar

Additional QC check to be incorporated

During deliberation, it was agreed that this will be discussed in RCA committee.

Page 15: Turbine Issues Resolution

Problem Measures Taken

27. While assembly of LP inner -inner casing , 25 nos. of studs were fouling with inner casing top half (Drg no. 0-107-43-04000). Also holes/slot to be provided in LP inner casing upper half for locking of washer is absent. Moreover, LP inner -outer casing bottom half along with inner-inner has been transported without jack bolts Holes in inner-inner casing upper half provided for parting plane studs be enlarged by 2-3mm to remove fouling of casing. Haridwar team rectified the problem

Parichha

Checking at shop after ensuring 100% use of all fasteners.

Jacking bolts assembly from shop will be ensured before dispatch.

Feedback of unit technicians’ visit to sites will be utilized towards preventive measures.

28.LP shaft seal: The slots provided for fixing of keys have depth 10-12mm against 25 mm(Drg no. 0-107-10-30014) Depth was increased by grinding / cutting the material & achieve proper matching

Parichha, TDL Panipat

Feedback shared with QC-SC.

Drg clarity has been given to subcontractor and being revised for better understanding.

Page 16: Turbine Issues Resolution

Problem Measures Taken

29. In section-BB of LP inner-outer casing assembly (drg no. 0-10741-04000), after centering of diffuser it was observed that holes provided were not matching with that of LP inner-outer casing. 15 nos. of holes were not matching on Generator side and 5 nos. holes on Turbine side. Holes in diffuser were enlarged to remove the mismatch in centerline of the threaded holes in inner-outer casing.

Parichha, TDL Panipat

Trial assembly of diffuser is done at works with all fasteners.

Sites to give feedback with detailed sketches for unit understanding showing mismatch locations and extent of the same.

Sites to adopt suitable wedging and trials to get the best assembly.

30. The key way provided in the casing does not match with keyway provided in IP inlet insert, if alignment is done as per drg no. 0-10612-01000. Separate keyway in casing to match corresponding groove provided in IP inlet insert were made

Parichha

Drawing shall be reviewed to provide better understanding and to avoid similar error in future.

Page 17: Turbine Issues Resolution

Problem Measures Taken

31. Aux. Oil Pumps supplier-Mather & Platt, PuneIn Unit No 3 during pump in service abnormal noise was noticed in Pump Sl.No.43805001/1, Pump was opened for inspection & following observation made - Impeller locking nut with shaft was not found locked properly resulting in lock nut getting loosened & impeller rubbing with pump casing at bottom side.- Pump back plate LG-2 holding brass sleeve found cracked near grub screw for locking purpose - Thrust ball bearing found jammed resulting in abnormal sound during pump running.- Pump back plate (cracked), brass sleeve & bearing required replacement.- Pump Sl.No 43805001/2 was opened to check Impeller locking & Impeller casing. (Pump casing) was found cracked on mounting flange at topside –Casing replaced from Pump Sl.No 43805001/3.

Rihand

Interaction done with supplier to prevent recurrence. CQ Secunderabad is being informed for needful.

Quality plan shall be reviewed to avoid repetition of such events.

Page 18: Turbine Issues Resolution

Problem Measures Taken

32. In Turbine as well as Generator coupling faces, coupling radial, Journal radial run outs observed beyond 0.02 specified Engg. requirements in Unit No III & IV

Rihand and other sites

Matter has been taken up in RCA committee and interaction with sites and unit will continue.

Run out values beyond permissible limits sites have to inform through email /fax/ telephone to Engg and QA of Haridwar prior to taking up any rework.

Unit will depute representative to analyse the issue and to know differences, if any in measurement practices at shops and sites.

33.Three(3) nos. holes of LP casing base plate were sent with diameter. 66mm instead of diameter. 78+1mm.Pkg no:75101,item no:02(drg. No-1-10723-25000) Required size holes were made at local workshop. Sometimes it is very difficult to get the facility for machining such a heavy job at site.

