FUNCTIONS

EXTERNAL SERVICES
EXTERNAL SERVICES
AND
FIELD SUPPORT SERVICES
FIELD SUPPORT ERECTION AND RLA AND
SERVICES COMMISSIONING R&M

RESIDUAL LIFE ASSESSMENT AND R&M

FUNCTIONAL RESPONSIBILITIES

FIELD SUPPORT SERVICES

• LIFE ASSESSMENT STUDY AND SUBMISSION
OF REPORTS
• POST WARRANTY CUSTOMER COMPLAINTS
• FAILURE ANALYSIS
• OVERHAULS
• PRE OUTAGE SURVEY OF UNITS
• TROUBLE SHOOTING
• PRESENTATION ON REFURBISHMENT AND
• REPAIRS LIFE ASSESSMENT OF OLD PLANTS

• ERECTION AND COMMISSIONING SUPPORT • SUBMISSION OF R&M PROPOSALS

SERVICE SECTORS
PRODUCT RANGE
• FERTIZERS
• INDUSTRIAL STEAM TURBINES
• PETROCHEMICALS
• GENERATORS • REFINERIES

• COMPRESSORS • STEEL
• CEMENT
• HEAT EXCHANGERS
• SUGAR
• PUMPS • PAPER

• GAS TURBINES • BIOMASS

• CAPTIVE POWER PLANTS
• AUXILARIES
• COMBINED CYCLE PLANTS
• OVERSEAS PROJECTS

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 CASE STUDY
PROJECT ACTION TAKEN
1. SAIL ROURKELA (C P P) - 60 MW TG
2. DESU RAJGHAT - 67.5 MW TG • The problem was discussed with NTPC and
DESU engineers
PROBLEM
• Root cause was identified as lifting of casing at the
Bearing high vibrations causing load limitation exhaust hood
OBSERVATIONS • Bottom casing was dismantled, cutting the
• Machines developed high vibrations in due course condenser connecting piece
of operations • Turbine vertical flange was de-fastened and
• Rear bearing vibrations shoot up on loading the exhaust hood separated
machine beyond 40 mw
• Turbine casing exhaust hood getting lifted. • Exhaust hood bottom and sole plates were ground
and matched
• Casing deformed
• Normal overhauls could not resolve the problem

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 • Exhaust hood anchoring key was modified

• All seal fins were replaced

• Condenser was re-floated

• Turbine and condenser were re assembled and

connected by providing spool piece.
• Turbine parting planes matched

• Seal bores corrected

STATUS

• Machine was put back in to service and loaded to

full capacity

• All the vibration levels are normal

• Problem has been resolved

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 Bharat Heavy Electricals Limited
Ramachandrapuram
Hyderabad
INDIA

TEST REQUISITION

EVALUATION OF TEST RESULTS FOR ! VISUAL EXAMINATION

! DYE PENETRANT
RESIDUAL LIFE ASSESSMENT (RLA) ! ULTRASONIC TESTS
! BOROSCOPIC
! BOROSONIC

FIRMING-UP SCOPE FOR

! BORE - MPI
! EDDY CURRENT
LIFE EXTENSION, REPAIR-RUN OR ! DIMENSIONAL
! HARDNESS
REPLACEMENT ! METALLOGRAPHIC

INPUTS REQUIRED FROM

ENGINEERING INPUTS
OPERATION PLATFORM
• BASIC DESIGN PARAMETERS
• PERFORMANCE REPORTS

• OPERATION AND MAINTENANCE PRACTICES • STARTUP AND SHUTDOWN CURVES

• FAILURE HISTORY
• STRESS ANALYSIS DATA ON CRITICAL COMPONENTS
• OPERATIONAL HOURS
• MATERIAL CERTIFICATES
• STARTUPS & SHUTDOWNS

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 SMALL COMPONENTS WHICH ARE RETIRED
OR RE-USED, BASED ON
H.P. ROTORS
DIMENSIONAL INSPECTION
Oper. Temp. >480 ° C )
! Turbine rotors ( Oper.
• SEALING FINS • Cyclic thermal stresses
• LABRYNTHS • Centrifugal stresses
• Creep
• FASTENERS
! Low cycle fatigue cracking.
• COUPLING BOLTS ! Bend / Bow - Deciding factor for repair-
repair-run
• OIL GUARDS or replacement.
• BEARINGS ! Remanent life of rotor by Manson&Halfords
10% rule.
• GEARS

