FEEDBACK NO.

13

2 x 125MW GIPCL, SLPP, MANGROL A REPORT ON STEAM TURBINE INSTALLATION

INTRODUCTION During the inception of BHEL, the various manufacturing units collaborated with manufacturers from Russia, Czechoslovakia, America and England for Engineering, Production and installation of power plant equipment. Steam turbines were being manufactured at Haridwar, Bhopal and Hyderabad. The design of steam turbines manufactured at Hyderabad, Haridwar and Bhopal were with the collaboration of England, Czechoslovakia and Russia. A few years later, with advancement of technology and increasing familiarity of the product, the need to manufacture steam turbines which were efficient & user friendly was felt and with this, followed a collaboration with Germany for Engineering, manufacture, production and installation of steam turbines of Siemens design (erstwhile KWU). The first few machines were directly imported from KWU, Germany, and were installed by BHEL under the supervision of KWU Engineers. The first generation steam turbines with collaboration of KWU was called the HMN series Turbines, H- high pressure, M-medium (intermediate) pressure and N- Nether (low) pressure. As the name suggests, the HMN series Turbines constituted 3 separate modules, one each for high pressure, intermediate pressure, and low pressure. Twenty years since, BHEL has made a name for itself in the global market as one of the leading suppliers of power plant equipment, and has standardized the HMN series machines upto a rating of 500MW. Having successfully stabilized the HMN series machines, BHEL has now introduced to the Indian customer a new generation of steam turbines called the KN series turbines, K-combined High Pressure & Intermediate Pressure, and N- Low Pressure. As is the case with any new product, the first experience with the KN series machines supplied by BHEL Hyderabad to GIPCL, Mangrol and JTPCL, Bellary has not been free from problems, which have now been overcome.

The following is a dissertation on the experience of erection of BHELs first KN series machine at GIPCL, Mangrol. The K-Turbine The K-Turbine or the combined HP-IP module, as the name suggests, is a single module, which houses the HP & IP stages of the turbine. The 125MW K-Turbine has 25 HP stages and 19 IP stages, all on a single shaft 6.5M long. The module, in construction, is very similar to the IP module of the HMN series machine in that, both the inner and outer casings are split. Though on a common shaft, the HP and IP stages are separated by glands at the intermediate zone called the Intermediate Glands. In January98, the K-Turbine of Unit # 1 of GIPCL was dispatched from Hyderabad as a single module and in completely assembled condition. Weighing 115MT gross, the turbine was transported by road and 25 days later arrived at site. The module was unloaded using a 175MT EOT crane specially procured by the customer to handle the weight of the K-Turbine and the Generator Stator. The pedestals were received in advance of the Turbine. On receipt of the pedestals the usual checks such as Pedestal seal bores, Bearing bore diameters, etc. were carried out and the pedestals were grouted on 29/12/97. Stretching of foundation bolts 48hrs after grouting using Hydraulic Bolt Stretching device, meant that the module was ready for placement on the bearing pedestals. The combined HP-IP turbine rotor is simply supported on 2 bearings, one at the front and the other at the rear. While the rotor rests on the bearings, the casing (module) rests on its palms on the bearing pedestals. The N-Turbine or the LP turbine The N-turbine is similar to the 120MW HMN series LP turbine and is a double flow machine with 9 stages on either side and 3 extractions. The LP turbine was engineered at Hyderabad and manufactured at Haridwar. The first 5 stages are housed in a separate casing called the Inner Inner casing (Inner Casing-I) and have blades with integral shrouds. The Inner Inner casing is seated in an enclosure called the Inner Outer casing (Inner Casing-II). The last 4 stages are individually bolted to the Inner Outer casing and are called the Guide Blade carriers (GBCs) 1, 2, 3 & 4. The guide blade carriers of the casing are fabricated rings with blades welded to it and a common shroud for all blades of a stage. While the casing blades of the last 4 stages are shrouded, the blades in the corresponding stages of the rotor do not have shrouds. The LP turbine shaft is supported on its rear end only thus making it a cantilever beam type arrangement. Comparison between the KN series turbine and the HMN series turbines

KN Series

HMN Series

1.

2 cylinder machine

1.

3-cylinder machine

2.

3 Bearings & Bearing Pedestals

2.

4 Bearings & Bearing Pedestals

3.

Thrust bearing in Front Brg. Pedestal (Brg. No.1)

3.

Thrust bearing in HP Rear Brg. pedestal (Brg. No. 2)

4.

The rotor and casing both Expand towards Generator

4.

The HP rotor and casing expand towards Front and IP & LP rotor expands towards Generator.

5.

Main steam & Hot reheat stop and control valves are mounted on the K-turbine itself.

5.

Main steam and Hot reheat stop and control valves are Separately mounted on Aframes in the valve room.

6.

Turning gear operation is by Hydraulic Turning gear mounted in front bearing pedestal.

6.

Turning gear nozzle is located in pedestal no.3 (IP Rear) with Oil impinging on 2 rows of

impulse blades. 7. No shaft mounted MOP 2 Nos. AOP in continuous operation. 7. Shaft mounted MOP

8.

Heat rate of 2022kcal/hr. for a typical 120MW ST.

8.

Heat rate of 2150kcal/hr for a typical 120MW steam turbine

9.

No governing racks. Electronic governing

9.

A HP control rack and LP Bypass rack are used for Governing.

Special features of the KN Series Turbine system at GIPCL Mangrol The 120MW KN series steam turbine system at GIPCL Mangrol has been incorporated with certain special features, many of which have made their debut. 1. There is no mechanical over speed trip device. Speed is measured by 2 sets of 3 electronic speed probes. The oil used for lubrication and governing is different. Servo prime 46T is used for lubrication and Servoact 100 ash free oil is used for governing. Governing system is a high-pressure system operating at 160bar. Opening and closing of ESV & IV is by solenoid operated servo valves. No thrust bearing trip device. Instead axial shift is measured. Mounting of valves on the Turbine casing ensures that steam blowing of pipes can be done right upto the point of entry of steam into the turbine. Split HP outer casing. Hydraulic turning gear making use of high pressure jacking oil for providing the motive force. No measurement of differential expansion. 2 Nos. foundation bolts of HP Front bearing pedestal extending beyond pedestal parting plane & through the pedestal top cover.

2.

3. 4. 5. 6.

7. 8. 9. 10.

With the above features, cycle time of turbine erection can be reduced considerably. However factors beyond the control of site have contributed to the delay in commissioning the units. The sequence of events is as enumerated below.

Chain of events

Apr97

-Receipt of Condenser from Hyderabad and LP turbine material from Haridwar -Start of Condenser erection

Dec97

-Receipt of Unit # 1 bearing pedestals. -Alignment and grouting of base plates and bearing pedestals.