Talcher

Isolated case

Page 19: Turbine Issues Resolution

Problem Measures Taken

34. No clearance between the Hyd. Barring Gear wheel(pgma-11501) & guide cover(item no-11 of 0-11653-27000) of front pedestal cover. Cover bore dia.475mm, barring gear wheel diameter. 480mm. Incomplete machining. Required bore diameter on the cover made by grinding at site and clearance achieved. Very difficult to achieve required. machining by manual grinding - Talcher

Missed operation is due to human failure. QC took care by making a check list in advance.

Page 20: Turbine Issues Resolution

Problem Measures Taken

35. Only one set of O-rings (item no-02&03) & sealing rings (item no-05&06) for hyd. Test & steam blowing arrangement of valves are supplied for all the units. Pkg no-75319drg. No-1-12023-05000,1-12024-05000,1-12025-05000,1-12026-05000,1-12050-25000 & 1-12062-01000. Required Materials arranged at site. These consumables are required to be supplied by Mfg. Unit . One set for each unit is essential for smooth & successful conducting of tests.

Talcher and other sites

Agreed

CBOM for 250 / 500 MW sets shall be revised.

In the meanwhile, present running sites can get the same by putting request to Haridwar unit.

36. Edge of inlet pipe of ESV casing was not perfect (tapered face). Difficult in joint fit-up. Edge correction was made perfectly by manual grinding. Perfect machining is to be carried out at works. Delay in erection activities due to rectification work

Talcher

Additional care shall be taken by unit.

Page 21: Turbine Issues Resolution

Problem Measures Taken

37. Assembly problem of IP Turbine due to supply of wrong fitted keys & spacers. Required material arranged by Haridwar unit & correct assembly of IPT completed successfully at site. During packing & dispatch correct material/ parts to be identified & supplied for the equipment.

Talcher

To avoid mix up proper identification shall be marked on keys and packers.

38. Face run out of and parallelism problem faced at TAPP for LP 1&2 rotors at all four faces. The same has been corrected at site. Same is to be ensured during manufacturing/ slow speed balancing at unit.

Tarapur

Feedback noted by unit.

39. Mismatch between Equipment drg and Customer layout drg. have been observed in many cases e.g. PW Unit, Oil Supply rack for ESV /CV, Turbine Cladding, Seal Oil in Oil Canal, CRH & HRH Piping Support EP.

Tarapur

Problem due to customer drawing mirror image betweeen Unit 3 and 4.

Feedback noted by unit. Drawings of Tarapur shall be corrected so as in future similar sets, problem may not recur.

Page 22: Turbine Issues Resolution

Problem Measures Taken

40. Control Oil Pump (Imported from KSB Germany) not developing pressure. One pump has been sent to KSB Pune for testing. Results awaited.

Tarapur

Being investigated by vendor.

Site informed likely delay in oil flushing activity

41. In LP shaft sealing, the dimension ‘E’ of keyway is 29mm whereas ‘E’ of key is 42 mm. (drg. No. 0-107-44-18000)& (drg. No. 0-107-64-18000)

7 nos. keys machined

TDL Panipat, Parichha

Proper sequence of operation to be followed by sub contractor. Feed back shared with QC-SC

42. In LP casing assembly, there is mismatch in holes of inner guide plate of diffuser U/H & LP shaft seal compensator of the order of 3-4mm in all holes .The holes were enlarged

TDL Panipat, Suratgarh (all units)

Drawing of compensator to be reviewed to include the tech. requirement

M/s Lonestar, Chennai is the supplier and CQS Chennai will be given feedback.

Page 23: Turbine Issues Resolution

Problem Measures Taken

43. Wrong machining of Flange item no. 01 of drg. No. 1-10740-02500(atmospheric relief diaphragm) Assembly is done by using longer bolts with spring lock washer since the modification/ rectification is not possible (SAR HWF-004 dated : 3/08/2004 )

Talcher

Site representative provided sketch during meeting and it has been agreed to take up in RCA committee.

44. SUGGESTION (Talcher)

Spare Lead diaphragm(2 nos per unit) may be supplied for all the future projects for emergency requirements till handing over.

Suggestion has been accepted by unit.

Sites to contact Haridwar unit for needful.

45. 1)20 mm gap observed between collar of screw and bracket. (2)Beam could not be inserted into support since dimensions of beam and support are equal.

