REPAIRS AND REMEDIAL MEASURES TO TURBO GENERATOR FOUNDATION IN UNIT V & VII / T S II

1)K. Govindaraj 2.) K Chakkaravarth 3.) B. Sivagnanam

INTRODUCTION: Power is the most important need for our day to day life of mankind and industries. Neyveli lignite corporation caters major power requirement of our nation and 60% of the power requirements of Tamil Nadu. In Neyveli Lignite Corporation Limited, second Thermal Power Station is a major Generation Plant which consists of 7 Units of 210 MW having total generation capacity of 1470 MW. TURBO GENERATOR FOUNDATIONS : The Turbo Generator is mounted over RCC deck slab which is supported by TG foundation columns of six pairs C1 (N&S) to C6 (N&S) over the common raft as detailed in the drawing D1. The structural details of the Turbo Generator Foundation are as detailed below. DIMENSIONS: a. b. c. d. e. f. g. Overall Dimension of Raft : 25.40 X 12.00m Overall Dimension of pedestal : 24.725 X 11.00m Overall Dimension of Deck : 26.725 X 12.00m Thickness of Raft : 2.00 m Height of Pedestal above raft : 14.02 m Maximum Depth of deck : 2.63m Minimum Depth of deck : 1.80 m

COLUMNS / PEDESTALS : Nomenclature C1 C2 C3 C4 C5 C6 Numbers 2 2 2 2 2 2 Dimensions in Metre 1.40 X 0.85 1.25 X 0.80 1.40 X 1.00 1.20 X 1.00 1.40 X 0.85 1.10 X 1.20

1. Executive Engineer/ Civil/ TS II / NLC 2. Chief Engineer/Civil(ic) / TS II/NLC 3. Dy. General Manager / Civil (ic) TS II / NLC

CONCRETE DETAILS: Description PCC RAFT PEDESTAL DECK AUXILARY COLUMNS CONDENSOR COLUMNS CONDENSOR BEAMS Grade M 15 M 20 M 25 M 25 M 25 M 25 M 25 Quantity in cum 27.6 530.00 205.00 325.00 7.20 37.00 12.00

The deck slab had been tested with Ultra Sonic Nondestructive testing during construction period and has been found to be satisfactory. The Unit V of Thermal Power Station II was commissioned during December 1991. Since commissioning, the Turbo generators were running normal with full efficiency till the year 1994. In 1994, after 12, 008 running hours of Turbo Generator, it was noticed that vibration levels of nearing 5 & 6 in Unit V have increased suddenly to unacceptable levels. Immediately the vibration levels of TG columns were checked and it was noticed that the vibration readings in C5 North and C4 south have been increased to 160 and 84 microns. But the acceptable limit is only 50 microns. The Vibration in the columns were measured both in axial and in horizontal direction by using vibro meter IRD 308 and IRD 880. The vibration in the axial direction is the direction which is parallel to the rotor and the horizontal direction is the direction perpendicular to the rotor. The vibro meter measures the velocity in meter per second and the displacement in microns. It was reported that the machine vibration had occurred due to dislocation of wedges in Generator rotor. At the same time, the vibration in Generator bearings was observed to be high and the alignment bearing and wedges in Generator rotor were rectified during overhaul. After these mechanical rectification and reassemble, the vibration levels have reduced to 90 microns. But with in next 30 days, the vibration levels in the two columns (C4 South and C5 North) were increased extensively to 84 and 160 microns. To identify the cause, the subject matter was referred to M/s Structural Engineering Research Centre (SERC) , Chennai , Bharat Heavy Electricals Limited ( R&D) / Hyderabad ( Suppliers and erectors) and our consultant, M/s. Development Consultants Private Limited for a study and detailed report on the cause and remedial measures. M/s BHEL came out with a suggestion of balancing weights to arrest the vibration. This measure of counter balancing with weight had neither solved the problem nor identified the causes. M/s DCPL orally suggested to encompass the columns with brick masonry. This was not practically unworkable due to space conditions. M/s. SERC after resorting to ultra sonic scanning of the columns, inferred that the columns may have unacceptable level of imperfections which might be voids, micro or macro cracks in the concrete columns, M/s. SERC came out with a project proposal with the components of field investigation and remedial measures as detailed bellow.

