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14

MAY

2009

TS TIDINGS

FEED BACK NO.1


Project : Vijayawada stage IV, 1 x 500 MW Problem : Generator seal oil system Emergency DPR (Differential pressure regulator) valve was not operating and not responding while adjusting the pressure setting spring. Generator seal oil system is provided with emergency source from turbine lub oil system to supply seal oil during non availability of both AC and DC seal oil pumps. The oil tap off is taken from Turbine AOP/MOP discharge header at TG floor elevation in the oil canal and it is connected to seal oil discharge header before seal oil cooler. An isolation valve and DPR is provided in the line. The DPR valve was located near seal oil supply unit at 0 meter elevation. During setting of the Emergency Differential Pressure Regulating valve without running any Seal oil pump, the DP was not rising from 0 kg/cm 2. Adjustment was done with adjusting springs and no variation in DP was observed in any of the spring position. Also, no oil flow to seals was observed as the DP regulating valve is in closed position and did not open at all. The Emergency DPR valve is of the diaphragm type whereas the main DPR valve in seal oil system is of metallic bellow type. The DP impulse lines to emergency DPR valve were vented and checked for through ness and vented near DPR valve while running seal oil pumps and again emergency DPR valve was not working. After thorough investigation/study it was suspected that the problem may be due to very high head is acting on the diaphragm because of additional height of 19.5 meters (Signal from generator seals to DPR location at 0 meter) on both seal oil pressure as well as H2 pressure signal lines. This would have caused bellow to stick in one side and found no variation in DP or no pressure is developing after DPR.

15

MAY

2009

TS TIDINGS

HEAD CORRECTION TO SIGNAL PRESSURE. 1, Seal oil DP at seal 2, Head from Generator shaft 19.5 meter Oil pressure at E DPR with out H 2 pressure 1.5 kg/cm 2. 1.9 kg/cm2. 3.4 kg/cm2.

Oil side pressure with 3.5 kg/cm 2 of H 2 pressure 6.9 kg/cm 2.

These types of Differential pressure regulation valves are working in KWU 200/210 MW Generators where two DPRs are in parallel and H2 pressure is 2 kg/cm2 and also head is 1 kg/cm2. The pressure at bellow is 3 kg/cm2 in maximum condition. In 500 MW unit, due to high head the oil pressure of 3.4 kg/cm 2 to 6.9 kg/cm2 range (minimum without H2 and Max with H2 pressure of 3.5 kg/cm 2) the diaphragm stick to one side. These operating pressures are suspected to be beyond spring adjustment range as there was no response with full range of adjustment. The normal DPR in seal oil unit is of different type with metallic bellow and no problem was noticed. Similar problem was observed at Sipat site and Bellary site also. The emergency DPR was kept isolated. The high static head in the DPR impulse line can be nullified by relocating the DPR in the oil canal. It was decided to relocate the emergency DPR and check the behaviour and the modification was carried out at Vijayawada site. The emergency DPR was located at elevation of SOST in the oil canal as the oil tapping was from MOP/AOP discharge at oil canal. The behaviour of DPR was found satisfactory. The DP variation with adjustment of spring was also found normal.

16

MAY

2009

TS TIDINGS

Adjustment of emergency DPR: AOP suction pressure was 7.5 kg/cm 2 before E DPR and 9.0 kg/cm2 before seal oil cooler. AC Seal oil pump was switched off. Differential pressure was adjusted to 1 kg/cm 2 with emergency DPR. Generator air pressure was raised in steps of 1 kg/cm2 and found that the seal pressures are also raising accordingly. Readings during observation are giving below:
Generator Air pressure kg/cm2 0 1 2 3 3.5 3.5 3.5 Air pressure removed 0 kg/cm2 Pump Pressure Differential in before Pressure service cooler EE 2 kg/cm kg/cm2 AOP 3.7 0.95 AOP 4.7 0.95 AOP 5.9 0.96 AOP 7.4 0.90 AOP 8.0 0.90 AC 9.0 1.60 SOP-1 AC 9 1.7 SOP-2 AC 5 2.0 sop-2 AOP 4 1.10 Differential Pressure TE kg/cm2 0.98 0.98 1.03 1.0 0.94 1.70 1.75 2.0 Seal oil Pressure At seal EE 0.95 1.95 2.80 3.83 4.2 5.0 5.0 2.0 Seal oil pressure At seal TE 0.98 1.98 2.80 3.90 4.30 5.10 5.0 2.0

1.15

1.10

1.15

The H 2 side impulse was originally taken from the H2 chamber of seals. In case of failure/puncture of the diaphragm, the seal oil below the diaphragm can go to inside the generator through the H2 impulse line. To avoid this, the H2 side impulse tap of is taken from the H2 side drain line below generator after prechamber with one meter siphon as shown in the enclosed sketch.

17

MAY

2009

TS TIDINGS

Prechamber

Emergency DPR located at SOST elevation

From AOP/MOP Discharge

SOST

H2 signal from TE prechamber drain line Seal oil pressure impulse from valve rack To SOT

To seal oil cooler