STEAG ENERGY SERVICES (INDIA) PVT. LTD.

2 x 600 MW STPP – (UNIT#1 TURBINE & TURBINE AUXILLIARIES AOH)

HISTORY OF MACHINE

S.No Details Date/Year

1 Machine First Synchronized 13 March 2016
2 COD 25 Sept 2016
3 Total Running Hours 13191.55 Hrs
4 Overhauling Work Started 04 June 2018
5 Machine Put On Barring Gear 16 July 2018
6 Machine Synchronized After Aoh 17 July 2018

Turbine Maintenance 1
 UNIT # I AOH OF TURBINE, GENERATOR AND TG AUXILLIARIES
(10.06.18 TO 14.07.18)
MAJOR WORK CARRIED OUT DURING AOH OF UNIT NO 1

1. Turbine general overhaul

2. Lp turbine overhaul
3. Mpi & nft of free standing blades
4. Generator overhaul
5. Bearin no 3 & hydrogen seal ring replacement
6. Lp turbine left and right side last stage blades replacement.
7. HP-IP(1 no), IP-LP(3nos), LP-LP(2 nos) coupling bolts cutting and replacement.
8. Modification in the drainage of lp turbine as per technical circular no x-143-a
9. Bvms and owvms installation.
10.Catenarycheck after one year of operation as per bhel circular no x-85
11.Bearing no 04 lifting problem resolved.
12.Emergency governor striker boltproblem resolved.
13. Condenser Tube & PHE Chemical Cleaning
14.Replacement of damaged internals of ACW & DMCW Pumps
15. Position corection of CDV – 39 valve (earlier, was not as per scheme)

MAJOR EVENTS

S.NO DESCRIPTION DATE

01 Unit shutdown 04/06/18
02 Turning gear stopped 10/06/18
03 Generator rotor treadout 17/06/18
04 Modification work of drain holes in LPT 1 & LPT 2 casing 26/06/18&22/06/18
bottom half completed
05 Catenary value measured at all pedestal and locking of 16/06/18
springs
06 Generotor thread in 26/06/18
07 Catenary correction done by m/s gerb after reasling of 05/07/18
springs.
08 Pedastal box up and oil flushing started 14/07/18
09 Machine put on turning gear 16/07/18
10 Rolling and syncronisation 17/07/18

Turbine Maintenance 2
 ACTIVITIES CARRIED OUT DURING OVERHAUL

I. TURBINE-GENERATOR
A LP TURBINE
Observations –

 All the three casing of LP 1 &2 Turbine (outer, inner- outer, inner-inner) were opened.
 Silica deposition found on the LPT1&2 blades.
 LPT atmospheric relief diaphragm checked and found ok.
 Last stage blades and rotor grooves of both LP rotors MPI & NFT done and two nos blades
found cracked at root of blade( one blade each of left and right side of LPT 1).
 All palm packers, axial and radial keys of HP and IP Turbine checked and found OK.
 LP turbine bottom casing drain modification.
 LP steam path radial clearance found less in few stages at both turbine and generator end.
 NFT values not coming as per requriment between new blades and rotor groove of LPT 1
(Left side).
Action Taken :-
 LP rotor was lifted from position. Sand blasting of Rotor and LP inner inner & inner outer
top half casing carried out.
 MPI (Magnetic Particle Inspection) test of freestanding LPT1& 2 Rotor blades (8th stage on
either side)was carried and crack / abnormalities were reported in LPT 1 stage 3L blade no
34 & stage3R blade no 30.
 NFT of LPT 1 stage 3R 14 nos blades blue matching done with rotor groove to achieve the
requried NFT values.
 LP Inner inner casing ovality checked and found O.K.
 LP Gland box segments checked and found in good condition. All Extraction, CAP (Cross
Around Pipe) and LP Rotor Bellows were checked and found O.K.
 BVMS installed for LP last stage blades.
 LPT flow path checked and stage blade shrouds were ground off to improve the radial
clearances and LP Roll check carried out.
 LPT atmospheric relief diaphragm replaced.
 IP Turbine centering done, Roll, Bump check and Horn drop test carried out.
 HP Turbine centering done, Roll, Bump check and Horn drop test carried out

Silica deposit on LP Turbine Blades

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 LP Blades Crack at root.