L.P. ROTORS
MOVING BLADES
! Creep influence on LP rotors is negligible.
! Common defects on shrunk fits :
" Deformation ! Life of the moving blades is unpredictable.
" Cracking through keyways
! Condition assessment is by DP, MPI and
" Permanant elongation & relaxation shrunk
Frequency tests.
fit
" Corrosion cracking
! Bend / Bow

GUIDE BLADES CASINGS

! Common defects :
! Common defects
" Parting plane deformation
# Mechanical hits
# Rubbing " Bore deformations
# Solid particle erosion " Stress corrosion cracking
# Corrosion fatigue . "Creep damages in case of high
! Performance deterioration temperature regimes.

! Recommendations - Repair-
Repair-run / Replace. ! Recommendations - Repair / Replace

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 AUXILIARIES AUXILIARIES

! CONDENSER !EJECTOR
# Nozzle erosion
# Tube leakage # Tube leakage / puncture
# Scaling
!HEATERS
# Erosion / Corrosion on baffles tube # Too many flange joints in feed water
plate and other internals. system.
# Frequent tube failures from coil type tubes.
# Poor performance of level control system
Eddy Current Tests for tubes Eddy current test for tubes.

CASE STUDY - I CASE STUDY - I

CRACKING IN MOVING WHEEL DISC KEY WAY CRACKING IN MOVING WHEEL DISC KEY WAY
OF A 60 MW LP ROTOR. OF A 60 MW LP ROTOR.

Tests Conducted and Inferences :

$ The shrunk-fit discs of the LP rotor were subjected
to wet fluorescent magnetic particle test as well as
ultrasonic examination.
$ A special ultrasonic examination using manually
articulated arms was conducted from the hub face
for detection of radial & axial sections at the disc
bore/key way.
$ Ultrasonic examination was also conducted on disc
shoulder using 45° shear wave probe (MW45N2 of
M/s Kraut Krammer-make).
$ The examination showed defect (crack) emanating
from the key way of second stage disc - 2 A.
FIG. 1 ULTRASONIC TEST INDICATIONS FROM DISC KEY

CASE STUDY - I CASE STUDY - II

CRACKING IN MOVING WHEEL DISC KEY WAY THERMAL FATIGUE CRACKS ON A 110 MW HP
OF A 60 MW LP ROTOR. ROTOR.
$ The presence of defect was confirmed by alternative
scanning with other frequencies and techniques. Tests conducted and inferences :
$ A double echo indication, one from the defect and the $ The HP rotor was subjected to visual, magnetic
other from key way, was noticed in the clock-wise particle and ultrasonic examination.
scanning. The anti-clock wise scanning showed only
single echo indication with relatively higher amplitude.
$ Visual examination revealed a circumferential crack
$ In view of the seriousness of the above defect, it was
further examined at BHEL works. near the Curtis wheel.
$ Fracture mechanics analysis showed that the crack $ Wet fluorescent magnetic particle test revealed that the
was near to the critical size.
above crack was continuous and present all around.
Corrective action :
% The disc was retired and a new disc was put
into service.

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 CASE STUDY - II CASE STUDY - II
THERMAL FATIGUE CRACKS ON A 110 MW HP THERMAL FATIGUE CRACKS ON A 110 MW HP
ROTOR. ROTOR.

$ Crack depth measurements with crack depth

R26 25
meter of M/s Kraut Krammer-make showed that

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the crack near Curtis wheel had a depth range of
12
R5 R 2.5
55 18 to 20mm.

$ The cracks in the heat relief grooves showed a

depth of 7.5 mm in the first groove, which
gradually fell to 3 mm in the sixth groove. These
defects were also circumferential but
CIRCUMFERENTIAL CRACK NEAR CURTIS WHEEL discontinuous except in the first one.