FIELD INVESTIGATION: 1. Visual inspection 2. Measurement of vibration. 3. Assessment and condition of concrete columns using Non Destructive Test. 1. VISUAL INSPECTION The visual inspection was carried out to find the quality of construction, cavities, colour and cracks on the surface of the concrete. On visual inspection, the colour of the concrete was normal and no apparent voids, cracks, cavities of serious nature were found and the surface were smooth as cast. 2. MEASUREMENT OF VIBRATION Description of the instrument Table 1 gives the instrumentation scheme planned for the measurement of dynamic displacements at the selected location on the TG installation. Each of the system 1 to 4 consists of a standard B&K accelerometer type 4370 which serves as the vibration sensor connected to the matching charge amplifier (B & K type 26350 which serves as the signal conditioner and amplifier. System 5 represents the B & K measuring system consisting of the same type accelerometer (B&K 4370), and connected to ab amplifier-cum-indicating meter (B&K type 3513). The later has a continuously tunable filter set to filter out unwanted noise and signals outside the frequency of interest. The selected measuring systems are suitably grouped, keeping in view their compatibility and adaptability to the tests planned. The output from the amplifiers is connected to the various channels of the FM tape recorder. Vibration measurement in all the columns was conducted from the O m level. Six recording stations were arranged, three on the northern side ( east , west and central) and three on the southern side of the foundation. The stations were chosen for easy access to the nearest available power source available for the operation of the measuring equipment and to avoid long length of signal carrying cables. 16. METHODS OF TESTING: Generally condition of in-situ concrete can be identified by the following tests. Destructive testing Partially destructive testing and Non-destructive testing. In TG column the destructive testing and partially destructive testing is not possible for assessing the conditions of concrete. Hence only non-destructive testing technique can be adopted. NON DESTRUCTIVE TESTING: There are two popular non destructive testing namely, rebound hammer test and ultrasonic pulse velocity test. The former test measures the hardness of the concrete surface while the latter measures the velocity of the ultrasonic pulses of a particular frequency through the concrete medium. Since the impact energy used in the hammer is relatively less, the test can indicate the quality of concrete only near the surface. As the structure in question is having a depth varying between 0.80 to 1.4m, the rebound hammer test can not indicate the quality in the interior zones of the TG Columns. On the other hand, the ultrasonic pulses can be transmitted through the concrete medium, and any flaw, void, or crack can be detected based on the velocity values. In view of this, the ultrasonic pulse velocity was chosen to evaluate the quality of insitu concrete in this structure.

PRINCIPLE AND INSTRUMENT: When a concrete mass is subjected to an impulse, three dominant waves propagate through the solid. These are: 1) P Waves or compressional waves 2) S Waves or shear waves 3) Raleigh waves The P waves are the fastest among these and have longitudinal displacement in the direction of the wave. Electroaccoustical generators produce primarily the waves of this type. The travel velocity of the P waves depends on the following important parameters. Dynamic modules of elasticity of the solid, which is generally 20 to 50 percent higher than the Corresponding static modules. Mass density of the solid The Poisson's ratio - In an infinite, homogeneous and isotropic elastic medium, the P wave velocity is given by the equation , VC = Ed ( 1 P ) (1 + P ) ( 1- 2P ) P where, Ed = Dynamic modulus P = Poisson's ratio P = mass density Vc = wave travel velocity

The methods consists, basically, of measuring the transit time of ultrasonic pulses transmitted through the concrete medium and calculating the pulse velocity by dividing the path length by time. The pulse velocity measurements can be used to establish the following characteristics of the concrete structure. 1. 2. 3. 4. 5. 6. the homogeneity the presence of cracks, voids, and other imperfections changes in the structure of the concrete which occur with time the quality of the concrete in relation to standard requirements the quality of one element of concrete in relation to another the values of elastic modulii of concrete.