Jan98

-Start of LP turbine erection -Receipt of Unit # 1 K-Turbine

Mar98

-Receipt of Unit # 2 bearing pedestals -Alignment and grouting of Unit # 2 base plates and bearing pedestals

Apr98 Jun98 Aug98 Oct98

-Receipt of Unit # 2 K-Turbine -Box up of Unit # 1 LP turbine carried out in the presence of Haridwar representatives -Box up of Unit # 2 LP turbine carried out in the presence of Haridwar representatives -Discussion between Hyderabad(designer) and Haridwar(manufacturer) drawing values of LP casing axial clearances and float -Site advised to grind GBC IV of LP turbine to increase the float -Rectification of LP casing float of Unit # 1 carried out regarding lesser than

Dec98

-Barring gear of Unit # 1

Feb99

-Axial rubbing at JINDAL of LP rotor with inner guide cone of diffuser and front oil guard of LP rear bearing pedestal (ped 3) -Instructions to machine front and rear inner guide cones so as to get a clearance of minimum 40mm and 12mm between rotor and the cone at front and rear respectively. Also it was advised to machine front portion of LP rear bearing pedestal by 10mm and fix a brass pin in the pedestal at a distance of 36mm from the rotor. Modification completed. -Steam Blowing of Unit # 1 completed -Unit # 1 Turbine rolled but could not be synchronized due to problem in boiler parameters -High shaft vibrations measured during coasting down of the machine

Mar99

Apr99

-Site was advised by Hyderabad to carry out inspection of bearings and roll check if possible -During inspection of Bearing No.2 it was revealed that radius R3000 was not machined in these bearings in both Unit # 1 & 2. However, R3000 was machined in Bearing No.3 of same size. -Hyderabad experts visited site and it was decided to send back the Bearing No.2 of both units to Hyderabad works for rectification -It was decided to use Bearing No.3 of Unit # 2 as Bearing No.2 of Unit # 1. Bearing No.3 of Unit # 2 shifted to Unit # 1

May99

-All rotors of Unit # 1 de-coupled, re-aligned, centered and coupled -Unit # 1 turbine put back on Barring gear and ready for re-rolling & synchronization

Jun99

-All arrangements for re-rolling of Unit # 1 made but site was advised to stall rolling program in light of the damage to the K-turbine of Unit # 1 -Site advised to carry out roll check and axial float of K-turbine of Unit # 1

-Roll check and axial float of Unit # 1 K-turbine performed and found the values to be much lower than pre-rolling/erection values -Site advised by Hyderabad to open up Unit # 1 K-turbine for inspection by Siemens expert Mr. Elfert Jul99 -Unit # 1 K-turbine opened and found damage in Balancing Piston gland area and intermediate gland area of both rotor and casing. Also a run out of 0.15mm measured at the intermediate gland area indicative of rotor bend -Site advised by Hyderabad to send back K-turbines of both Unit # 1 & 2 -Dismantling of Unit # 2 started. -Unit # 1 & 2 K-turbines dispatched to Hyderabad works in knocked condition. -Siemens expert advised opening of LP turbine of Unit # 1 to inspect for damage as a consequence of damage to K-turbine -LP turbine of Unit # 1 dismantled and found rubbing marks in GBCs and damage to rotor fins in stages 6, 7, 8 & 9 Aug99 -Rectification/modification of Unit # 2 K-turbine completed at works and dispatched to site. Material starts arriving. -Haridwar representatives arrive for rectifying LP turbine of Unit # 1. Rectification begins and is underway Sept99 -LP Turbine rectification of Unit # 1 completed. -Assembly of Unit # 2 K-turbine begins in the presence of Hyderabad QA engineer -Siemens erection expert Mr.Kaluza Micheal arrives on 24th and demands alignment probes and Dummy shaft for Box-up of Unit # 2 K-turbine -Dummy shaft arrives from Hyderabad

Oct99

-Unit # 2 K-turbine boxed up. -Alignment of Unit # 2 rotor system completed. -Machine put on Barring gear on 18th -Steam Blowing completed.

Nov99

-Unit # 2 machine rolled and synchronized with the grid on 6th -Unit # 2 machine tripped to attend to passing of MS & HRH control valves -High velocity of Exciter bearing housing vibration recorded at 17mm/s -Team from Hyderabad arrives to attend to MS & HRH control valve passing problem. -Unit # 2 machine re-rolled after attending the valves and synchronized. Machine loaded upto 106MW. -High shaft vibrations recorded in HP rear and LP rear. Shaft vibration at LP rear Journal recorded as 140m at 106MW load -Unit # 2 machine stopped for inspection of Bearing No. 2 & 3 by Hyderabad QA representative. -Unit # 1 K-Turbine parts arrive. -Unit # 1 K-turbine boxed up. -Unit # 1 rotor system aligned. -Unit # 1 machine put on barring gear on 27th

Dec99

-Unit # 2 bearings inspected and machine rolled -Vibrations of LP shaft increased and a creeping tendency was noticed

-It was decided to attend to Exciter bearing housing vibration problem and watch the behaviour of LP Shaft -Stepped pins for locating Exciter rotor with respect to Generator rotor changed to straight pins and Exciter re-aligned -Unit # 2 rolled again and found that Exciter bearing housing vibration increased to 28mm/s at 3000rpm -Exciter dismantled and blue matching of sole plate with respect to base frame carried out. Exciter aligned in different method (for details, read chapter on Exciter) -Unit # 2 Machine rolled. Exciter vibrations settled to 11mm/s at 3000rpm but very high LP shaft vibrations recorded -A task force was constituted comprising of experts from PS-TS Hqr, Haridwar, Hyderabad and PSWR -Task force recommends opening of LP Turbine of Unit # 2 to inspect for damage. -LP Turbine of Unit # 2 opened and damage similar to that of Unit # 1 observed. -Task force meets in New Delhi to review the damage and suggests further stiffening of condenser dome in both units, which apparently was the prime cause of damage to LP turbines of both units -Also the task force suggested other checks, which have been dealt with separately

Jan2000

-Dome Stiffening of Unit # 1 condenser as per revised drawing carried out -The effect of dome stiffening of Unit # 1 condenser on the roll check values of LP turbine checked. -LP turbine boxed up -Unit # 1 machine rolled and synchronized on 16/01/2000. Performance of the machine found satisfactory. -LP turbine rectification and modification of Unit # 2 dome stiffeners completed. -Entire rotor system re-aligned and catenary checked.