CASE STUDY - II CASE STUDY - II

THERMAL FATIGUE CRACKS ON A 110 MW HP THERMAL FATIGUE CRACKS ON A 110 MW HP
ROTOR. ROTOR.
OBSERVATIONS :
$ Transient temperature distribution
$ Borosonic test - No other significant defects.
$ Cyclic Thermal Stresses
$ Stress concentration in Fillets & heat relieving
$ Microstructure Examination - Inter-granular cracks. grooves.
$ Cracking due to low cyclic fatigue.
$ Crack can grow to critical size resulting in
catastrophic failure over the period of operation.

CASE STUDY - II CASE STUDY - II

THERMAL FATIGUE CRACKS ON A 110 MW HP THERMAL FATIGUE CRACKS ON A 110 MW HP
ROTOR. ROTOR.

CORRECTIVE ACTION
$ The rotor was machined and cracks were R26 25
12
12

removed. R5 R 2.5
55

$ Curtis wheel fillet grooves, sealing fin grooves

and heat relief grooves were modified.
$ The rotor was returned to service and is
running for the last 12 years. CIRCUMFERENTIAL CRACK NEAR CURTIS WHEEL

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 CASE STUDY - III CASE STUDY - III
LIFE EXTENSION OF 110 MW TG SET BASED ON LIFE EXTENSION OF 110 MW TG SET BASED ON
RESIDUAL LIFE ASSESSMENT RESIDUAL LIFE ASSESSMENT
$ LE Based on overall performance of $ General Performance after 20 years :
& Maximum Load - 90 MW (Derated)
equipment, auxiliaries, systems and sub & PLF - 55 %
systems. & Overall heat rate - 3050 KCal / KWHr
$ Typical life history & Turbine heat rate - 2440 KCal / KWHr
& Rated parameters :
Load - 110 MW $ Salient points from residual life assessment
MS pressure - 130 ata tests :
MS temperature - 530 ° C
Condenser vacuum - 0.9 kg/cm2 & HP rotor cracks in fillet & heat relieving grooves.
Overall heat rate - 2537 KCal/ KWHr & HP blades - mechanical hits and erosion.
Turbine heat rate - 2153 KCal/ KWHr & C1 & C2 shrouds damaged - mechanical rubbing
& Commissioned - Early 70s & Sealing fins uprooted.
& Operational Hrs - More than 2 Lakhs & Coupling bolt holes enlarged due to repeated
reaming.

CASE STUDY - III

LIFE EXTENSION OF 110 MW TG SET BASED ON
RESIDUAL LIFE ASSESSMENT
& IP rotor
# Bend/Bow - 0.2 mm
# Eccentricity - 150 µ.
# Repeated blade failures in 18 and 19 stages.
# Coupling holes enlarged.

& LP rotor
# Erosion and corrosion in blades.
# Repeated blade failure in 3 & 3A stages.
# Stress corrosion cracking in shrunk fit Corrosion & Erosion of Moving Blades
moving wheels.

Shearing off of Blades due to stress corrosion

Pitting on Blades

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 Shearing off of Blades due to stress corrosion

CASE STUDY - III

LIFE EXTENSION OF 110 MW TG SET BASED ON
RESIDUAL LIFE ASSESSMENT
& HP nozzles thinned, deformed and damaged.
& Guide wheels - severe mechanical damages
# Dents
# Deformation
# Thinning of blade profile.

& Casing is also affected by creep damage to the extent of level 2.

& IP casing carriers deformation caused severe rubbing in
17,18 & 19 stages. Labyrinths damaged.
& LP casing developed severe cracks in the middle part and calls
for metal stitching and repair.

Blade profile thinning

Blade profile thinning

Fatigue Cracks on the casing

Stress Cracks on the Casing

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 CASE STUDY - III CASE STUDY - III
LIFE EXTENSION OF 110 MW TG SET BASED ON LIFE EXTENSION OF 110 MW TG SET BASED ON
RESIDUAL LIFE ASSESSMENT RESIDUAL LIFE ASSESSMENT

& Oil leakage through servo cylinders. LIFE EXTENSION PROPOSALS :

& HP heaters - Non functional

$ OBJECTIVES :
& Uprating to 120 MW
& LP heaters I & II - Out of service
& Life extension by 20 years
& Inadequate vacuum (-0.8 Kg/cm2)due to poor & PLF - 80 %
performance of ejectors, condenser and vacuum & Heat rate improvement - 20%
system.