There are three possible ways of measuring pulse velocity 1. Direct transmission 2. Semi-direct transmission 3. Indirect transmission The direct transmission method is generally preferred since the maximum energy of the pulse is being directed at the receiving transducers and this gives maximum sensitivity. In this investigation direct transmission methods was adopted since both faces of the columns were easily accessible. The pulse velocity measured in reinforced concrete in the vicinity of reinforcing bars is usually higher than in plain concrete of the same composition. This is because the pulse velocity in steel is 1.2 to 1.9 times the velocity in plain concrete and under certain conditions, the first pulse to arrive at the receiving transducer travels partially in concrete and partially in steel. Where ever possible measurement should be taken in such a way that the steel does not lie directly in the path of the pulse. Correction factors should be applied if measurements are taken in the proximity of reinforcing bars.

INSTRUMENT DETAILS: The instrument used in this investigation is of the following specifications. Commercial name : PUNDIT (Portable Ultrasonic Non destructive Digital Indicating Tester) Transit time Measurement : 0.1 to 9999 micro seconds Units : Two ranges : 0.1 and 1 micro sec. Timing Pulses derived from a 10 MHz crystal oscillator Accuracy : + 0.1 micro sec Input sensitivity : 250 Micro volt between 20 kHz and 500 kHz Impedance : Approximately 1M Transmitter energising pulse : Nominal 1 KV or 500 V, 1.5 Microsec: Switch selected. Pulse repetition frequency : 10 pps synchronised to mains frequency; 8 pps when powered by battery Power supply battery : Internal rechargeable Ni-cd battery Mains : 220/250 V, 50- 60 Hz External : 11 to 13 volts D.C. 140 mA Display : 4 digit, 0.5 in. Transflective crystal PROCEDURE: As already indicated, the primary objective of this investigation was to assess the effectiveness of the compaction and to identify any weak zones or presence of voids, cavities, etc. In order to achieve this objective, it is necessary to take the pulse velocity measurements on a number of points which are close to each other so that adequate data will be available to make a reliable assessment. For this purpose, the column portion was divided into a several individual. These individual portions were further divided into well defined grid points and the spacings of the points Was approximately between 200 mm in both vertical and horizontal directions. The path length of each portion was measured and also given in the respective drawings. In order to obtain steady reading, the surface of the concrete at each point was thoroughly cleaned and smoothened. The transducers were kept on opposite faces by applying a small quantity of grease to obtain a perfect acoustic coupling. After ensuring that the readings obtained in the instrument remained steady and constant, that reading was noted and recorded. This procedure was repeated on all the points. ANALYSIS OF RESULTS AND CONCLUDING REMARKS: The velocity values in km/sec were calculated and have been indicated at the respective points in the drawings The general guidelines for assessing the concrete quality based on pulse velocity values are as follows : "V" Greaten than 4.0 Km/Sec. - V.Good "V" Less than 4.0 KM/Sec but greater than 3.5 KM/Sec. - Good but porous "V" Less than 3.5 Km/Sec but greater than 3.0 KM/Sec. - Poor "V" Less than 3.0 KM/Sec - Very Poor In order to declare the concrete quality as acceptable, it is to be ensured that the pulse velocity values. At all locations are greater than the minimum velocity obtainable for that concrete composition. However, in majority of the cases, especially in large blocks, there may be a few locations having lower pulse velocity values. If such values occur at discrete locations, it may not adversely affect the overall strength and serviceability. The statistical parameters such as the minimum velocity, average velocity, and standard deviation, help to take a quick assessment on the uniformity of concrete quality. The indication of velocity values in the drawing help to locate weak spots. The notation used to represent a line in horizontal is A,B,C,D,E,F and in vertical lines by 1,2,3,4,5 and so on for the purpose of indicating the velocity.