Feb2000

-Unit # 2 put on Barring Gear on 02/02/2000 -Unit # 2 machine rolled and synchronized on 05/02/2000 -Vibration on LP rear journal found high of the order of 140m. However machine was run on full load and during this period the vibrations reduced to 120m. -Unit # 2 machine tripped due to Boiler tube leakage. The opportunity was utilized to check the LP gland clearances and LP rear bearing. LP gland clearances were found same as before, but Side Oil clearances of Brg. No.3 were found to have been disturbed. The clearances on left hand side were more than that of the right. This was corrected by changing a shim of 0.07mm from left to right. Problems faced during initial erection

During initial erection of the K-N series turbine, not many problems were faced. The K-turbine was received in assembled condition, thus reducing the cycle time of assembly, flow path clearance checks etc. However, the Nturbine had its share of problems. Following is a jist of the major problems faced during erection of the LP turbine. No. 1. Problem Faced Mismatch of 3-15mm at the joint of the two halves of LP outer casing top. Cause/Rectification This was due to different radius of curvature in the fabrication of the two halves. Could not be rectified.

2.

Low radial flow path clearances.

3.

Low axial float of 34.9mm in Unit-1. After box up of Unit-1 & 2, Hyderabad calculated the axial float in October98 and found it less.

A smooth joint made in the above condition. Rectified by filing wherever required. Unit-1 LP turbine boxed up on 04/06/98 & unit-2 on 22/08/98 in the presence of Haridwar reps. This was due to machining error of GBC IV. GBC IV dismantled and grinding done to improve the axial float of Unit-1 to 37.35mm. The axial float of Unit-2 was ok.

During operation of Unit-1 at JINDAL at about 60 MW load, the LP rotor was found to rub against the LP rear inner guide cone of diffuser and also against the front oil guard of LP rear pedestal. The reason for rubbing of LP rotor to the rear inner guide cone of diffuser was because of caving in of the LP sidewall when vacuum is pulled. After the visit of GM (PSTS & Q) New Delhi, Hyderabad and Haridwar reps to site it was decide to machine the inner guide cone of diffuser of both the TS & GS by 6mm to 8mm each. The gap between the LP rotor and inner guide cone measured at various locations is as below: Location TS GS Gap as per Drg. 6mm 34mm Actual gap 6mm 32mm Gap after rectification 11mm 42mm

Gap measured between LP rotor and Pedestal 3 front oil guard = 33 mm Expected maximum expansion of LP rotor at the rear Gap measured after machining of the oil guard = 36 mm = 43 mm

The above rectification was done before rolling of Unit-1 machine.

Rolling of Unit-1 The machine was rolled to 3000rpm at 1630 hrs of 31/03/99. The first run up of the machine was very smooth and shaft vibrations were normal at about 40-50m. Due to low Boiler parameters, the machine was tripped at 1900 hrs. During coasting down of the machine from 3000rpm,abnormal sound was heard emanating from HRH pipe indicative of hammering, which was followed by high shaft vibrations in excess of 400m at HP rear. Also, sparks were noticed at the HP Front glands. The machine was rolled again to 3000rpm at 2230hrs and the shaft vibrations at HP rear reached 240m during run up. The machine remained at 3000rpm until 0800hrs. Of 01/04/99. The machine could not be synchronized due to repeated drop in Boiler parameters and instability of the Boiler. During this period, the shaft vibrations had settled at 170m. The aftermath of rolling In the aftermath of rolling, the problem of high shaft vibrations was discussed at Hyderabad and the following checks were advised. 1. 2. 3. 4. 5. 6. 7. 8. Opening of front and rear bearing pedestals of K-turbine. Inspection of front bearing of K-turbine for any damage. Inspection of oil guard, Hydro motor connecting shaft pickup. Dismantling of front and rear see through glands of K-turbine and inspect for damage. Checking of centering of K-turbine outer casing with respect to site protocol values for any disturbance. Checking of casing guides for any disturbance. Check for free rotation of the K-rotor by manual barring with jacking oil. Check for shaft eccentricity at slow speed and compare with old recorded value.

Observations and rectification

No. 1.

2.

3.

Observation Due to a gap of 0.80mm between the bearing spherical and spherical seat, a tendency of thrust bearing to tilt was observed when the load of the rotor is removed from it. Improper contact between spherical seat and bearing spherical of the thrust bearing. In place of full contact, contact was observed only at the center and a gap of upto 0.20mm was observed at the sides. HP rear bearing (Brg. No. 2) had full contact with its cylindrical seat against line contact. (Hyderabad make)

Cause/Rectification This tendency was found to be less in the thrust bearing of Unit # 2. The thrust bearing of Unit # 2 was used in Unit # 1. This was rectified by scrapping, colour matching and lapping.

This was due to a missed machining operation. The cylindrical bearing is machined to 2 radii- one of R900mm and the other of R3000mm. Radius R3000mm was not machined in the Brg.2 of both the units. Brg.2 of both units sent to Hyderabad for machining of R3000mm radius. The desired line contact was observed in Brg.3 of both the units. Brg.3 of Unit # 2 shifted to Unit # 1 as Brg.2.

4.

LP rear bearing (Brg.3) which is similar in construction to was checked for line contact.

The oil guards, Hydro motor and see through glands of the K-turbine were inspected for damage and were found OK. With the interchange of bearings from Unit # 2, all bearings required for commissioning of Unit # 1 were made available. The entire rotor system was re-aligned and Unit # 1 was put on Barring gear on 17/05/99. After completion of C&I checks, the machine was ready for rolling on 06/06/99. However, due to the seizure of K-rotor at JINDAL, rolling of Unit # 1 machine was stalled until the cause of seizure at JINDAL was established. Also, site was advised to carry out the following checks and compare with values obtained during erection.

1. 2.

Roll check of HP casing of Unit # 1. Axial float of HP casing of Unit # 1.

The above checks were performed and it was found that these values were in drastic variation to those achieved during erection. A comparison of the values before and after rolling is given below: 1. Roll check during erection

1.05

1.05

0.90

1.02

0.97

0.96

0.90

0.90

Roll check after rolling

1.45

1.45

0.70

0.35

0.68

0.80

0.80

0.80

2.

Axial float values

Before rolling +ve float float 2.35mm ve 5.22mm float

after rolling 1.90mm 2.87mm 2.90mm 1.00mm Total

From the above values of Roll check and float, it became clear that there has been some damage to the HP casing. After various deliberations at site and at Hyderabad, it was decided to disassemble the HP casing of Unit # 1 and inspect for damages. On June 29 th, 1999, site was advised to open up the K-turbine of Unit # 1 for inspection by Siemens expert Mr. Elfert. The following observations were made on opening the K -turbine of Unit # 1: 1. A difference of 4.6mm between the horizontal and vertical bore diameters of Balancing Piston gland (BP Gland), indicating distortion of the gland. Damage to rotor and BP Gland fins due to rubbing. Shaving off of fins on rotor and inner casing top in the Intermediate gland area. Bending of Middle fins on the HP side of the K-rotor towards IP side upto stage 19, and towards HP side from stage 19 to stage 25. Rust marks in HP outer casing bottom half indicating water collection and improper draining. Run out of 0.15mm in the Intermediate gland area indicating rotor bend.