HP TURBINE
CASE STUDY - III
LIFE EXTENSION OF 110 MW TG SET BASED ON
RESIDUAL LIFE ASSESSMENT
LIFE EXTENSION PROPOSALS :

$ PROPOSALS
& Keeping outer casings as it is, replace the liners,
diaphragms and rotors with a new inner casing and
rotors with reaction blading for HP, IP and LP
cylinders.

IP TURBINE LP TURBINE

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 CASE STUDY - III FEATURES OF CARTRIDGE DESIGN
LIFE EXTENSION OF 110 MW TG SET BASED ON
RESIDUAL LIFE ASSESSMENT
LIFE EXTENSION PROPOSALS :
The Boiler Feed Pump Cartridge is a
completely shop assembled Pump except
$ PROPOSALS FOR AUXILIARIES the barrel (casing).
& State of art U-tube HP heaters in place of Coil This does not involve extensive assembly
type HP heaters . and skilled centering at site
& LP heater I&II are removed.
& SS tubes for Condenser and Ejector.
& New piping for Vacuum system.
& Repair of LP casing by metal stitching.
& Cartridge design BFPs with better efficiency in Total replacement of the cartridge can be
place of 200KHI BFPs. completed in a maximum of two shifts.

BFP BARREL & CARTRIDGE

Bharat Heavy Electricals Limited
Hyderabad

RETORFTTING OF HYDRAULIC GOVERNOR

67.5 MW TG DESU RAJGHAT

ELECRO HYRALIC GOVERNING SYSTEM HYDRODYNAMIC GOVERNING SYSTEM

• PICK UP
• EH CONVERTOR ' Governing console
• WOOD WARD GOVERNOR ' Servomotor/ control valve actuator
' Yoke assembly
' Control valves
' Trip solenoid valve
' Governor impeller
' Mechanical tripping device
' Overspeed governor

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 HYDRODYNAMIC GOVERNING SYSTEM HYDRODYNAMIC GOVERNING SYSTEM

' GOVERNING CONSOLE SSD

• Speeder gear CONTROL
GOVERNOR AMPLIFIER SERVOMOTOR
• SR IV governor VALVES

• Oil filter
• Accumulator SPEED SENSOR

• Overspeed tester
• Automatic low load limiting device
• Axial shift protection
• Pressure gauges
• Starting device

SR- IV GOVERNOR FACTORS FOR SLOW RESPONSE AND HUNTING

' Many mechanical linkages

STARTING DEVICE
SPEEDER
SPRING ' Wear and tear of components
ACCUMULATOR
' Slow response
' Components are obsolete
ORIFICE
' Difficult for fault finding
INNER BELLOW ' Longer duration for maintenance
OUTER BELLOW

PRIMARY OIL

• ELECTRONIC GOVERNORS • ELECTRONIC GOVERNORS

' Development of digital technology

' Faster data processing system ' WOODWARD GOVERNOR
' Compact design and Low cost - Speed control
- Load control
' Compatible for variable operations
' Control functions are through
' EHTC- EDN BANGALORE
servo coil actuators
- Speed
' Self diagnostic / fault detection
- Load
' Easy maintenance - Temperature
- Pressure
- Stress evaluator etc.

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 WOODWARD GOVERNOR
ELECTRONIC GOVERNORS

SPEED SETTING ' Low maintenance cost

CONTROL
' Less down time of machine
GOVERNOR I/H CONVERTOR SERVOMOTOR VALVES
' Simple for modification from existing
system
SPEED PICKUP ' Existing system can be kept as standby.
' Programmable controls for load through
off conditions
' Programmable for Auto, Semi auto and
Manual startup for cold, hot and warm
conditions.

To existing starting/Trip oil

To emergency stop valve

To existing secondary oil

To HP Control valve actuator

To existing secondary oil

To IP Control valve actuator

To existing secondary oil

To LP Control valve actuator

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THANK YOU

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