DYNAMIC ANALYSIS:

Dynamic response of the foundation has been computed considering the geometrical and inertial loading data supplied under study state dynamic loading condition. The structure is idealised as a space frame consisting beam bending element. The analysis has been carried out and the theoretical results for three typical columns (C4S, C5N and C6S) which were seen to be experiencing relatively large vibrations. INFERENCES OF FIELD TESTS: The vibration data collected on the columns of the TG foundations revealed that Columns C4 South and C5 North experienced relatively high vibrations and gives room for the suspicion of the likely presence of voids in the region of 0 to 2 m and 6 to 7 m from the base of the column. The UPV data (Ultra sonic pulse velocity) showed that concrete in the columns viz., C1 North, C4 south, C5 North and C6 south are below satisfactory indicating presence of voids and loss if integrity. In addition C1 South was also identified to possess a few isolated locations of unsatisfactory concrete. REMEDIAL MEASURES: The above mentioned columns were suggested for repair to restore the integrity by cement grouting followed by Monopol injection. In each identified columns the locations possessing a velocity value of 3.0 Km/sec and less for cement grouting followed by Monopol injection and the locations possessing a velocity value of 3.0 to 3.5 km. Sec by only Monopol injection. METHODOLOGY OF EXECUTION: For execution the following methodology was adopted. (a) Earmarking the locations for grouting and injection. (b) Drilling of holes to depth of 200mm (c) Fixing of GI ferrules of 15mm dia (d) Grouting with cement of 53 grade. (e) Injection of monopol / epoxy (f) Removal of ferrules and Sealing of drill holes with epoxy & Quartz sand mix. EARMARKING THE LOCATIONS FOR GROUTING AND INJECTION: Based on the report of M/s. SERC, the points where the Ultra sonic pulse velocity value was 3.0Km/Sec and less were marked with red paint for grouting with 53 grade cement. The points where the Ultra sonic pulse velocity value between 3.0Km/Sec to 3.5 Km/sec were marked with yellow paint for injecting with Epoxy/ Monopol. The points were marked on both faces of the column (East to west and North to south). The points were marked at the interval of 400mm spacing. DRILLING OF HOLES TO A DEPTH OF 200MM: At the marked locations of points holes drilled by using rotary cum hammer drill of 20mm dia operated by using compressor of capacity 10ksc. For speedy execution two numbers of compressors were used. The depth of drill was fixed as 200mm maximum with slight upward inclination for easy grouting. At certain locations where the reinforcement rods were intercepted, adjacent locations were chosen for drilling. It was noticed that the drilling was very easy where the voids in the concrete were at the shallow depth itself. The depth of drilling was made to be increased due to very loose concrete at some locations since the ferrules are to be fixed tightly. FIXING OF GI FERRULES OF 15MM DIA: The drilled holes of the TG columns were cleaned with compressed air for removing fine dust. In the mean time ferrules of 15mm dia GI pipe of length 200mm with one end threaded for a length of 25mm were fabricated. The fabricated ferrules were fixed in position so as to have a length of 75mm projecting out side the concrete surface. After positioning the ferrules in the drilled location, the outside peripheral gaps between the holes and ferrules were sealed with the mortar of Non shrinking Epoxy and Quartz sand.The ratio of mortar of Non shrinking Epoxy and Quartz sand is1:2 (one part of Non shrinking Epoxy and two parts of Quartz sand). The Non shrinking Epoxy consists of base resin of EMG 183 and a hardener of EH 400. The mixing of mortar was carried out in a bowl and consumed within 15 minutes before the expiry of its pot life. The sealing was allowed for 12 hours for hardening and setting to withstand grouting and injecting pressure. GROUTING WITH CEMENT OF 53 GRADE:

