22

DECEMBER 2009
FEED BACK NO. 2

TS TIDINGS

PROJECT : PROBLEM :

NALCO, ANGUL, UNIT 9, 120 MW TURNING GEAR SLOWING DOWN

Problem details: This 120 MW unit is provided with a hydromotor to drive the turbine on turning gear. The normal speed of the machine during turning gear is 110 RPM. On 12/09/09 at 10.15 hrs it was observed that the turbine turning gear speed was suddenly going down from 110 rpm to 96 rpm, and after some fluctuations in speed , it decreased and finally came to zero ( the turbine rotation stopped physically) with rubbing noises in the LP turbine seals. Immediate checks showed no abnormal conditions i.e. lifting oil pressure, vacuum , seal steam pressures and temperatures were normal. After thirty minutes, with hand barring, it was made free, and turning gear was restored. Analysis and resolution: The trends of turbine speed with various parameters like seal steam parameters, vacuum, lifting oil and lube oil pressures were collected for studying behaviour of the speed drop. It was seen that there was no influence of any of these parameters. Further search and analysis revealed that one hour before speed reduction, LP Exhaust hood spray had opened on protection at LP Exhaust temperature of 90 C. This temperature immediately dropped to 33 C and was seen maintaining at this value because of the continuation of LP exhaust hood spray. The restoration of turning gear was done after closing this spray. The next time when unit was tripped and turbine came to turning gear, the same behavior was observed. Turbine speed started reducing from 110 rpm to 95 rpm and then started to rise after closing the exhaust hood spray manually.
TECHNICAL SERVICES / PSSR

23

DECEMBER 2009

TS TIDINGS

Further study of trends of turning gear speed with seal steam parameters, vacuum, lifting oil , lube oil, and LP Exhaust hood temperature, it was observed that speed drop was significantly affected by LP Exhaust Hood spray only i.e.Turning gear speed dropped when LP Exhaust temperature went below 40 degrees due to opening of LP Exhaust hood spray valve, and then recovered when LP Exhaust spray was cut off. This slowing down behavior was seen repeatedly (observed at least five consecutive times) during trip outs with vacuum and seal steam in service. The turning gear speed could be restored to normal by simply cutting off LP Exhaust Spray manually. Trends of turning gear showing speed reduction and restoration with LP exhaust temperature is enclosed for reference. The original logic given by BHEL, Hyderabad was checked. The auto close command is given when speed less than 1850 RPM or load more than 10% provided LP exhaust temperature is less than 90 deg C. The auto closing of LP exhaust spray valve was additionally given at site with temperature lower than 50 deg C. The auto logic with opening of LP Exhaust spray valve at 90 C and closing of the valve at 50 C of LP Exhaust temperature was ensured. CONCLUSION: No such fluctuation in turning gear speed has happened since this logic was implemented in end September 2009. LP Exhaust temperature was maintaining between 90 to 50 degrees with LP Exhaust spray opening and closing in auto mode as per the above logic. The problem is thus resolved.

TECHNICAL SERVICES / PSSR

24

DECEMBER 2009

TS TIDINGS

TECHNICAL SERVICES / PSSR