Blue matching of rotor blades Flow Path Reading –LP Turbine

B TURBINE PEDESTALS (1-5) & TURBINE BEARINGS (1-8)
Observations :-
 LP shaft not lifting at brg no 04.
 Oil leakage through oil catcher at pedestal no 03 front & 05rear.
 All oil catcher bottom clearnce on higher side.
 Scoring mark observed in brg no 04 & rotor journal.
 Brg no 03 bottom and torous having heavy pitting marks.
 Coupling bolts of LP-LP (2 nos) , IP-LP(3nos) seized.
 Coupling Nut of HP- IP coupling 1 nos jammed .
 Emergency Governor Striker Bolts found in chocked condition
Action Taken :-
 Scrapping & polishing done for Bearing No - 4.
 Oil guard Fins of Pedestal 1-5 & generator outer & inner oil catcher (both end) , excitor
pedestal oil catcher replaced and clearances maintained as per requirement.
 Bearing no 3 replaced with spherical support and spherical piece.
 Bearing No -2.Axial key polishing done. Blue Matching of axial key area carried out.
 Scrapping & polishing done for Bearing No – 5
 DPT and Ultrasonic test of all Bearings carried out and found satisfactory.
 Side and Top oil clearances checked and found satisfactory.
 Side pad & yoke keys clearances set for all Bearings.
 Bearing no 2 Jacking oil Hose replaced.
 Coupling bolts of LP-LP (2 nos) , IP-LP(3nos) & HP- IP (1 no) cutting done and remove
with the drilling tool. All coupling bolts and cap nuts replaced with new bolts (machining
done as per requirement) & cap nuts.

Turbine Maintenance 4
  Honing of all coupling holes of HP-IP (16 nos) & IP-LP (3 nos) , LP-LP (2 nos) done for
maintaining the clearances.
 Emergency Governor Striker Bolt opened and servicing done
 Yoke Keys blue matching done and clearances maintained as per requirement.
 MOP Wear rings & Bearing clearances checked and found within limit. DPT of Impeller
carried out and found satisfactory. Bevel gear coupling checked and found O.K.

Bearings Dp Test Bearing No 03 bottom – Bearing No 03 torous –

pitting marks pitting marks

Overspeed striker bolt UT testing of Brgs Oil Catcher fins replaced

found chocked.
C GENERATOR AND EXCITER

OBSERVATION:
 Foreign material found inside genearator.
 Hydrogen seal ring (turbine side) clearance with rotor found more then design value.
 OWVMS installation work completed.
 Compressor centering reading was recorded however punch values not available in
corresponding segments.
 Minor pitting observed on coupling face of generator and excitor.
 Oil catcher clearance of bearing no 6 and 7 & 8 found on higher side
 Generator rotor CC bolts leak test done.

Turbine Maintenance 5
 ACTION TAKEN :

 Generator Rotor Threading out done. Rotor compressor blades checked for looseness and
found intact.
 DPT of blades and retaining ring carried out and found satisfactory.
 DPT and Ultrasonic test of seal ring(TE &EE) , retaining ring and bearings carried out and
found ok.
 DPT of compressor fixed blades carried out and found ok.
 Hydrogen seal ring (TE side) clearance with rotor was found on higher side and replaced
with new seal ring (machining done as per requirement)
 Blue matching of bearings and saddle carried out.
 Hydrogen coolers cleaning done and hydro test carried out and found satisfactory.
 Primary water system hydro test carried out and found satisfactory.
 Exciter coolers cleaning done and hydro test carried out and found satisfactory.
 Generator Rotor CC bolts leak test carried out with nitrogen pressure 6kg/cm2 and no
leakageobserved.
 Scrapping and Polishing of Bearing No-6,7,8 done. Blue matching of the Bearing with
Pedestal carried out.
 Air leak test of Generator carried out after boxing up and found satisfactory.

Primary water inlet strainer Generator rotor thread out Compressor three stage
moving blades.
D TURBINE SPRING DECK
OBSERVATION:

 Inspection of Spring units of TG deck carried out.

 Catenary value found less than the design value towarsds pedestal 1 and higher than the
design value towards excitor bearing. (details in attached protocols)
 Measurement of spring heights , Coloumn top –TG Deck bottom heights were recorded
before and after adjustment.
ACTION TAKEN:
 All 46 Nos spring units found in healthy condition.
 Re-Adjustment of Spring Units at Column No. A4 to A-7 and B-4 to B-7 carried out to bring
catenary measurement to near design value and completed.

Turbine Maintenance 6
E SYSTEM RESTORATION
OBSERVATION:
 For oil flushing all throttle replaced with the line filter with dummy flanges.
 Jop Header pressure and individual bearing pressure setting.
 Lube oil header pressure obsereved on higher side.
 Foreign material found in bearing no 07 throttle & line filter.
 Bearing no 03 indiviual oil pressure found on higher side.
 Bearing no 06 & 07 having more oil flow and Bearing No. 04 having less oil flow.
 Oil leakge obsereved through Bearing no 03 front oil catcher.
ACTION TAKEN:
 For oil flushing cloth bag also put in both basket strainers.
 Individual lift of rotor(as per design) at each bearing acheieved with adjustment of flow and
header pressure.
 Lube Oil Header Pressure reduced for flushing and after flushing adjusted according to
requirement of system.
 Bearing No 03 oil pressure adjustement carried out as per requirement.
 Machine Put on Barring after acieving the required oil specification.