2. 3. 4.

5. 6.

The damage to the 2 turbines was studied by the designers in consultation with Siemens Expert and certain major modifications were arrived at. It was thus decided to ship back both the Units of GIPCL and JINDAL to Hyderabad to incorporate the changes suggested by Siemens. The modifications carried out in the K -turbine have been dealt with separately. Besides the suggestions to modify the K-turbine, Siemens expert also called for dismantling and inspection of N turbine of Unit # 1 to see the effect of damage to K-turbine on the N-turbine. The damage to LP turbine of Unit # 1 and the rectification thereof has been enumerated in the adjoining page. After shipping the two K-turbines to Hyderabad, the N-turbine of Unit # 1 was dismantled. The following were the observations and rectification carried out in the presence of Haridwar reps thereafter: No. 1. Observation Damage to LP rotor fins of stages 6,7,8, &9 Rectification Damaged fins removed replaced with new fins.

and

2.

3. 4.

5.

Deep rubbing marks in Inner Outer casing stages 6,7,8&9 upper half on TS towards right and stages 8&9 upper half on GS towards left, indicating a twist in the casing. No damage to rotor or casing fins of Inner Inner casing Distortion to Inner Outer casing leading to a gap of upto nearly 10mm at the parting plane between the lower and upper halves of stages6, 7,8&9. Axial misalignment of blades between the lower and upper halves of stages 6,7,8&9

Sharp edges of rubbing removed by grinding.

marks

Left as it is. Gaps at parting plane left as it is, as it was felt that this gap would not functionally affect the performance of the machine. Corrected by grinding the blade shrouds and maintaining stage-tostage axial gap as per drawing.

Post damage Modification/Rectification on K-Turbines The post damage period of the K-turbines lead to extensive discussions on the various causes that could have contributed to the damage. What stood out prominently were the inadequate radial clearances in the balance piston area. Also the arrangement of BP gland in the Inner casing was reviewed. The following is the list of modifications carried out on the K-Turbines: No. 1. 2. Arrangement Before damage The minimum radial clearance was 0.70mm Min. Radial clearance at Intermediate gland was 0.90mm Radial clearance between BP gland and Inner casing was 0.300.45mm No dowel pin arrangement at P/P of BP gland Eccentric pin arrangement was provided in bottom half alone and Arrangement after damage The minimum radial clearance increased to 1.00mm Min. radial clearance at Intermediate Gland increased to 1.20mm Clearance increased to 0.751.00mm Vertical and Horizontal dowel pins introduced Eccentric pin arrangement introduced in top half also and

3. 4. 5.

was of Pin & Bush type 6. 7. 8. Sealing fins were caulked in Outer casing Rear gland The sharp edge of the sealing fins found machined Due to stagnation of water in outer casing, rust formation was noticed Axial gap between L-Rings and check nut of the MS & HRH Valves was 0.04mm Seal steam pipes connected directly to the outer casing

modified to Pin & sliding plate like LP turbines. Sealing Fins removed Sealing fins of all stages changed A drain channel made in the outer casing leading to Ext.4 drain hole for effective draining This gap increased to 0.140.18mm Radiation shield introduced in the pipes connecting the outer casing

9. 10.

Re-erection of K-Turbine After modification at Hyderabad, all the consignments of the K-Turbine of Unit # 2 were received at site by end July1999. While the damage to the 2 K-turbines-one each at GIPCL & JINDAL had thoroughly put BHEL on the back foot, it brought together the various experienced minds to show great resolve in solving problems related to the design, manufacture and erection of the K-turbines. All the modifications in design and manufacture at Hyderabad were carried out with the advice of Siemens, Germany. It was also de cided to seek the help of Siemens expert during re-erection. On 24th September, 1999, Mr.Kaluza Micheal, Siemens erection expert arrived from Germany. On arrival, Mr. Micheal asked for a dummy shaft for alignment of HP Inner casing with Outer casing. This came as a surprise as the use of dummy shaft is not in vogue in BHEL. Alignment with dummy shaft requires measuring feelers (alignment probes), which resemble dial gauges and work on the principle of LVDT. Arrangement of Dummy Shaft The dummy shaft or false shaft as it may be called, is a round piece of steel pipe with flanges on either end. The length of the dummy shaft is governed by the length of the casings and is required to be projecting beyond the extreme ends of the casings, which are being aligned. One end of the shaft rests on the rotor-lifting device located on the front bearing pedestal and the other rests on a specially made bracket located on the rear-bearing

pedestal. Alignment probes are fixed to the dummy shaft by clamps mounted on it. The number of alignment probes that can be fixed on the dummy shaft depends on 2 factors: a) b) The provision made in the switchgear for the probes. The number of areas in which measurement is sought by the user.

The probes are lead out of the dummy shaft through a hole in the shaft, to a switchgear unit. It may be noted that only as many probes can be used as the provision in the switchgear unit. The switchgear unit that was used at GIPCL had a provision for 8 probes. The switchgear unit is in turn connected to the measuring device. More than one switchgear unit can be used if there is a provision for connecting them to the measuring device. In case only one switchgear unit is available, the user may judiciously decide on the critical areas that require measurement. The measuring device used, resembles a multimeter and has an accuracy of 0.0001mm. Why Dummy Shaft? The idea of using a dummy shaft is to center the Inner casing with respect to the Outer casing. Concentricity is the key word. It is required to maintain concentricity of the Inner casing and Outer casing so that the two casings expand in the same direction. Also, box up conditions can be simulated with a dummy shaft and the behavior of the casing studied when the Top halves of the Inner and Outer casings are installed. Installation of the top halves of the Inner and outer casings leads to an addition in weight of approx. 40MT. The addition of weight is expected to lead to changes in the top/bottom clearances during box up. This variation can be recorded on the measuring device and corrective action if any can be taken during actual box up of the machine. Alignment with Dummy Shaft and Box up The following is procedure for alignment of the Inner casing with respect to the Outer casing using a dummy shaft. 1. 2. 3. Place outer casing bottom half. Place Inner casing bottom half. Lower the dummy shaft.

