NTPC/TSTPP OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /01

AREA TG Operating Instruction For Avoiding Barring Gear REV 0.00

UNIT - 3/4/5/6 Stalling in KWU Turbines Date : 10/04/2006

A PURPOSE :-

This document is prepared to guide the operating personnel for avoiding the barring gear stalling in Stage - II Units of
TSTPS .

B SCOPE: :-

This shall be applicable to all four units of TSTPS Stage- II ( 4X500 MW Unit)s

C INTRODUCTION : -

The term barring gear means the mechanism to rotate turbine shaft when motive steam is not available. This is required to
keep the turbine in rotation at nominal speed (Different for different design of turbines)
(a) After trips to prevent top/bottom temperature difference induced thermal bending in hot conditions and
(b) To prevent sagging due to gravity in cold conditions

The KWU turbines have been provided with a medium pressure oil ( sourced from Lubricating oil system through a
motorized valve) driven Hydraulic turbine wheel located at HPT front shaft, in pedestal 1. The Barring speed is around 70-
90 rpm with out vacuum & with vacuum 100-110 RPM . The arrangement is accompanied by hand Barring arrangement
provided in Pedestal 3 (to be used in case of need). Due to high coefficient of friction ( dry friction) at lower speeds, shaft
lifting( about 0.1 mm ) is enabled by jacking oil system supply to bottom of the bearing. The Jacking oil pressures are
different at different bearings based on the lifting load .These values are set during initial commissioning & also
during each overhauling .

In steam turbines of other design i.e. LMZ, Ansaldo, ABB, GEC motor driven turning gear is provided which will continue to
rotate the turbine shaft even if there is touching of rotating and stationery parts and hence normally the problem of Barring
gear stalling does not take place, even though abnormal noise may be there however is extreme case motor will trip on
overload, The torque provided by Hydraulic Turning gear is such that in case of any fouling of rotating and stationery parts(
seal fins etc.) the turbine will come to standstill gradually and damage to sealing components is prevented.

Since commissioning the Stage - II units have faced the barring gear stalling problem in almost all units at some
point or other .

This guideline looks into the various aspects affecting barring gear stalling & the means to prevent them

Major reasons for Barring Gear stalling

In case of Hydraulic Barring Gear, Turbine not coming on Barring Gear or stalling is not a problem but a symptom that
turbine unfit for rolling . This could be because of any one of the above reason or any other .
Abnormal gland steam containing condensate
Abnormal Mechanical clearances, casing / glands
Wet steam/water entry into Casing
Air chilling of glands
Loss of jacking oil Lift pressure/Hose puncture/groove on journal.
Loss of CW and emptying of water box in spring deck-some units.
Speed slow down on CW pump stoppage.
Other Malfunctions

Sheet 1 Of 6
Prepared By Reviewed By Approved By
 NTPC/TSTPP OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /01
AREA TG Operating Instruction For Avoiding Barring Gear REV 0.00
UNIT - 3/4/5/6 Stalling in KWU Turbines Date : 10/04/2006

D TECHNICAL DATA OF THE SYSTEM

D RESPONSIBILITY :

SCE / Unit controller / TG desk Engr /Operation Support Group

E TO PREVENT BARRING GEAR STALLING

The following points are to be looked into when a unit trips out or a planned shutdown is taken .

Barring gear speed slow down is observed along with reduction in Lubricating oil temperature.
Due to excessive cooling due to sticking of valve under extreme position and fault appears in 3 oil temperature control valve.
3 WAY CONTROL VALVE: 0 % and 100 % position range to be changed to 2 and 98 % to prevent extreme positions and
hence stucking up/fault. This will help maintaining the desired temperature of 45 0C lubricating oil temperature.
Ensure that CW water box remains filled with water.
In case of Barring stalling,
If Jacking oil header pressure and individual Lift pressure OK.
HPT/IPT Casing top/bottom DT normal
Hand barring with one person possible then Seal steam should be kept charged along with evacuation.
Raise aux seal steam temperature to 3000C.
This is not to be done for more than 4-5 hrs.
In 3-4 situations NTPC has seen the benefit. If no success then control cooling to be resorted to for faster cooling.