Unit action:1) 20mm washers provided. 2) Plate welded on beam at one end was cut and removed for insertion of beam and replaced later. (Drg.no.0-12321-25000)

Simhadri

Feedback has been noted by unit and problem has not recurred.

Page 24: Turbine Issues Resolution

Problem Measures Taken

46. Radial clearances of LP turbine found less than design values which necessitated grinding/cutting of fins.

Radial and axial offset noticed in the inner dia of guide blade carriers of LPT 4th,5th and 6th stages

Rihand, Vindhyachal, Mejia and other sites

Repetitive problem. Grinding data has to be provided to Haridwar unit for RCA committee.

It has been agreed that Sh B Murmu of PSSR will provide data of Talcher, Simhadri site and Sh O D Sharma of PSWR will provide data of Rihand & Vindhyachal sites.

47. IPSV’s failed to open in Unit-4 due to suspected problem in the valve block assembly of the supply rack. After replacing it by other valve block assembly, IPSV’s opened

Rihand

Valve block assy has been replaced from Vindhyachal site. Failed assy is presently at Haridwar unit.

Unit will inspect and re-test the same.

Procedure/ document will be revised accordingly.

48. M42 tapped holes missing in pedestal 3 and 4.

4 no holes not available and 3 holes did not have threads

Rihand

Sub-contracted item. Left over operations did not get recorded. Scope clarity between shop & sub-contractor as well as route card entries are being ensured to avoid recurrence.

Page 25: Turbine Issues Resolution

Problem Measures Taken

49. LP girder holding bolts- all round clearance found only 1.5 mm instead of 6-7 mm as per design

Rihand

It will be taken up in RCA committee.

50. Step of 0.02 mm height in the IP rotor front coupling face resulting in high value of coupled runout and swing check of HP front after coupling bolt elongation

Rihand

Feedback will be further deliberated in unit.

51. Some components of overspeed trip release device were found not assembled when received from works necessitating it to be sent back to works

Rihand

Assembly is being ensured at works prior to dispatch.

52. Thermal insulation data sheet for turbine needs to be revised as it is not suitable for the present design . No space for sufficient insulation thickness on shaft seal casings of HPT and IPT

Rihand and other sites

Unit has agreed with site feedback and will examine the issue

Page 26: Turbine Issues Resolution

Problem Measures Taken

53. Thickness of insulating sleeve on test oil pipe in MOP becomes very less after machining to the present drawing size which may result in the sleeve getting damaged in short time and part of it traveling to the overspeed bolts causing mal-operation of overspeed protection as well as failure of insulation between HP rotor and MOP.

Rihand

Site representative gave detailed feedback on the same.

Increase in diameter near emergency governor side shall be reviewed suitably by Engg.

54.Fouling of the stiffener plates of the LP rotor lifting beam with EOT crane main hook necessitating grinding and cutting of the inner stiffener plate

Rihand

Lifting beams specifications have been modified.

55. Fouling of the IP shaft support console on front side with slings while placing the rotor on stand. Necessitated in cutting the console top in taper fashion ( chamfering of about 50 mm width) to accommodate the slings

Rihand

Drawing revision will be considered.

Page 27: Turbine Issues Resolution

Problem Measures Taken

56. Non availability of shaft lifting device for IP rotor rear end. This is essential for removal of bearing no. 3 when LP rotor is decoupled from IP rotor

Rihand and other sites

Unit will examine request from sites.

Page 28: Turbine Issues Resolution

Problem Measures Taken

57. Casing exhaust portion of HPT was fouling with the front bearing pedestal support blocks provided for hydraulic jacks on both sides. The chamfering on the corners of the support blocks of FB pedestal was increased by 30mm on both sides. (Drg.no. 0-11601-27000)

Simhadri

Isolated case

Not repeated in subsequent sets

58. Baffle strip is to be provided in the gap between TG deck and oil canal. These strips are not shown in the civil drgs. Baffle strips provided at site. Baffle strips are not in Hardwar scope of supply. (Drg.no.0-131-00-81001)

Simhadri

Customer scope

(part of Civil work)

59. Orientation of gland steam inlet pipe is shown on LHS whereas the correct orientation of seal steam inlet is on the RHS. Assembly of shaft seal casings will be done keeping inlet steam connection on RHS. (Drg.no. 1-10710-

09000 ; 1-10711-09000) Simhadri

Drawing revised.