4. Support the dummy shaft on the bracket provided for the purpose on HP rear bearing pedestal and on the shaftlifting device of the HP front bearing pedestal. Note: It is not required to center the dummy shaft with respect to the pedestal seal bore. The idea is to maintain concentricity of inner & outer casings and assemble the module as if there were no bearing pedestals. 5. 6. 7. 8. Fix alignment probes in desired locations. Set the alignment probes to Zero. Center the outer casing bottom half with respect to the dummy shaft. In the above condition, check centering of the Inner casing bottom half. In case of misalignment, center the inner casing on left/right by radial movement of the inner casing and top/bottom by adjusting the jackscrews. Install bottom eccentric pins.

9.

10. Place inner casing top half and heat tighten the parting plane bolts. 11. Set the desired centerline offset of the inner casing with respect to the outer casing, in the top/bottom direction, by adjusting the jackscrews. Check centering readings again.

12. Insert temporary inner casing resting packers (u-Packers), thickness of which shall be equal to the gaps at the respective locations. 13. Transfer the load of the inner casing on the temporary U-packers and remove the jackscrews. Check centering again to see if there has been any disturbance during transfer of load from jackscrews to U-packers. In case of any disturbance, the same may be adjusted in the temporary U-packers. 14. Place outer casing to half and completely heat tighten the parting plane bolts. It is expected that the placement of outer casing top half will result in some deflection to the entire assembly thereby causing disturbance to the centering in step 12. 15. Install top eccentric pins. 16. Check centering again. Any variation in the centering readings shall be corrected as below:

a) b)

center the outer casing to the values achieved in step 12. In the above condition, check centering of the inner casing. Any variation in the inner casing centering in the top/bottom direction may be noted down and correspondingly reduce or increase the thickness of Upackers during final assembly. Any variation in the left/right centering may be corrected by rotating the eccentric pins at the top and bottom.

17. After the left/right centering has been completed by rotating the eccentric pins, lock the eccentric pins in that position. Installation of the eccentric pins in this position during final box up will restore left/right centering of the casings. 18. Dismantle the outer casing top half. 19. Dismantle the inner casing top half after transferring the weight of the inner casing on to jackscrews. 20.Disconnect the alignment probes and remove dummy shaft. 21. Place rotor and check flow path clearances. 22.Fix axial position of the rotor. 23.Finalize inner casing axial locating keys. 24.Carry out roll check at this stage for determining the minimum radial clearances at the left, right and bottom. 25.Install top half of inner casing and heat tighten parting plane bolts. 26.Inner casing resting packers made to thickness recorded in step 16b shall be installed. 27.Transfer the load of the inner casing on to U-packers and remove the jackscrews. 28.Carry out roll check at this stage to determine the minimum inner casing radial clearances at left, right, top and bottom.

29.Install outer casing top half and heat tighten parting plane bolts. 30.Carry out roll check once again. This completes box up of the turbine using a dummy shaft. The method can be universally adopted for box up of IP module and LP module of HMN series machines too.

Unit # 2 commissioning Subsequent to the box up of K-turbine of Unit # 2, the entire rotor system was aligned and the machine was put on Barring gear on 18/10/99. The machine was rolled on 05/11/99 and synchronized with the grid at 0100hrs of 06/11/99. The unit tripped at 0530hrs. due to operation of Generator protection. In subsequent starts, it was found that the when the MS & HRH stop valves were opened with control valves closed, the machine would roll to a speed about 900rpm.this behavior of the machine confirmed that the control valves were passing. All the stop & control valves were closed and one set of valves were opened to check for any increase in speed. Then, the open set of valves was closed and another set of valves opened. By doing so, the passing valves were identified. A meeting of task force constituted by a team of experts from BHEL, Hyderabad, PS-TS Hq, New Delhi, and PSWR, decided upon opening the stop and control valves and servicing them. A team arrived from Hyderabad works to open and service the valves. Since the temperature of the HP-IP shaft and the valves of Unit # 2 was high, it was decided to first open up the valves of Unit # 1 and service them as a preventive measure. As the temperature of the valves dropped to less than 80C, the Unit # 2 valves were opened up and serviced. The control valves were lapped and blue contact checked after lapping. One of the control valves was machined at the cone, as there were deep scoring marks, which could not be removed by lapping. Also, machining chips, cutting slag and welding slag were found deposited on the valve seats, which were removed and cleaned. The valves were then assembled and the machine rolled once again. Based on this the designers recommended to dismantle all control valves and carry out visual inspection valves after steam blowing operation. This time around, the control valves proved to hold with the stop valves open. The Unit # 2 machine was synchronized and loaded to 106MW after 4-6 days of continuous operation at various loads. The machine was tripped due to high vibrations of the Exciter bearing pedestal of the order of 17-21mm/s. High shaft vibrations of the order of 120m were observed on LP rear journal throughout the 5 days run of the machine. However, the vibrations on seemed to stabilize at 120m at LP rear. It was decided to open up the HP rear bearing and LP rear bearing for inspection as the vibration on LP rear journal was 70m during barring gear. Run outs at HP rear journal, HP rear coupling, LP front coupling, LP rear journal, LP rear journal vibration pick up area, LP rear coupling and Generator front coupling was measured and found to be as below:
HP rear journal During erection 0.01mm HP rear coupling 0.035mm LP front coupling 0.03mm LP rear Journal 0.015mm LP rear VP area Not measured LP rear coupling 0.04mm Gen. Front coupling 0.02mm

After first run

0.01mm

0.03mm

0.02mm

0.02mm

0.07mm

0.055mm

0.03mm

The high run out at LP rear vibration pick up area was discussed with BHEL Haridwar Engg. Rep. present at site and it was decided to leave it as it is, since, it was opined that the mechanical run out itself in that area may have been high and also it wouldnt have been possible to rectify the run out at site. The intervening period saw dismantling of the Exciter assembly, checking for proper tightness of the base and sole plate, re-aligning Exciter rotor and Generator rotor, changing stepped locating pins of Exciter rotor to straight pins of higher size, and loading the Exciter bearing. The machine was rolled again and this time the vibrations of the Exciter pedestals reached 28mm/s. After quite a few modifications and change in the alignment procedure, the Exciter vibrations settled at 10-11mm/s. The modifications carried out on Exciter has been dealt with in a separate report. While the Exciter vibrations showed signs of stability, the same could not be said about the shaft vibrations on LP rear journal. Within 15minutes of reaching 3000rpm, the shaft vibrations at LP rear journal read 197m. The bearing vibrations too were close to alarm values. The last time the machine was rolled on 20/12/99, a strange phenomenon was observed. The vibrations at LP outer casing were measured and found to be 1500m. It was decided to synchronies the machine in the same condition. On synchronization, the speed of the machine reduced to 2900rpm due to low grid frequency and the vibrations at LP outer casing reduced to 150m. However, the shaft vibrations at LP rear never seemed to stabilize and soared to 197m and the machine was hand tripped. The LP shaft vibrations soared to nearly 500m during coasting down of the machine. The vibration pattern of the Unit # 2 machine as recorded is shown in the adjoining sheet. Vibration pattern of Unit # 2 Date Time (Hrs.) Load (MW) Speed (rpm) HP-IP FJB Rel Shaft Vib. (m), L/R HP-IP RJB Rel Shaft Vib. (m), L/R 05.11.99 2235 Mech. Run 2993 90/116 77/114 06.11.99 0107 15 2959 83/104 75/115 06.11.99 0645 Mech. Run 2956 68/90 62/89 21.11.99 0115 11.71 2950 84/102 83/122 21.11.99 1730 36.60 2933 78/93 71/113 22.11.99 0045 44 2979 78/90 64/103 24.11.99 1045 52 2919 77/89 77/115