II. TURBINE AUXILIARIES

A Condenser Water-box Inspection& Tube Cleaning
Condenser water box manholes were opened after draining of condenser. Prior to cleaning visual
inspection of the CW water boxes & condenser tubes were carried out. Dummies on CW Inlet &
CW outlet were provided to facilitate Chemical cleaning. Chemical cleaning of Condenser Tubes
was carried out with Sulphamic acid ( 3% concentration). Subsequently, system was neutralised &
flushed. Dummies were removed & and soft scales were found on the tubes. Jet cleaning of the
tubes was planned to carry out after chemical cleaning as per procedures.
Dummy was provided in condenser inlet & outlet line before starting of chemical cleaning

Turbine Maintenance 7
B TURBINE MOT tank Inspection & Cleaning
Firstly, Dirty oil tank cleaning done. Oil from main oil tank was transferred to dirty oil tank and
the manholes were opened. Main oil tank was cleaned and final cleaning was done with flour. After
cleaning carefully inspection of all the pumps suction & pipelines flanged found AC lube oil
pump-B discharge flange gasket damaged & pump-A bearing housing loose & removed condition.
After rectification of gasket & bearing housing final inspection with SSCl & Steag Operation team
,box-up done Hence oil was restored back to MOT through oil purifying device and purifier kept in
service .

C PLATE HEAT EXCHANGER

TGDMC-A,B & C plate heat exchangers of cooling system were dismantled, found dirt and scaling
layers on the plates. PHE plates cleaning done by water washing after chemical leaning & damaged plates
and gaskets were replaced after proper inspection. 45 new plates were added in PHE-A place of damaged
plats & so overall heat coefficient is increased. Finally hydro-test conducted before box up by charging of
PHEs.

Turbine Maintenance 8
D Hotwell Inspection
Hotwell A & B manholes were opened for hotwell inspection. After getting confined space work
clearance from safety department, inspection was done.Mud & slight traces of resin found on the
hotwell surface and then the surface was cleaned. Outlet strainers of hotwell (suction strainers of
CEP) were cleaned. Expansion joints were inspected and then the hotwell was boxed up.

E Deaerator Inspection
Deaerator manholes were opened for internal inspection after ensuring proper isolation & draining.
Internal inspection was carried out, slight layers of resin found inside & RC line end dummy plates
wars fund damaged condition so dummy welding done. Rest of all internals were found in good
condition. Inspection of major welding joints & found some gaps in protection plate so welding
done. Cleaning of resin done & flange bolts tightened done after inspection of deaerator by
operation & chemist dept boxed up done with replacing of new gasket.

F Turbine Driven Booster Pump-A

After complete isolation of the TDBFBP-A, D.E & N.D.E bearing top cover of the pump were removed.
The DE & NDE bearings inspection were done and found that bearings were in good condition. The
bearing cooling line & cooling coil were inspected. After properly inspecting all the parts, the pump was
and coupled. Trial was taken & found ok.
TDBFP (MAIN AND BOOSTER PUMPS)
TDBFBP-B was completely isolated, then D.E & N.D.E bearing top cover of the pump were
removed. The D.E & N.D.E bearings inspection was done, during inspection found that bearing sitting

Turbine Maintenance 9
 area of shaft damaged. Damaged shaft, bearings were replaced with new one. Coupling was checked and
found normal. The bearing cooling line & cooling coil were inspected and acid flushing done. After
properly inspecting all the parts, the pump was assembled and coupled.
TDBFP-A
TDBFP-A D.E & N.D.E bearing top covers of turbine were removed. Both side journal bearing,
thrust bearing inspected & DP test was done and found that bearings were in good condition.
Coupling was checked and found normal. After properly inspecting all the parts, bearings were
boxed up. Oil tank of cleaned after tranferring oil to main oil tank and restored after proper
inspection.
TDBFP-B
TDBFP-B was completely isolated, then D.E & N.D.E bearing top covers of turbine were removed.
Both side journal bearing, thrust bearing inspected & DP test was done and found that bearings
were in good condition. Coupling was checked and found ok. After properly inspecting all the
parts, bearings were boxed up. Oil tank is cleaned after tranferring oil to main oil tank and restored
after proper inspection.
Whole catridge of pump is replaced by Gangotri Turbo Tech.(external agency), alignment done and
coupled with turbine.
Final alignment readings of pump to turbine are mentioned below

ACW Pumps System

CT basin and forebay draining done for both CW pumps AOH work. During visual inspection
pump bell mouth checked and found normal. Energy efficient ceremic coating was done on bell
mouth of both the pumps. DP test carried out for the impeller and no defects observed.

