DETAILS OF ACTIVITIES OF UNIT- 3 , AFTER TG PUT ON BARRING GEAR

DURING ANNUAL OVERHAUL ( 10/12/05 TO 5/01/06)

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Description of the activities
no
1.

2.

3.

Rotor Zero position

Final Clearance By TMD/C&I

after Bearing boxup & TSI
work completion

TG lub oil Flushing

Date

Start
Time

02-01-06

17:30

Complete
Time

Duration

02-01-06
17:30

4:30

11:00 hrs

6:00 Hrs

6:00

24 hrs

12:45

1:45 Hrs

03-01-06

02-01-06
03-01-06

4.

Clearance after TG Lub oil

Flushing Completion ,

03-01-06

10:15

5.

P&I check for TG lub oil

/Jacking oil/Barring gear

03-01-06

11:00

6.

Machine put on barring

gear , Full speed reached
65 RPM ( with out vacuum)

03-01-06

13:15

7.

Clearance for BLU

03-01-06

13:15

8.

BLU ( already lined up)

03-01-06

15:05

Remarks
Clearance Given By TMD

Clearance for Bearing Box up By C&I

after C&I Connection completion .
TMD Clearance after Boxup of all
Bearings
Final C&I clearance after Vib pickup
fixing
Clearance Given at 4 :15 hrs
DCEOP was not taking start , attended by
EMD , (Control supply problem ins tarter
panel . )
All line filters were clean
Both Basket filters were removed &
cleaned inside the tank.
All Throttles are set to original value
Oil pumps started at 10 : 50 Hrs
TG JOP started at 11:20 Hrs
Puja performed before Put on barring
gear
After the M/C came on barring Lub oil
Protection was checked by actually
draining the Lub oil PS , Found OK
Barring gear valve Close Open Oprn
was OK.
After M/C has come on barring gear the
BLU clearance was given . CO2 purging
with H2 under progress.
BLU done after all maintenance people
were made available for Gun cleaning
Sheet 1 of 8

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Description of the activities
no

9.

Vacuum Pulling

ATT for Valves dry run

Checking By BHEL /C&I
Drum Vents Closing at 3
11.
ksc
10.

Date

Start
Time

Complete
Time

Duration

Remarks

03-01-06

03-01-06

17:00

18:00

18:15

19:14 Hrs

1:15 Min

03-01-06

12. SH drains closing at 6 ksc

03-01-06

13. MSVs IBV opened

03-01-06

14. HP/LP Bypass charging

03-01-06

15.

Turbine Stop Valves Opened

for warm up

03-01-06

19:25
21:03
21:35

22:10

H2 casing pressure 2.64 ksc at 22:24 Hrs

Steam pressure - 35 ksc

MS temp -350 0C
HRH Temp -290 0C
Steam Purity SiO2 - 19 ppm
ATRS rolling done , after following
bypassing
Step- 2
MS strainer drain
feedback

Step- 7
BLI >15 %
bypassed

Step -10 Speeder gear >

100 %
H2 gas pressure reached 3.34 ksc at
3:30 AM
After the X 6 criteria was satisfied

16.

TG Rolling parameter
Reached

03-01-06

23:45 hrs

17.

TG speed raised to 360 rpm

& soaking at 360 RPM

03-01-06
04-01006

23:45 hrs

5:00 Hrs

5:15 Min

18. TG speed to 3000 rpm

04-01-06

etc.
BLU with AB elevation LDO Cor- 2& 3
1st VP started 17:00 hrs
Seal steam charged 17:35 hrs ( Temp
244 )
2nd VP started 18:10 hrs
18 :15 Vacuum -0.62 ksc
All 4 valves set checking done & found to
be OK .

5:00 hrs

Sheet 2 of 8

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Description of the activities
no

Date

Start
Time

Complete
Time

Duration

Remarks

19. Elect. Testing

04-01-06

5:30 Hrs

20. GT back charge

04-01-06

11:50 hrs

21.

UT A/B Charged & station

breakers made off .

04-01-06

22.

Oil injection test at 3000

RPM from Local

04-01-06

23. Speed Regulation check

04-01-06

12:00

12:40

12:40

Leakage observed in test oil gauge .

M/C was taken in hydraulic mode .

Speed regulation was checked by
opearting SD/SG to 100 % , Actual speed
rise was 3120 RPM in place of 107 % ~
3210 RPM . Suspected problem in Gov
system setting .
RTD- 1 , RTD-2 , Low Vacuum Trip
devices are tested
Over speed trip Device testing was not
completed as the Test Oil pressure <4,5
ksc criteria was not getting satisfied
Generator trip to turbine trip was checked
by simulating Gen trip .
Turbine was tripped .
AOP-1 came on auto
Coasting down Vibrations went very high
in most of the bearings at about 1100- 800
RPM .
JOP-1 came on auto < 510 RPM
TG valve opened on auto < 210 RPM at
14:41 Hrs
Sheet 3 of 8

13:20

24. ATT for safety devices

04-01-06

13:30

13:55

Inter Trip Checking

25.
( Generator trip to Turbine
Trip) & Turbine tripped

04-01-06

Max Vibration During the critical speed

was 267 micron at Exciter bearing
Clearance for Elect testing at 5:30 hrs

13:55 Hrs

Sl
Description of the activities
no
26.