After the setting of sealing, the ferrules were cleaned with jet of water to clean the dust and to keep the ferrules in wet condition. For grouting purpose, Grade 53 cement mixed with plasticised expanding grout admixture of Conbex 100 was used. Mixing proportion of plasticised expanding grout admixture with 53 grade cement is 225 grams per 50 kg of cement. Grade 53 cement was chosen due to its strength and attaining early strength. Conbex 100 is a combination of plasticising agent and a gas producing expansion medium supplied in power form. It allows the use of reduced water cement ratio with consequent increased strength and durability. The expansive medium counteracts the natural settlement and plastic shrinking of the grout and aids stability and cohesion. The cement slurry was prepared in a container fixed with a stirrer. The water cement ratio for the slurry was kept as 0.4 After the preparation of cement slurry, the same was poured in the pressure grouting tank through the funnel at the top of the tank fitted with valve. The capacity of pressure grouting tank was two bags. One end of the pressure grouting tank is connected with air inlet of the compressor and the other end is connected to coupling type hose. The female end of the coupling has to be connected to the male end fixed in the ferrules during the grouting operation. Initially, before starting the grouting operation, the inlet value of funnel was closed tightly and the valve of the co pressed air was opened so as to mount the required pressure inside the tank and hose line. Before joining the female end of the coupling to male end the air in the hose was released and the line pressure was checked. After ascertaining the pressure, the female and male ends were connected tightly and the outlet is opened by operating the lever fixed in the hose. The grouting operation was continued till the firm resistance from the surface was received. The firm resistance could be experienced when the cement slurry rebounds from the ferrules. In some locations, while grouting, the cement slurry oozes out from other ferrules of adjacent locations. During that time, the opening of adjacent ferrules was plugged with dummies and the grouting operation continued till the firm resistance from the surface was experienced. For each operation, two bags of cement were used for the preparation of cement slurry. After completion of one operation, the pressure tank and hose were cleaned thoroughly with water and compressed air. The cleaning operation was done to clear off line choking due to setting of cement.The consumption of cement was depending on the quantum of voids and cracks in the particular locations and the quantity was a maximum of 50 kgs in a single ferrule point.Similar operation was carried out in all the points earmarked of cement grouting. Totally 95 bags of cement were consumed. The consumption details for each column are as detailed below.After completion of cement slurry grouting, the grout was allowed for setting for 24 hours.

Column No.
C1 NORTH C1 SOUTH C2 NORTH C2 SOUTH C3 NORTH C3 SOUTH C4 NORTH C4 SOUTH C5 NORTH C5 SOUTH C6 NORTH C6 SOUTH

No. of cement bags consumed

20 11 2.5 2.5 26 17 16

INJECTION OF MONOPAL / EPOXY: After completion of cement slurry grouting, holes were drilled in the points ear marked for Monopol /Epoxy grouting. The same procedure as mentioned in drilling of holes and fixing of GI ferules was adopted. Monopol is a high molecular weight thermosett polymer (HMWP). By virtue of its low viscosity , it will penetrate well in to the concrete and strengthen the matrix. It has been considered one of the best materials extensively used in the rehabilitation of concrete structures like TG and crusher foundations. It has a viscosity of 2 - 5 Centipoise and having the mix proportion of 490 grams of base and 12.5 grams of curing agent. The mix has a pot life of one hour for 500gms mix. It has excellent adhesive and chemical resistant property and it is Non-toxic on cure & non obtrusive odour. The ferrules were cleaned well with high pressure of air to make the surface free from moisture and dust particles. The base and curing agents of Monopol were thoroughly mixed in a separate vessel and poured in a small pressure injecting tank. One end of the pressure injecting tank is connected with air inlet of the compressor and the other end is connected to coupling type hose. The female end of the coupling has to be connected to the male end fixed in the ferrules during the injecting operation. Before starting injection, the inlet valve of funnel was closed tightly and the valve of the compressed air was opened so as to mount the required pressure inside the tank and hose line. Before joining the female end of the coupling to male end the air in the hose was released and the line pressure was checked. After ascertaining the pressure, the female and male ends were connected tightly and the outlet is opened by operating the level fixed in the hose. The pressure injection was continued till the firm resistance from the surface was received. The firm resistance could be experienced when the Monopol mix rebounds from the ferrules. In some location while injecting, the Monopol mix oozes out from other ferrules of adjacent locations. During that time, the opening of adjacent ferrules was plugged with dummies and the injecting operation continued till the firm resistance from the surface was experienced. For each operation, five litres of Monopol mix was used. After completion of one operation, the pressure tank and hose were cleaned thoroughly with water and compressed air. The cleaning operation was done to clear off line choking due to setting of Monopol. The consumption of Monopol was depending on the quantum of micro and macro cracks in the particular locations of concrete and the quantity was a maximum of 5 litres in a single ferrule point. Similar operation was carried out in all the points earmarked for Monopol injection. Totally 442 litres of Monopol was consumed. The consumption details for each column are as detailed below. After completion of Monopol injection, the concrete was allowed for setting for 24 hours. At some locations where the pulse velocity was less than 2 Km/sec and where the quantum of cement consumption was more than 20 kgs to fill up the micro voids and cracks, Non shrinking Epoxy was injected. For Epoxy injection separate holes were drilled and ferrules were fixed. Non shrinking Epoxy is a material consisting of a base resin of EMG 183 and a hardener of EH 400. The mixing ratio of base and hardener is 1: 0.5 (one part of base resin and half part of hardener) The injection procedure was same as that of Monopol injection. The setting time of the concrete was 24 hours after injection. Totally 255 kgs of Non shrinking Epoxy was consumed. The consumption details for each column are as detailed below.