Gland steam temperature as per rated parameters i.e 300 0C and ensure no steam is condensed upstream of Seal
steam supply control valve.
Continuously trend aux. Gland steam temperature and maintain close to source temperature

Keeping continuous warm up line open MAW 11 with bypass orifice ,

Check warm up flow( through Orifice or manual drain valves) for effectiveness
Check the steam traps provided in aux PRDS are working .
Check source HT aux. Steam Hdr temp > 300 0C
After unit trips out

Sheet 2 Of 6
Prepared By Reviewed By Approved By
NTPC/TSTPP OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /01
AREA TG Operating Instruction For Avoiding Barring Gear REV 0.00
UNIT - 3/4/5/6 Stalling in KWU Turbines Date : 10/04/2006

Do not keep Gland seal steam charged for more than 1 to 2 hours
Do not empty condenser water box till HPT temp < 290 deg C is achieved .Keep At least one CW pump running till
then(due to effect on disturbance in turbine seal fin clearances)
Air Chilling of Glands

Post Trip vacuum killing sequence of Operation:

Stop Vacuum pump.
Kill Vacuum by opening Vacuum breaker.
Isolate Gland seal steam at Vacuum of 0.2-0.3 Kg/cm2 or Back pressure of 0.7-0.8 kg/cm2
Stop Gland steam Exhauster immediately after isolation of gland seal steam.

In sufficient Lift of Rotor Journals

Check that no pocket is formed near jacking oil recess inside the bearing
Lift Pedestal covers and see if any abnormality or leakage is there in hose, joints, pressure gauge etc.
Check J.O.Hose of proper length, routing and flexible clamping with adjacent oil piping in each pedestal
Check and set required bearing lift by adjusting jacking oil pressure with one jacking oil pump and Maintain protocol
for jacking oil header pressure, bearing lift and jacking oil pressure at each bearing.
Checking of J.O.Pipe clamps/ supports from MOT room to Bearing Pedestal for tightness/adequacy by actual
shaking of piping.(To prevent pipe failure due to shaking. vibration during start up shut down)
Jacking oil hose replacement to be done whenever bearing is removed for inspection.

Hose failure:
Jacking oil hoses pressure rating and quality to be ensure
Trend monitoring of Jacking oil back pressure (provided inside in bearing No.1,2,3,4) at all brgs.,
J.O. Flushing of the system to be done during overhauls( whenever bearings are opened)(To prevent scoring marks
in journal and bearing which leads to leakage of lifting pressure)
Retrieve Jacking oil header pressure to ensure than Safety and pressure regulating valve is not getting disturbed.
After unit synchronization clean J.O. filter
Make arrangement for locking/covering of J.O. pressure setting valve for Brg.,5,6,7( if applicable)
Check J.O. NRVs(provided inside the pedestal (brg.1,2,3,4) ( to prevent sticking/passing)
Improper Seal Fin Clearances
LPT gland clearance: Ensure at least 0.9 mm radial clearance all around the front and Rear glands by inserting long
feeler( 500 mm long)
Check that Gland box is not skewed and keys are properly set.
Improper Seal Fin clearances
Disturbance in casing position/centering due to pipe push/pull in Turbine area MS,CRH, HRH, Cross around piping
Hangers and supports.
Walk down survey and Healthiness
Checking in Hot ( Pre-shut down),Cold ( Shut down)and setting and final checking in subsequent hot(after shut
down) condition.
Record and trend coasting down time during each unit tripping
After each unit tripping, when turbine on Barring gear , Check whether any abnormal sound is coming near Glands
and bearings or any abnormal vibration
Entry of steam into Turbine during HPBP operation

Check CRH NRVs for proper seat contact area (If passing it is likely to decelerate the turbine when on Barring).