LP RJB Rel Shaft Vib. (m), L/R Gen. FJB Rel Shaft Vib. (m), L/R Gen. RJB Rel Shaft Vib. (m), L/R HP-IP FJ Brg. Housing Vib. (mm/s), V/H HP-IP RJ Brg. Housing Vib. (mm/s), V/H LP RJ Brg. Housing Vib. (mm/s), V/H Gen. FJ Brg. Housing Vib. (mm/s ), V/H Gen. RJ Bearing Housing Vib. (mm/s), V/H Exciter RJ Brg.Housing Vib. (mm/s), V/H

58/54 37/64 43/38

69/61 32/62 41/44

70/62 39/60 38/41

73/68 71/62 36/44

126/123 50/76 57/76

118/113 41/71 64/79

116/111 56/67 53/79

0.9/3.4 1.9/2.3 3.3/1.9 0.7/4.8

0.8/2.8 1.4/1.3 3.9/1.9 0.8/5.4

0.7/2.2 1.9/1.8 3.8/2.1 0.4/3.8

1.2/3.2 1.6/1.7 4.0/1.7 0.7/5.8

1.3/3.3 1.9/2.1 5.5/4.6 1.1/5.1

1.6/2.7 2.0/1.4 5.0/4.25 1.5/5.8

1.6/4.3 2.2/2.7 6.1/5.5 0.9/4.3

1.2/1.5

3.2/1.9

0.8/1.4

1.9/1.8

4.8/2.2

5.5/2.5

4.4/2.3

6.3/4.9

6.6/5.1

5.5/4.2

4.2/13.7

6.3/17.3

7.4/19.0

6.0/17.2

After synchronization, the machine tripped on 06/11/99 at 0646 Hrs. on Generator protection. During coasting down, the maximum shaft vibrations recorded were 242m at 1532rpm on HP-IP RJB. The machine was rolled again and tripped at 0815 Hrs. The maximum shaft vibrations recorded during coasting down was 272m at HP-IP RJB at 1559rpm and 208m at LP RJB. The machine was stopped to attend to the problem of MS & HRH stop and control valves passing, after which the machine was rolled again on 20/11/99 at 1130 Hrs. the machine tripped on low vacuum at 1316 Hrs. The maximum shaft vibrations recorded during coasting down was 230m. At HP-IP RJB. The was rolled again and tripped at 1344 Hrs. while checking vibration protection. This time the maximum shaft vibration recorded during

coasting down was 354m at HP-IP RJB. The machine was rolled again and tripped at 1638 Hrs. due to high top/bottom differential. The maximum shaft vibration recorded during coasting down was 478m at HP-IP RJB at 1473rpm.

However, it was decided to roll the machine and synchronies and then look for any appreciable change in the behavior of the machine. The machine was synchronized at 0115 Hrs. on 21.11.99 and run continuously at various loads and to a maximum of 106 MW. A brief shutdown was taken to check the babbit material of Brg. No. 2 & 3. The behavior of the machine in subsequent runs was not conducive to operation and the unit was shutdown. The vibration pattern of the unit leading to shutdown are as below: Date Time (Hrs.) Load (MW) Speed (rpm) HP-IP FJB Reel Shaft Vib.( m ), L/R HP-IP RJB Rel Shaft Vib.( m ), L/R LP RJB Rel Shaft Vib.(m), L/R Gen. FJB Rel Shaft Vib.(m), L/R Gen. RJB Rel Shaft Vib.(m), L/R HP-IP FJ Brg. Housing Vib.( mm/s ), V/H HP-IP RJ Brg. Housing Vib.( mm/s ), V/H LP RJ Brg. Housing Vib.(mm/s), V/H Gen. FJ Brg. 24.11.99 1845 64 2906 71/86 69/109 107/107 24.11.99 1911 78 2932 68/84 67/106 109/108 24.11.99 2210 106 2902 60/79 69/109 104/109 17.12.99 0140 Mech. Run 2990 87/87 81/108 46/35 17.12.99 0213 Mech. Run 2995 113/127 103/149 76/58 17.12.99 0340 Mech. Run 2995 140/148 122/186 106/83 20.12.99 2046 Mech. Run 2990 128/132 119/153 49/48

47/58 45/61 1.4/4.4

48/58 49/64 1.5/3.9

45/44 33/40 1.6/4.1

44/70 39/44 1.4/3.2

51/85 43/40 1.8/3.5

59/86 41/45 2.3/3.9

39/80 35/32 1.5/4.4

1.7/2.8

1.7/2.6

1.9/2.9

2.2/3.4

2.5/4.0

3.4/4.6

2.8/4.8

5.9/4.9 0.9/3.6

6.4/5.2 0.8/4.3

6.2/7.1 1.1/3.5

3.0/2.2 1.6/4.8

3.9/2.7 1.5/5.4

5.3/3.9 2.0/4.3

2.8/1.9 1.7/4.9

Housing Vib.( mm/s ), V/H Gen. RJ Bearing Housing Vib.( mm/s), V/H Exciter RJ Brg.Housing Vib. ( mm/s ), V/H

4.4/2.5

4.9/2.5

3.2/2.3

2.1/2.3

2.1/2.6

1.2/3.3

1.9/2.9

6.5/18.0

6.8/17.7

7.1/19.0

4.4/11.2

5.6/13.2

4.7/12.3

4.2/12.1

The machine was tripped on 24/11/99 at 2245 Hrs. and a maximum shaft vibration of 274m was recorded on HPIP RJB at 1550rpm. After the rough mechanical run of 17/12/99, it was decided to bring down the shaft temperature to less than 250C and roll the machine. The machine was rolled again on 20/12/99 in the presence of BHEL, Hyderabad Engg. Representative and the machine showed no semblance of stability. The maximum shaft vibration recorded on HPIP RJB at 1500rpm was 495m. Also the vibrations ao LP outer casing were measured and recorded to be in excess of 1400m. The verdict was pronounced-Open up LP turbine, Inspect for damages if any, analyze the cause and eliminate it. The cause of the damage to the LP turbines in both the units zeroed down to distortion of the casing under vacuum due to lack of proper stiffness of the condenser dome walls. This was later rectified by further stiffening the dome walls. The task force suggested that the following checks be carried out on the LP turbine based on which rectification would be done. No. 1. What to check Check for free expansion of LP casing by removing the gussette block radial keys and re-inserting them without much force. Check for other areas of constraint to LP Observation All the gussette block keys were removed one by one. The front right and rear left keys were found to be tight, but on removal of these keys there was no movement of the casing. a) The LP inner outer casing axial Rectification After rectification, these keys were made to the required clearances.

