RE-COMMISSIONING STEAM TURBINE GOVERNING SYSTEMS: PROBLEMS FACED AFTER OVERHAUL. PROJECTS: 1. 2. 3.

NTPC, RAMAGUNDAM STPP, UNIT - 6, 500 MW NTPC, SIMHADRI TPP, UNIT - 1, 500 MW TNEB, TUTICORIN TPS, UNIT - 4, 210 MW

1. RAMAGUNDAM UNIT 6: (i) IPSV-1 was tripping while opening with starting device from UCB and (ii) Turbine was reaching over speed value with speeder gear. Both these problems were observed during regular operation before planned overhaul. (i) To overcome IPSV-1 tripping, which was suspected to be due to fluid leakage within its test valve, customer has replaced the liner of the test valve for IPSV-1. During re-commissioning of the system, the same IPSV servomotor was again tripping while opening from starting device. While observing the local pressures of above and below piston during SV opening, the pressure above piston was reducing to 5 ksc, and the valve was tripping at almost in full open condition. The rate of opening was also found to be faster than other valves. When the IPSV operation was done locally, slowly, by limiting the test valve stroke, the servomotor opened smoothly and did not trip. This indicated that the tripping occurred due to draining of large quantity of trip fluid, during opening. By limiting the stroke of test valve, the draining was controlled and the pressure above piston was kept at more than 6 ksc, while opening of the servomotor.

To limit the stroke permanently, the test valve cover was opened for introducing washer / ring (Refer Figure 1) inside the test valve. The test valve drawing was referred, and it was found that the adjustment ring was missing. A ring of 9 mm thickness was introduced. Thereafter, the operation of all stop valves, with starting device, from control room, was found to be normal.

Figure 1

(ii)

To over come the problem of over-speeding with speeder gear, the speeder gear stroke length was reduced to 24 mm from 30 mm by shifting the stopper nut, during overhaul of the governing rack components. For checking the speed regulation with Hydraulic

governing, the machine was changed over to speeder gear. When Hydraulic governing had taken over from Electro Hydraulic Governing ( EHG ) at 3000 RPM, the speeder gear position was reduced from 24 mm to around 8 mm. As with this position the speed could go to more than 3200 RPM, the adjustment with adjusting screw (Refer Figure 2) for speeder gear was made, but only 3 mm could be adjusted and further provision was not available in the adjusting screw. With this limited adjustment, speed was raised with speeder gear up to 3210 RPM. The speeder gear position was around 16 mm at this speed. Hence to achieve speed regulation of 3210 RPM, speeder gear limiter is to be advanced by further 5 mm.

Adjusting screw

Figure 2

2. SIMHADRI UNIT 1: (i)IP secondary oil pressure not responding to EHC voltage (ii) EHG hunting during rolling The above mentioned problems were encountered during calibration of governing system after servicing of all control elements in the governing system by BHEL/Hardwar technicians during overhauling of unit by SAS. (i) EHC vs IP secondary fluid pressures were not responding. The IP secondary fluid pressure is developed as per the required characteristics, With EHC coil voltage at zero, IP sec. pressure is 2 ksc and With EHC coil voltage at 1.7, IP sec pressure is 6 ksc On observation, it was found that the spring of one of the follow up pistons was found to have displaced and defective. The follow up piston was replaced and this problem was resolved. EHC voltage vs IP sec pressures characteristics were taken and found to be alright. (ii) EHC hunting problem during rolling: While rolling the machine, hunting was observed. The following observations were made during the analysis of EHC hunting problem. i) ii) iii) iv) Hydraulic controller is found to be alright. EHC is hunting (hunting observed from 25% to 35% of command) other than this range, there is no EHC hunting. Individually EHC & Hydraulic is alright. (Checked by closing both isolation valves on secondary fluid headers). When the entire system (HP and IP secondary fluid circuits) is in service, more draining of fluid is taking place, and hunting is observed especially when the IP secondary fluid circuits are taken into service.

v)

IP secondary fluid system was checked but no abnormality was observed. vi) At EHC positions between 25% and 35% range, while opening extraction NRVs, trip fluid pressure was varying, which was causing secondary fluid pressure fluctuations. vii) All extraction NRVs openings were adjusted / staggered to open one by one, to avoid variation in trip fluid pressure. But still minor variations were observed both in trip fluid pressure and Secondary fluid pressure. viii) The trip oil line to extraction relays was inspected for its orifice size. The 5 mm dia orifice in trip fluid line to extraction relay (installed during initial commissioning based on BHEL / Hardwar instructions) was not in position. The desired orifice was introduced and characteristics were retaken. The unit was rolled and synchronized. No further hunting was observed in EHC. 3. (i) (ii) TUTICORIN TPS, UNIT 4: EHC not responding with respect to the feed voltage Balance voltage indicates maximum instead of -1.0 0.2 volts.

To analyze, EHC behavior was checked by simulated inputs during shut down. By that it was found that pilot piston was disturbed from its equilibrium position. Inconsistent behavior of IP follow up pistons was also noticed. It was decided to service EHC pilot (item 6 in Fig 3), and do a complete inspection of follow up piston feedback linkages etc.

Figure 3

Accordingly, when the EHC unit was dismantled along with coil, it was noticed that the bottom screw (Refer Figure 3) of pilot valve, which acts as a plug to prevent trip oil draining from the pilot, was found

loose. This probably has caused disturbance to the equilibrium position of the pilot valve. Also the pilot valve was not spinning because of dirt in the assembly and jets. The screw was tightened properly with thread sealing compound. Pilot valve and sleeves were serviced and free rotation of pilot valve was ensured. While checking the follow up piston behavior by opening the side cover of assembly, it was found that one no. IP follow-up piston control sleeve (Refer Figure 4) got dislodged from the assembly because the cylindrical link pin, with its 2 nos. of locking split pins, were missing and could not be located. Spare cylindrical pin and split pins were assembled and EHC characteristics were corrected. The behavior of EHC was now found satisfactory. Further, Hydraulic governing HP / IP control valve characteristics were also checked and minor deviations from design value were readjusted. Turbine was rolled on 26-09-06 and behavior of EHC was found to be normal.

Figure 4

CONCLUSION: The above problems faced in the governing system in three different power stations indicate that a thorough checking of governing system components during every overhaul is essential. Customers are being advised to ascertain the healthiness of the governing system during shut down and overhaul. Unhealthy deviations are to be identified and the critical components that are to be serviced, or replaced, can be decided during the study.