NTPC-SAIL POWER

NTPC-SAIL CO.CO.LTD.
POWER PVT. LTD
2X250MW BHILAI
2X250MW BHILAI EXPANSION
EXPANSION PROJECT

TOPIC: 250MW GENENERATOR FAILURE& RESTORATION

Presented by
Nagamalleswararao
Emp.No.100047
Presented by
P N M RAO
250MW GENENERATOR FAILURE& RESTORATION
 250MW BHEL Make Turbo Generator
 Event: Unit-1 tripped on Generator differential
Protection on 18.11.2018, 9:12 Hr.
 Experiences
 Visual Images at different stages
 Restoration process
 MILESTONE ACTIVITIES
 Total outage-80 days
 Mobilization – with in 5days
 Dismantling- with in 4days
 Removal of physically damaged bars- 2days
 Removal of top bars- with in 8days
 Removal of bottom bars- with in 2days
 Core cleaning & stator readiness- with in 5days
 Connecting bus bars readiness- 3days
 Bottom bars laying- with in 9days
 Top bars laying- with in 7days
 Nose joints brazing & insulation- with in 13days
 Assembly, Oil flushing & ATT- with in 8days
 ROTOR TREAD OUT
Soot deposits Molten copper particles

Dismantling under progress Fault location 4 O-clock

 INITIAL INSPECTION

Soot deposition on Stator Soot deposition on Rotor

 INSPECTION

16 Top

15 Top

14 Top

13 Top

12 Top

Soot deposition before Soot after cleaning

 INSPECTION

Winding after cleaning Damaged terminal bushings

 OBSERVATIONS ON JOINTS

Over heated nose joints on TE Other Over heated nose joints on TE

 CLEANING OBSERVATION Status as on 24th day

Soot deposition inaccessible area Soot deposition back side of winding

REWINDING
REWINDING
REWINDING
REWINDING-BOTTOM BARS

Started on 35th day & Completed on 43rd day

REWINDING-TOP BARS

Started on 45th day

REWINDING-TOP BARS

Completed on day-51
 HV AC TESTING

Connecting bus bars tested @25KV AC for 1min.

Bottom bars tested in groups @24KV AC for 1min
Top bars & bottom bars tested in groups @23KV AC for 1min
Each phase complete winding including bushings tested@21.5KV AC for 1min
PRE HEATING & CURING

Pre-heating , Glue application & Curing day-52 &53

 BRAZING & QUALITY

Started on 54th day & Completed on 63rd day

 BRAZING

Normal joints Busbar joints

 INSULATION & WEDGING

Started on 62nd day & Completed on 66th day

 CURING

Bus bar joints

Normal joints

U-loop joints

Pre-heating , Glue application & Curing day-67 &68

CURING
VMS & SPACERS FIXING

Installation of VMS & NFT day-70&71

 ROTOR THREAD-IN AND ASSEMBLY
New spare rotor Exciter assembly

Terminal Bushings with adopters

Terminal Bushings

Rotor thread in day-72 & Barring gear day-79

 IPBD CT REPLACEMENT
IPBD Joint for removal of CTs

IPBD CTs

IPBD CT
 ROTOR REPAIR AT HARIDWAR
Rotor Rewinding
Rotor Test bed

CC bolt centre chek

Slip-Ring arrangement Gas leakage test

 EXPENSES
• Total No.of Service POs-8
• Total No.of Material POs-11
• Total No.of User POs- 8
• Services-14.11 Crores
• Material-10.12 Crores
• Miscellaneous-18.64 Lakh