Barring Gear Jamming Leading to IP Turbine Overhauling (500 MW BHEL KWU Design)

- N.K.Satnami, E.E (M), TAMS

ABSTRACT:

DVC, BTPS has 1 x 500 MW BHEL KWU design & 1X 210 MW LMZ design turbines. 1X210 MW unit is
operational since 1988 and 1 X 500 MW unit operational since Feb’17. On 23rd Oct’18, 1 X500 MW unit
of BTPS was taken out of bar due to BTL. During Coasting down of the turbine, all parameters were
healthy and after killing vacuum the turbine was running at 82 RPM on barring gear and JOP pressure
140 ksc post 10 Hrs of unit trip until at around 10:15 Hrs when the barring speed started decreasing and
finally the TG set came to stand still at 14:30 Hrs. The machine never stalled out of barring since COD of
unit and the problem was first of its kind for the newly commissioned machine.

Machine was rotated on hand barring every half an hour for few turns until at around 16:30 Hrs when it
could not be rotated any further and machine was totally jammed. It was suspected to have caused due
to gland segment of shaft and casing clearances interference and was decided to wait until HP shaft
temperature to come down below 370 deg in order to have seal clearances, but still after HP shaft temp.
falling below 370 up to 100 deg. Machine could not be rotated on hand barring gear.
It was decided to check the lift of all shaft journals at respective positions from bearing 1-7, JOP pressure
was adjusted to 160 ksc and shaft lift was recorded, all lift positions were found disturbed and Lift of
shaft at Brg.#2 was observed to be around 0.03 mm, after final adjustment of all shaft journal Lift, it was
tried for hand barring but still the machine could not be rotated. The matter was taken up to BHEL, the
OEM and its site engineer visited site for carrying out troubleshooting work.
HP turbine shaft sealing gland clearances reading were taken using feeler gauge, top side no feeler was
going in and the bottom 0.8 mm feeler was going in with ease. Accordingly shim adjustment done on
front load packer of HP casing in left and right by adding 0.3 mm shims. After correction, machine was
tried to be rotated on hand barring still shaft was jammed. It was tried to rotate the machine by moving
the casing up & down and left & right by shifting with hydraulic jack by 0.1 mm after removing radial and
axial keys of HP Casing, still jamming persisted.
After lot of deliberation at project and corporate level, it was decided to go for bearing inspection (1-7),
Roll Check of HP, IP & LP Turbine. After awarding the contract on urgency basis, bearing inspection was
carried out and bump check of HPT & IPT+LPT done. Bump check of IPT was done by shifting casing, the
recorded values deviated hugely from the erection values;
Design Value Observed value
+ ve - ve + ve - ve
2.3 mm 1.8 mm 0.1 mm 1.3 mm

Subsequently It was decided to dismantle IP turbine for internal inspection for suspected damage due to
poor bump value of IP Turbine. Contract was to be awarded on urgent basis for the overhaul of IP
Turbine, LP Turbine & Generator-Exciter.
This paper gives the details of jobs carried out for attending the problem of Turbine barring gear stalling.
Observations

On opening IPT turbine inner casing top halve, lots of foreign materials were found to be tangled in the
inter stages. Upon inspection it was found that the foreign materials were broken pieces of strainer
elements.

.
MS and HRH strainer inspection was done. Upon dismantling the HRH strainer element (LHS)
leading to IPCV# 1 was found severely damaged, Total one third portion of element was found
missing and the same material was passed into the IP Turbine and got dislodged into various inter
stages of IP Turbine causing barring gear to stall. Subsequently the other strainers of HP & IP
turbine were also opened and inspected. These strainers were found intact. New strainer element
for HRH (LHS) was installed.
Damaged caused to IPT Casing & Rotor inter stage sealing strips
Other Observations :

 Bearing #1: Top oil clearance was on higher side of 0.46mm as against design value of
0.3 +0.061 mm, Bearing assembly replaced.
 Bearing # 2: Geometry of One JOP pocket was deformed, Scrapping done to form a new
pocket and one pocket was totally rubbed, new pocket made.
Brg# 1 Top.
BRG.#2 Bottom JOP Pocket prior to pocket scrapping

As per drawing, the depression of 0.5

mm across 90 mm width was found
rubbed off in both pockets of Brg#2
Bottom.

This was the probable cause for low lift of shaft journal at Brg.#2. It was recommended to
replace the bearing assembly. Due to unavailability of the same, pocket was cut out by
scrapping Babbitt surface giving due diligence to Top oil clearances.
Brg# 2 Bottom after pocket scrapping

After completion of overhauling works, TG set was brought to barring gear on 23/12/2018
and the unit was synchronized on 01/01/2019.

Conclusion:
 Due to overhauling, few other troubles were found viz. Bearing # 1&2, Leakage found in one
CC bolt upon leakage test performance.
 The unplanned overhauling was a stressful period for the entire Turbine maintenance team
due to unavailability of major spares as the unit was under operational since COD and all
the spares procurement were in pipeline. However due to support from other field projects
of DVC, the situation was contained.
 All the departments like workshop, Operation and other maintenance groups have
supported immensely in the successful execution of the job. Thanks to Senior officials of
BTPS management and DVC headquarters for unprecedented support and for keeping
confidence on the Turbine maintenance department.

---- Thank you ----