Clearance for pressure rising

to 150 kg from 50 Ksc

Date

Start
Time

04-01-06

14:00 Hrs

Complete
Time

Duration

Remarks

At 100 Ksc Boiler Expansion Checked

At Bottom Ring header C-1 & C-3 285 &
290 MM respectively
16:10 - Dr pressure- 110 Ksc
17:00 - dr pressure- 130 Ksc
17 :30 dr pressure- 150ksc

04-01-06

14:00 Hrs

17:30 Hrs

3:30 Hrs

04-01-06

17:30 Hrs

20:30 Hrs

3:00 Hrs

Pressure raised to 186 ksc

29.
Safety valve floating ( MS SV-8)

04-01-06

21:00 hrs

30. Parameter reduction

04-01-06

21:00 hrs

27. Pressure raised to 150 kg

28.

Treavy test Completed for

all 8 valves

31. Boiler Tripping

32. CF system stopped

04-01-06

04-01-06

21:30 hrs

21:35 Hrs

21:30

0:30 hrs

3:00 Hrs

04-01-06
33. Gov. system working by TMD

21:30
05-01-06

6:00

8:30 hrs

34. Clearance for BLU

05-01-06

6:00

Pressure reduced to 75 Ksc

It was decided to attend to the Gov
system problem by TMD/BHEL
21:45 -One set of fans stopped
22:30 2nd set Fan stopped & Boiler Boxed
up at 25 Ksc pressure
Vacuum breaker /LPBP spray main valves
were kept closed first then CF was
stopped .
SD/SG assy was opened
Again the adjustment was done as per
drawing
All other checks carried out by injecting
primary oil from a hand pump .
Gov lift Vs the aux sec oil pressure were
checked
Boiler Pressure - 8.3 ksc
Sheet 4 of 8

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Description of the activities
no

35. BLU carried out

36. Rolling parameter reached

37.

TG set rolling to 360 rpm &

Soaking at 360 RPM

38. TG set rolling to 3000 rpm

39. Gov. system adjustment

Date

05-01-06

Start
Time

Complete
Time

6:20

8:30

05-01-06

8:55

9:20

05-01-06

9:20

9:25

9:30

Remarks

05-01-06

05-01-06

Duration

0:25

Max Vibration was at brng - 7 265 microns

Machine taken to hydraulic Mode , EHC

was isolated . Tracking Made Off
Speed regulation was checked , with both
100 % speed was 3220 RPM.
SG position feedback was again
calibrated by C&I
After speed regulation check clearance
was given at 10 :30 hrs
Over speed trip was checked , again the

10:30

40. ATT checking for O/S Trip

Device

05-01-06

10:30

11:30

1:00

MSV/MCV - 325/323
HPC/HPS -297/299
IPS - 202
MS temp 358/363
HRH temp 237/254 vac - 0.94
12 oil guns cut in
One mill - B taken in service
Spray lined Up
Other mill - C kept under running
MS temp dropped to 298 & then
increased
MS pressure 65 KSC
MS temp 420 0C
HRH temp 400 0C
MS silica 12 oil guns & One mill in service
Before Rolling Turbine Trip to Gen trip
was checked .
Rolled through ATRS
Speed Hold at 360 RPM as MS temp
Has gone above 400 deg cen

Sheet 5 of 8

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Description of the activities
no

Date

Start
Time

Complete
Time

Duration

Remarks

41. Turbine run up to 3000 rpm

05-01-06

12:15

42. Unit synchronization

05-01-06

12:20 Hrs

All FW heaters (LPH/HPH) &

Ext to D/A Charged
44. Load Raised to 200 MW

43.

13:30 hrs

45. ATT for valves

TDBFP-A taken in service at

250 MW load
One VP stopped as Vacuum
47.
Was -0.95 Ksc
48. Load raised to 400 MW
49. Load raised to 500 MW

46.

50. TDBFP-B taken in service

51. Load raised to full load
52. MDBFP-C put on recirculation

05-01-06

15:35

05-01-06

16:10

17:00

18:20 hrs
hrs

06-01-06
05-01-06
05-01-06

16:04

0:30

0:12 Hrs

0:12 hrs

same problem , TG set tripped during

Reset program.
Coasting down shaft vibration of Bearing
3&4 went up to 380 microns
Bearing Vibrations went >100 microns
Speed was picked up at 380 RPM while
coasting down & then raised to 3000 RPM
Synvhronised through Auto
synchroniser
Block load pickup was OK .
In between 100 MW to 150 MW load all
these activities are completed
ATT for valves carried out at 250 MW
load
Load variation during the valve
operation are as follows .

HPCV/SV-1

HPCV/SV-2

IPCV/SV-1

IPCV/SV-2

1st it was loaded at 20 : 09 hrs but tripped

with out any known cause ( First up was
trip oil pressure Low)
Finally loaded at 0:12 hrs

Sheet 6 of 8

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Description of the activities
no
53. MDBFP-C stopped

Date
05-01-06

Start
Time
6:00 Hrs

Complete
Time

Duration

Remarks

Sheet 7 of 8

Sheet 8 of 8