Page 29: Turbine Issues Resolution

Problem Measures Taken

60. Supplied flexible bends had an arm length of 1800mm whereas drg. Shows from valve centre to flexible bend with drain header connection as 1205mm. Drain pipe line arm length is to be increased to the required dimension by using extra elbows. (Drg.no. 0-13112-81004)

Simhadri

Document has already been revised to have flexible bends

arm length 1200 mm

61. Lube piping scheme for all bearing pedestals return oil lines shows 2 temperature stubs in each return oil line whereas lub oil piping layout shows only one stub on each return oil line. Site provided 7 nos. of stubs and weld on lube oil return lines. (Drg.no. 2-131-00-81101; 0-13111-81003)

Simhadri

Documents has been revised

62. Refer lub oil piping layout.Nb-150 drain line can't be connected with Nb-200 flange due to non-availability of sufficient space at that location. Site made Nb-200 flange with 150mm eccentric opening to suit Nb-150 pipe. (Drg.no. 0-13111-81003,81004; 9-139-36-01000)

Simhadri

Documents has been revised

Page 30: Turbine Issues Resolution

Problem Measures Taken

63. Control fluid supply line to duplex filter at ele.12.7M was fouling with LP Bypass up stream line to LP bypass valve no.01 Control fluid supply line was cut and re-routed. Pipes Nb-50 & below are site routed and are to be erected after critical piping erection.(0-13155-81006)

Simhadri

Site routed pipes to be erected only after erection of critical pipes

64. Line filters for oil flushing of lub oil system are getting damaged frequently due to inadequate strengthening. Site locally manufactured these line filters with perforated sheet fitted out side the mesh .Feed back given to concerned personnel. (Drg.no. 1-11717-18000; 2-11648-27000)

Simhadri

Design has been modified now using perforated sheet as per site recommendations.

Page 31: Turbine Issues Resolution

Problem Measures Taken

65. Groove provided on bearing shell on bottom half below the bearing liner is extended and connected to the groove provided for O-ring on one of the jacking oil port openings. O-rings may get damaged. Unit to suggest rectification procedure. Under cut area may be built up by

TIG wire ER 70S. (Drg.no. 0-1170327000) Simhadri

Isolated Case

66. Pressure switch MAV82CP011 is of the range -1 to +1kg/sq cm which will not be able to detect fall in vacuum due to higher hysterisis. Unit to supply 2 nos. pressure switches of range -5 mBar. No such pressure switches available. Change over of exhausters may be done using discrepancy signals

Simhadri

Not required. Added on request of NTPC and later withdrawn by NTPC

Page 32: Turbine Issues Resolution

Problem Measures Taken

67. Heavy leakage was observed from the bottom side of LP/Generator pedestal through welding joints between the vertical stiffeners and base plate on both LHS & RHS. Stiffeners were also not welded from inside Welding done at site by Haridwar team

(Drg.no. 0-11803-02000)

Simhadri

Fabrication drawing has been revised

68. As per PEM drg, there is no pressure gauge tapping with root valve after the isolation valve of ECW piping to exciter cooler but as per Haridwar drg, pressure points are in PEM scope. Site provided the above. (Drg.no. PD-DG-186-179-0101)

Simhadri

During discussions, it was conveyed that PEM was not provided this input and it is being taken care now.

Page 33: Turbine Issues Resolution

Points agreed during discussions

1. Runout & swing check measurement instructions will be made available to sites from Haridwar unit

2. Swing check device of PSWR - Dimensions to be provided to Haridwar unit by the PSWR for review.

3. For MS and HRH strainer welding, supply of two packets of Nicro-82 welding electrodes per unit will be supplied.

4. All sites to provide package nos. in SARs/ CARs/ MDRs raised.

5. Unit informed that they are not receiving Field Quality Plans from Power sector –Regions for vetting and comments, if any. PS –Regional HQs may take note of this for needful.

6. Product Engg groups at Haridwar will identify list of Corporate Standards requiring reference at site. This list will be provided to Power Sector Regions. In turn, PS-Regions/sites will arrange for these standards at the sites.

Page 34: Turbine Issues Resolution

THANK YOU