Sheet 3 Of 6
Prepared By Reviewed By Approved By
NTPC/TSTPP OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /01
AREA TG Operating Instruction For Avoiding Barring Gear REV 0.00
UNIT - 3/4/5/6 Stalling in KWU Turbines Date : 10/04/2006

Motive Power
Visually check the condition of Barring Gear Oil supply isolation valve.
Ensure that pipe for Manual Barring is always available at fixed location near the Barring gear.
Check condition of Barring gear nozzle and wheel blades.
Miscellaneous
Covering of Turbine floor Oil piping trench with Grilled plate.
01. Covering of oil piping in Pedestal approach area with removable grilled plate platform (wherever not provided)

Sheet 4 Of 6
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 NTPC/TSTPP OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /01
AREA TG Operating Instruction For Avoiding Barring Gear REV 0.00
UNIT - 3/4/5/6 Stalling in KWU Turbines Date : 10/04/2006

Check list for Condenser Vacuum Killing

Condenser Vacuum is to be killed under the following conditions.
Unit is shut down for more than 8 hrs or if it is not possible to maintain supply seal steam temperature
more than 260 0 C / Barring gear stalled otherwise as decided .
Checked
Sl.No Check List Activity
Status
Boiler Box Up by Close Boiler Stop v/vs with IBV & Manually tighten Them
1. closing MS stop Isolate Power Supply
valves . Open all drains to UFT
Open HP / LP BP till complete depressurization of MS / HRH line .
Depressurization of Close HP /LP Bypass
2.
MS Line MS/CRH/HRH Keep open the atmospheric drains , drain to UFT .
Isolate HPBP spray manual valve at 8.5 Mtr .
MS line depressurized .
TD A /B aux. steam at APRDS floor isolated ..
Kill cond vacuum through SGC Shutdown programme .
Close Vacuum p/p suction v/v
Condenser Vacuum
Stop vacuum p/p. / Stop recirculation pump.
3. Killing
Open Vacuum Breaker.
At Vacuum 0.2ksc isolate gland seal steam to turbine at 8.5 mtr / at
APRDS Floor .
Stop seal steam exhauster.
Switch off SLC Vac Pump
Monitor barring gear speed reduction after vac killed . It should be
4. Barring gear speed
around 70 rpm .
Monitor Hot Well / Normal level is to be maintained. 470 mm
5.
Daerator Level Monitor D/A level it should not Over flow to Hot well . (level 570 mm)
Condenser CW Let both CW passes be in charged condition. Till HPC temp < 290 0 C.
6.
passes Both pass should be charged & Both CW pump should run .
Observe drop in turbine barring speed) i,e see that speed remains
around 70 to 80 rpm. If speed drops below 70 rpm inform TMD
7. Turbine speed immediately.
When speed stabilizes, note down jacking oil pressures at inlet to all 7
bearings along with TMD .
Isolate Valve Gland Sealing system . Keep MAL 81 , MAW 11 open .
8. Others
SLC Drain should be ON

Sheet 5 Of 6
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 NTPC/TSTPP OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /01
AREA TG Operating Instruction For Avoiding Barring Gear REV 0.00
UNIT - 3/4/5/6 Stalling in KWU Turbines Date : 10/04/2006

ACTION PLAN FOR AVOIDING STALLING OF BARRING GEAR.

UNIT 3/4/5/6 DATE :-

Sl no Action Plan Responsibility

1. MAW11 drain to LPFT with orifice line should remain always open SCE/DGM(O)

2. Monitoring of JOP pressure /Filter status when the machine is on barring gear . SCE/DGM(O)

3. Operation of AOP /JOP/Barring Gear valve at respective speeds SCE/DGM(O)

4. Maintain Lub oil temp at 45 0 C SCE/DGM(O)

5. Monitoring of JOP pressure at each bearing & correlating with past data DGM(TMD)

Maintain HT Hdr temp > 300 0 C by keeping MS line partially charged & all Steam
6. traps in service .
SCE/DGM(O)

7. Maintain seal steam supply temp > 280 0 C SCE/DGM(O)

8. Killing Vacuum as per procedure if not required after isolation of MS system . SCE/DGM(O)

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