2.

a)

This clearance

was

casing expansion.

keys were found to have 5mm radial clearance between the keys and the girder.

increased to by shaping the axial key in the area of likely contact of the key with the girder b) The radial key block was gouged & removed and shaped to get a minimum clearance of 7.00mm.

b)

Clearance of 10mm required between bottom of gussette block and radial key guide block was found to be min.-1.00mm and max. -3.6mm. Expansion clearance required in each holding down bolt and clearance between holding down bolt and washer checked and found to be OK.

c)

c)

Since the expansion clearances of holding down bolts were found to be OK, these were left as it is.

3.

Open up LP turbine and check for rubbing if any.

a)

Rubbing observed in top half of stages 6, 7, 8 & 9 GBCs in locations similar to LP turbine of Unit # 1, but less severe. No rubbing observed in Inner Inner casing (Inner casing-I). The rotor fins were found

a)

Rectified grinding

by

to be intact. b) Dirt and welding slag found in the Crass Around Pipe (CAP) at the point of entry of steam into LP turbine. No axial rubbing was seen. Gaps at parting plane of GBC shrouds of Inner outer casing (Inner casing-II) from a min. of 0.90mm to a max. of 6.4mm noticed. Axial offset of upto 5.60mm noticed between the top and bottom of GBCs. e) b) This was rectified by cleaning the existing dirt and also cleaning all joints of the CAP from inside. Left as it is. Left as it is, as these gaps do not affect the performance of the machine.

c)

d)

c) d)

e)

Rectified grinding.

by

4.

Check for bend of LP rotor by measuring run outs at various locations.

Run outs recorded at various locations were within 0.03mm, which does not indicate a

Left as it is.

5.

Remove the LP rotor and check for concentricity of LP Inner outer and Inner inner casing by bolting the two halves together.

bend. The concentricity of Inner inner casing (Inner casing-I) was found to be OK whereas, there was variation in the concentricity of the Inner outer casing(Inner casing-II) of the order of 2-3mm.

The variation in concentricity of Inner outer casing(Inner casing-II) was corrected by grinding the shrouds of GBCs of stages 6, 7, 8 & 9.

No. 6.

What to check Check for radial and axial clearances in the lower part and compare it with previous values. Check for looseness of blades in general and fir tree root blades in particular. Check for proper resting of LP inner outer casing(Inner casing-II) on palm packers. Check whether guide wheels are fixed to the Inner outer casing(Inner casingII) by cylindrical pins to avoid disturbance of the GBCs during operation.

7.

Observation In general the clearances were found to be OK in all the stages except in a few locations where dirt was seen stuck between the casing and rotor. All the blades were found to be tight and intact. Found that in certain areas, the inner outer casing(Inner casing-II) was not fully resting on the palm packers. All the cylindrical pins were found to be in position.

Rectification Rectified by removing the dirt and grinding wherever required.

Left as it is .

8.

This was corrected by blue matching.

9.

Left as it is.

Besides the checks, observations and rectification on the LP turbine and Condenser Dome, certain checks were suggested by the task force for the entire rotor system. These have been enumerated below : No. What to check Check the alignment after decoupling and correct if required. Observation a) LP-Generator alignment Radial Axial a) Rectification LP-Generator alignment Radial Axial

3.00

9.87

3.00

9.58

3.32

3.08

9.88

9.88

3.005

3.015

9.58

9.58

1.

3.39

9.89

3.01

9.575

b)

IP-LP alignment Axial 1.35

b)

IP-LP alignment Axial 1.285

1.39

1.36

1.29

1.29

1.40

1.30

The alignment had got disturbed.

2.

Check catenary

The catenary was checked with a locally manufactured device and was found as follows: Brg.1 As per drawing +2.201 Brg.2 +0.903 Brg.3 0.00

This was corrected during re-alignment and the final catenary recorded is as below : Brg.1 As per drawing +2.201 Brg.2 +0.903 Brg.3 0.00

As set before rolling

+1.10

+0.50

0.00

As set before rolling

+2.51

+0.98

0.00

No. 4.

What to check Check bonding of white metal of bearings by ultrasonic testing. Ensure lifting of Inner outer casing(Inner casing-II) w.r.t shaft center line and also LP glands w.r.t shaft center line as per protocol.

Observation Checked and found OK.

5.

The offset in the centerlines of the casing and the glands w.r.t shaft centerline was checked and found to be in order.

Rectification Replaced bearing No.3 with new bearing as, side oil clearances were found to be on the higher side. After re-alignment, the required center line offset was ensured.

The final alignment and Boxup of LP turbine was done after modifications to condenser dome stiffening. The LP turbine was boxed up and the rotor system was coupled. The final runouts as measured on various locations of the rotor system are as below: Location Runout HP rear journal 0.01mm HP rear coupling 0.03mm LP front coupling 0.025mm LP rear journal 0.025mm LP rear coupling 0.04mm Gen. Front coupling 0.04mm Gen. Front journal 0.025mm

The Unit # 2 machine was put on Barring gear on 01/02/2000 and rolled on 05/02/2000. During mechanical run and after synchronisation, the vibrations of the shaft were found to be normal except in LP rear journal, which was found to be stabilising at 140m. However, since there was no creeping tendency of the vibrations to increase, the machine was loaded to the rated 125MW and it was found that the LP shaft vibrations settled to 120m. It was decided to run the machine in the above condition and rectify the problem of vibration at a suitable time. The vibrations of the unit recorded at various loads and upto full load have been shown in the adjoining page.