Turbine Maintenance 10
 OCCW Pumps A & B
During overhaul, both occw pumps were dismantled for inspection. The condition of bearings was
found ok , DPT was done on the impeller & no cracks were found. Suction mov of pump-A
replaced. Both pumps discharge nrv seals replaced. Energy efficient ceramic coating was also done
inside the housing of both pumps as shown in figure below.
Self cleaning strainer cleaning & inspection
Strainer tank was drained and top cover was removed for inspection of strainers and tank.The
inside of stainer cleaned with buffing wheel. All the six strainers were in choked condition, they were
dismantled and properly cleaned. Gear box oil & gland packing replacement was done. After cleaning and
proper inspection, strainers were boxed up
OLTC SCREEN CHECKING
Manholes were opened for inspection of OLTC screens on both the cooling water return lines from
condenser. Screens were inspected and maintenance was carried for free movement of the screens.
Glands were replaced for the links holding the screen.OLTC-B screen actuator was replaced by
C&I.

SGDMCW PUMPS
For overhauling, both pumps were dismanled. pump-A & B DE & NDE side bearings were
replaced. Mechanical seals of both the de & nde sides were replaced for both the pumps. DP test
was done on the impellers & no cracks were found. Impeller of both the pumps were in good
condition. Assembly of both pumps done after proper inspection.

Turbine Maintenance 11
 Generator H2 Cooler Cleaning

For cleaning of generator H2 cooler, all coolers were isolated from tube side. Top and bottom
covers of all the coolers were removed. All the tubes were cleaned with the help of brush attached
to rod end. All the coolers were boxed up after proper cleaning and inspection completed.

Stator Water Cooling System

Both stator water pumps inspection done, bearings and mechanical seal were replaced. Felt seal
was replaced with indigenous oil seal prepared at site with the support of Workshop personnel.
Stator water tank inspection & cleaning done.Two coolers of the stator water cooling system were
isolated from tube side and shell side, later both the inspection doors were opened. Tubes were
cleand with the help of a brush attached to the rod end. Coolers hydro was carried out before boxup
done.

Turbine Maintenance 12
  Complete overhauling of LPT-1 & LPT-2.

 Turbine Bearing #1 to 8 inspection done.

 Complete overhauling of Generator Rotor threading & thread-out.

 Generator air tightness test was carried out.

 Inspection of clamping plate of stator overhang bolts.

 Main turbine Lube oil tank(MOT)system were completely drained cleaned & inspected..
 TDBFP -A & B lube oil system, HP-LP bypass oil system were completely drained cleaned &
inspected.
 Condenser chemicals & jet cleaning done & flood test was carried out and 02nos dummies plug
were made on the condenser tubes.

 Energy efficient ceramic coating done inside condenser & replacement of resilience seals of
condenser water box-A & B inlet & outlet valve.

 Condensate hot-well inspection and cleaning done.

 ECW tank inspection and cleaning done.

 Deaerator internals inspection & cleaning done, slight traces of resin and welding joint cracked
observed.

 CEP-A, B & C suction strainers cleaning, all CEP bearing lube oil flushing done.

 TDBFP-A & B bucket strainers & MDBFP bucket & conical strainer cleaning done & flange
gasket was replaced.

 Both TDBFP all bearings inspection done and found normal.

 TDBFP-B Booster pump mec.seal & oil catcher replaced.

 ACW pump A, B&C overhauling done

 OLTC pumps A & B water box-A & water box-B inspection done including its strainer.

 TGDMCW pump A, B & C overhauling done.

 SGDMCW pump A & B overhauling done.

 Replacement of resilience seals of passing butterfly valves - ACW PUMP A, B & C suction &
discharge valve, TGDMCW pump-A, B & C suction & discharge valve.

 Inspection & rectification of all TGDMC & ACW pumps discharge NRV.

Turbine Maintenance 13
  MOT coolers-A,B tubes were cleaned & water flushing was carried out.

 TDBFP-A & B cooler-A & B tubes were cleaned & water flushing was carried out.

 MDBFP working oil & lube oil cooler tubes were cleaned & water flushing was carried out.
 All valves related to above systems lapping done and wherever required replaced.

 Insitu machine lapping of 41major valves was carried out.

 Replacement of MAL-22,MAL-23,MAL-31,MAL-12 & EXV-159 due to valve set damaged.

 Replacement of DRV-51 & deaerator drain valve due to damaged of valve set & plug

 TG & SG PHE’s online acid cleaning done.

 HT PRDS all S/V modification carried out.

 MS strainer inspection & cleaning done.

CONDENSER FLOOD TEST

After cleaning of condenser tubes, condenser flood test was done. 2(two) tubes
Were plugged to arrest leakage. No other leakages was found after flood test.

Turbine Maintenance 14
Turbine Maintenance 15