Column No Consumed in litres C1 NORTH C1 SOUTH C2 NORTH C2 SOUTH C3 NORTH C3 SOUTH C4 NORTH C4 SOUTH C5 NORTH C5 SOUTH C6 NORTH C6 SOUTH

Quantity of Monopol Consumed in Kgs 60 165 110 107

Quantity of Epoxy 93 4 3 3 14 3 3 31 56 3 3 39

F) REMOVAL OF FERRULES AND SEALING OF DRILL HOLES WITH EPOXY & QUARTZ SAND MIX: After completion of grouting and injection operations, the fixed ferrules were removed by hammering. After removing the ferrules the drilling holes were sealed with Epoxy and Quartz sand mortar. REMEDIAL MEASURES FOR UNIT VII In the second week of December 98, in Unit VII. It was noticed that vibration in the bearing had increased to higher level and immediately, the vibration in the TG supporting columns were measured. It was found to be 180 microns in C4 S column when the unit load was 135 MW and frequency was 48.5 Hz. Hence the unit was shut down to attend the vibration problem. Since the problem in the TG is of the same nature as in Unit V , M/s. SERC, Chennai had conducted the UPV test for the all the 12 columns. As per their interim report it is found that the columns were having voids and micro / macro cracks. The remedial measures had to be completed with in the short shut down period of 15 days including investigation. Hence, the following remedial measures were taken. (a) Earmarking the locations for grouting and injection. (b) Drilling of holes to a depth of 200mm (c) Fixing of GI FERRULES OF 15mm dia (d) Injection of Non shrinking Epoxy where the pulse velocity is less than 3.0 Km/sec. (e) Injection of Monopal / epoxy where the pulse velocity is in between 3.0 to 3.5 Km/sec. (f) Removal of ferrules and Sealing of drill holes with epoxy & Quartz sand mix. The work was carried out in seven days under war foot operation. CONCLUSION: After the completion of total remedial measures, UPV tests were again conducted. The results showed marked improvements in the homogeneity and integrity of the concrete. The vibration in the unit V TG columns has reduced considerably. The results are tabulated in the Table 2 before and after undertaking remedial measures. The vibration in the unit VII TG columns has reduced to 57 microns after under taking remedial measures. The repairs and rehabilitation works were carried out with in the major overhaul period for unit V and within 7 days for unit VII On completion this timely task, Electricity Board of Tuticorin Thermal Power Station have contacted NLC for similar problem and as per the suggestions, the remedial works were taken in the TG columns of their plant. Recently Nuclear Power Corporation also has enquired about the vibration problems in TG columns. As proverb says "A stitch in time will save nine" , the remedial measures taken in time has saved greater loss in the Production of Power generation.