Sub:-GTG-2, Atomizing Air Compressor Failure Report.

1-On 15th November,2010, loss of generation occurred on failure of AVR system

due to heavy lighting and thunder at Al Ghail and EDG could not be started on time to cater power to auxiliaries, there was a complete BLACK OUT at Plant, where as the unit was on FSNL for about 10 mnts. EDG could not start or EDG did not start, please clarify.Was any fault on EDG? In how much time EDG should be able to deliver power in case of failure of Generation? You need to make comparison that whether such amount of time is enough for survival of AAC So,AAC failed (at 3000 hrs) on high atomizing temp, due to stopnonavailability of cooling water Circulation in atomizing air cooler. 2-To avoid such incidents as failure of AAC in case of black out (failure of AAC in blackout), BHEL-EDN has modified the logic for both the units,i.e tripping of Unit at Atomizing air temp-HIGH, which has been successfully demonstrated with GTG-1 in March, 2011. What were correspondence with BHEL between failure of compressor and modification of logic 3-On 22nd August, 2011, we installed a new AAC in GTG-2, and loaded the modified Mark-VI logic to demonstrate fuel changeover from PC what is PC here? and tripping of units at high atomizing air temp. but unfortunately the same could not be demonstrated, because AAC failed as soon as Unit-2 reached FSNL. 4- Failed AAC, sent to Atlascopco work shop on 24/8/2011for inspection and failure analysis on .The failure was found due to less this is less lubrication or no lubrication , please clarify lubrication to bearings. So, Atlas Copco deputed his field engineer on 18/10/2011 for site inspection. The service engineer of Atlas copco found wrong tubing of lube oil supply to AAC of both the units, and they suggested for rearrangement of tubing of both the units as per OEM. 5- The feedback of Atlascopco was intimated to Mr.KB.Raja & Mr.S.C.Garg of M/S.BHEL on 31/10/2011 for review of Lube oil piping connections as suggested by Atlas Copco. Can you enclose copy of this correspondence. 6-After review, Mr. Raja approved the Lube oil piping with diagram and surprised to see the wrong connection in both the units, but could not conclude , where the error

has occurred. It was cleared cleared or demonstrated or assured or just clarified ? what was done by AGP please clarify by AGP that the tubing is originally from BHEL, because, AGP has not done any modification at site as AAC is an integral part of GTG. Also, AGP argued if, this is the case, then how AAC of GTG-1 has been in Operation since the date of commissioning without any trouble. Did any one verified the tubing connection in GTG-1 7-The tubing was changed as per the recommendation of BHEL & Atlascopco. Refurbished AAC from Atlascopco installed on 12/12/2011 in the presence of Atlascopco Service Engineer and the unit kept on FSNL for 10 mnts, without any Trouble. 8-On 20/12/2011, GTG-2 taken in service due to failure of GTG-1, VCMI-Mark-VI Card, but unfortunately again AAC failed at 2MW Load. 9-Atlascopco Service Engineer visited site on 21 & 22/12/2011,for investigation of Failure. After dismantling AAC, we observed Lube oil pressure to AAC at cranking speed & FSNL are 1.0 Bar & 0.70 bar respectively, where as the recommended lube oil pressure as per OEM is 1.5 bar at AAC inlet. 10-The same intimated to Mr. Raja, BHEL and asked for his feedback to check the test bed reading of lube oil pressure at AAC inlet, as this parameter is not available with us to cross check. 11- After review Mr. Raja confirmed the lube oil pressure to AAC should be 1.5 bar Where is in our case we dont achieve this pressure at GTG-2, AAC inlet. So, Mr.Raja suggested AGP for checking of internal lube oil supply piping of AAC through accessory gear box.