Unit # 2 Vibration Pattern after rectification of LP turbine and Condenser Dome Stiffening Date Time(hrs.) Load, MW Speed HP-IP FJB Rel. shaft vib.(m), L/R HP-IP RJB Rel. shaft vib.(m), L/R LP RJB Rel. shaft vib.(m), L/R Gen. FJB Rel. shaft vib.(m), L/R Gen. RJB Rel. shaft vib.(m), L/R HP-IP FJ Brg. Hsg. Vib.(mm/s), V/H HP-IP RJ Brg. Hsg. Vib.(mm/s), V/H LP RJ Brg. Hsg. Vib.(mm/s), V/H Gen. FJ Brg. Hsg. Vib.(mm/s), V/H Gen. RJ Brg. Hsg. Vib.(mm/s), V/H Exciter RJ Brg. Hsg. Vib.(mm/s), V/H 05.02.00 2350 52 3004 68/72 75/87 115/137 34/83 59/66 1.7/2.7 2.4/2.3 6.0/3.5 1.1/5.3 5.15/2.6 3.05/7.6 06.02.00 0513 74 3007 72/79 80/98 129/151 38/89 62/68 2.0/3.15 2.62/2.37 8.7/5.0 1.2/5.3 6.5/3.2 3.7/7.9 06.02.00 1035 102 2964 66/76 80/98 121/140 37/79 53/69 2.0/2.6 2.2/2.3 6.9/4.2 0.9/5.3 8.6/3.3 2.9/7.3 06.02.00 1112 113 2954 58/68 79/93 117/136 36/74 48/66 2.0/2.8 2.5/2.4 6.0/3.7 1.2/4.6 7.8/3.0 2.6/6.9 06.02.00 1211 125 3036 48/52 64/77 116/136 40/97 59/58 2.2/2.6 2.1/2.2 7.3/4.6 1.5/5.3 6.5/2.7 6.0/11.4

After the machine was loaded to the rated 125MW, the shaft vibrations at LP RJB were found high but stable. Also the LP rear journal bearing housing vibrations reached alarm values. However, the machine was continued to be in operation and during coasting down after various trips the maximum shaft vibrations recorded were 389m at 1500rpm at HP-IP RJB and 312m at 1584rpm at LP RJB. There was brief shutdown of the machine due to tube leakage in the Boiler. This period was utilised to inspect LP rear journal bearing & its side oil clearances and the clearances of the LP glands. The bearing side oil clearances were found disturbed. Following is the comparison of the LP rear bearing oil clearances before and after full loading.

Before Full Loading

After Full Loading

Front left-0.30 Rear left -0.35

Front right-0.32 Rear right 0.32

Front left-0.30 Rear left 0.48

Front right-0.33 Rear right 0.20

Also it was found that the contact between the journal and bearing was inclined and not parallel to the axis of the shaft. The bearing side oil clearances were corrected by changing a shim of 0.07mm from left to right. The contact between journal and bearing was corrected by scrapping the babbit material of the bearing. This had resulted in reduced bearing housing vibration at LP rear in the subsequent run of the machine which is as shown below.

Date Time(hrs.) Load Speed HP-IP FJB Rel. shaft Vib.m, L/R HP-IP RJB Rel. shaft Vib.m, L/R LP RJB Rel. shaft Vib.m, L/R Gen. FJB Rel. shaft Vib.m, L/R Gen. RJB Rel. shaft Vib.m, L/R HP-IP FJBrg. Hsg. Vib.mm/s, V/H HP-IP RJBrg. Hsg. Vib.mm/s, V/H LP RJBrg. Hsg. Vib.mm/s, V/H Gen. FJBrg. Hsg. Vib.mm/s, V/H Gen. RJBrg. Hsg. Vib.mm/s, V/H Exciter RJBrg. Hsg. Vib.mm/s, V/H

19.02.2000 2341 Mech. Run 2983 31/29 42/50 64/71 28/58 41/63 0.8/1.1 1.2/1.1 3.7/2.9 1.3/6.1 2.3/1.2 2.0/6.3

20.02.2000 0130 14 3012 40/41 60/69 97/113 30/69 51/63 1.0/2.0 1.6/1.5 5.0/2.4 1.5/4.8 4.1/2.0 2.4/7.1

20.02.2000 0556 42 2920 53/55 83/90 104/123 34/54 41/68 1.3/2.5 2.1/1.7 5.0/2.4 1.2/4.2 4.4/1.6 1.6/5.3

The coasting down vibration of the machine remained as high as 250-300m in the trips that occurred during the operation of the machine after attending to Brg. No.3., but has remained fairly stable. It has been decided to operate the machine in the same condition. However, it is the impression of experts that the K-turbine of Unit # 2 may require balancing at a later date.

UNIT # 1 COMMISSIONING-POST RECTIFICATION The machine was rolled on 16/01/2000 after completing the modifications to condenser dome stiffeners. The machine was synchronised on 16/01/200 and found to be smooth during runup, operation and coasting down. The vibration levels of the machine are as below : Date Time(hrs.) Load,MW Speed,rpm HP-IP FJB Rel. Shaft Vib.(m), L/R HP-IP RJB Rel. Shaft Vib.(m), L/R LP RJB Rel. Shaft Vib.(m), L/R Gen. FJB Rel. Shaft Vib.(m), L/R Gen. RJB Rel. Shaft Vib.(m), L/R HP-IP FJ Brg. Hsg. Vib.(mm/s), V/H HP-IP RJ Brg. Hsg. Vib.(mm/s), V/H LP RJ Brg. Hsg. Vib.(mm/s), 16.01.00 0630 Mech. Run 3000 50/32 74/59 54/42 17.01.00 0000 40 3093 79/67 56/45 65/56 21.01.00 1734 62 2972 67/53 49/53 65/74 21.01.00 2338 77 2925 66/50 54/60 64/73 22.01.00 0813 100 3008 68/55 50/59 57/63 24.01.00 2012 126 2987 60/44 53/60 62/67

34/47 58/31

34/51 78/29

40/45 29/85

39/45 29/80

48/41 33/95

41/41 37/91

1.0/0.5

1.5/0.8

1.2/1.8

1.3/1.8

1.0/1.0

1.2/1.4

1.0/1.1

1.0/1.0

1.6/1.2

1.8/1.2

1.4/1.1

1.4/1.3

1.6/3.4

1.4/3.3

1.9/3.2

1.9/3.3

1.7/2.8

1.7/2.6

V/H Gen. FJ Brg. Hsg. Vib.(mm/s), V/H Gen. RJ Brg. Hsg. Vib.(mm/s), V/H Ext. RJ Brg. Hsg. Vib.(mm/s), V/H

1.7/1.2

2.8/1.9

3.0/1.0

3.0/0.9

6.2/2.0

3.7/1.3

1.4/1.2

3.5/1.9

3.3/2.4

3.7/2.3

3.4/3.3

3.6/3.1

2.3/1.0

2.7/1.1

2.6/0.7

2.1/0.9

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