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Paper 1 Turbogenerator Cases

The document summarizes case studies of turbogenerator damage from an expert in turbogenerators. It describes instances of core damage in the Bhusawal TG-2 where melting was found between slots 51-52 of the stator core. Methods used for repair including inserting a dummy tooth are shown. Other cases discussed include stator winding issues, repairs of bars, instances of motoring damage, and failures of components like thrust seals and bearings that led to damage. Causes like overheating, gas leaks, and oxygen being fed instead of hydrogen in the cooling system also led to explosions in some cases.

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172 views43 pages

Paper 1 Turbogenerator Cases

The document summarizes case studies of turbogenerator damage from an expert in turbogenerators. It describes instances of core damage in the Bhusawal TG-2 where melting was found between slots 51-52 of the stator core. Methods used for repair including inserting a dummy tooth are shown. Other cases discussed include stator winding issues, repairs of bars, instances of motoring damage, and failures of components like thrust seals and bearings that led to damage. Causes like overheating, gas leaks, and oxygen being fed instead of hydrogen in the cooling system also led to explosions in some cases.

Uploaded by

Anonymous q8EusUC
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 43

Turbogenerators

Case Studies

Presented by

Abhilash Chandra Aron


Consultant, Turbogenerators
Managing Partner, Eron Services

Bhusawal TG Core Damage


THW-210 Bhusawal-2 TG overhauled in

1993 and then in 2002. During this ohaul,


ELCID readings were high for slots 51- 52
near 1st end packet on TE.
After removing few bars, core melt seen
between slots 51 and 52.
Tooth between 51- 52 was cut off, molten
iron removed to reach clear laminations.
CASES by AC ARON Feb 2012

Bhusawal Core Damage -2


View From Turbine End

Core Melt

CASES by AC ARON Feb 2012

Bhusawal Core Damage - 3

51

52

CASES by AC ARON Feb 2012

4
A C ARON

Bhusawal Core Damage - 4


Later, after the tests, few more hot spots

near end packets detected and repaired.


A dummy tooth was made out of glass
textolite and glued in place of removed
metal position.

CASES by AC ARON Feb 2012

Melting of Core Iron


Zone upto which
iron to be cut off

Core iron melt

10 - 15 mm
Healthy
core
CASES by AC ARON Feb 2012

Core Repair - 5
Stator Core
Long Wedges
Dummy Tooth

Normal
Wedges
CASES by AC ARON Feb 2012

Core Repair - 6
Dummy
Tooth

Slot Wedge
Core Iron

CASES by AC ARON Feb 2012

ELCID Test Results


Packet:
Slot 54
Slot 53
Slot 52
Slot 51
Slot 50
Slot 49
Slot 48
Slot 47

91
22
64
42
65
48
92
111
46

92
16
73
71/38
-145/196
275/298
342/343
179/203
CASES by AC ARON Feb 2012

93
26
71
-229
246
218
135
9

Core Loss Test


Test is done at flux density of 1 - 1.5 Tesla

for 90 - 45 min. Teeth temps. are checked


with infra red devices.
At the end, temp. rise of hottest point to
be < 25C and difference between the
hottest and coldest be within 15C.

CASES by AC ARON Feb 2012

10

Core Loss Test


Temp. Rises C after 90 min.
TE:Packet:
Slot 54
Slot 53
Slot 52
Slot 51
Slot 50
Slot 49
Slot 48
Slot 47

91
11
15
11
14
12
11
9
7

92
12
19
-16
13
13
11
7

CASES by AC ARON Feb 2012

93
11
21
-17
15
13
11
7

Dummy
Tooth

11

Turb End: Temp Rises after 30 min.


Max. rise permitted 25 C
16
11
11- 12

CASES by AC ARON Feb 2012

12

OHaul: Dec.2004
Overheating seen
at core back near
core bars in the
repaired zone.

CASES by AC ARON Feb 2012

13

Stator Damage
A 760 MVA Angara-Brazil : Core repaired
after 13,400 Hrs. Hot spots repaired using
electro-chemical process.
M/c tripped on stator faults, after another
1200 Hrs. Huge core melt seen on ExEnd.
High burrs; Insulation thickness too less.
Core was poorly clamped at two ends.
Machine was rebuilt at site by KWU.
CASES by AC ARON Feb 2012

14

Stator winding Leakage


Leak in stator winding caused H2 gas to
enter into it. H2 consumed @ 25 cylinders
per day. Gas pressure reduced and water
came out at leaking point, causing flash
over between phases. Machine rewound.
Ran for 30,000 hrs without mandatory
initial overhaul. H2 leak detected in the
gas trap device and in expansion tank.
Leakage was in 3 bars on EE side.
ACA by
- OH
- 2ARON
/ 50 HOFeb 2012
CASES
AC

15

THW: Stator Winding Vibrations


Radial Vibrations
Upper Bar
Teflon
Tubes

Lower Bar

Tangential Vibrations

CASES by AC ARON Feb 2012

16
A. C. ARON 1999

Chandrapur 500 MW U-7


TG having clocked 63,734 hours, running
with gas cooler leak, tripped on electrical
faults. Melting of copper lugs,Teflon tubes
water headers seen on turbine side.
Mostly,replaceable lug ends got damaged
but in one joint, 4 hollow strips melted.
A copper chamber was made in this lug
by brazing in situ, to restore water flow.
CASES by AC ARON Feb 2012

17

Damage at 7 OClock

CASES by AC ARON Feb 2012

18

Upper half box removed

CASES by AC ARON Feb 2012

19

Brazed jacket

CASES by AC ARON Feb 2012

20

Brazed top box cover

CASES by AC ARON Feb 2012

21

High Cold Gas Temps.


NEYVALI THW - 210 MW TG

CW temp. remains high in summer and


machine operated at maximum MVAR.
2 RTDs were defective due to cold solder
Hot gas leaks bypassed
H2 cooler inside stator.
Rubber seals in coolers
Core
were corrected.
CASES by AC ARON Feb 2012

22

210 MW: Motoring


North Chennai

2 ph steady state asynchronous motoring


for 6 minutes without excitation.
Generator: 12.9, 12.8,12.3 kV stator volts
and load: 2.8, 4.4, 3.0 kAmp; 0.5 MW.
Calculations showed: I2 was 5110 Amp
(56.5% FL) duration 3 sec., So, I2 t ~ 3,
which was permissible
Rotor was cleared without any inspection.
CASES by AC ARON Feb 2012

23

TG Motoring - 2
A 200 MW Mitsubishi generator
motored in asynchronous mode for
almost 34 minutes due to GCB fault.
I2 t value was computed by OEM
as more than 110.
Retaining rings were removed but no
physical damage seen.
CASES by AC ARON Feb 2012

24

TG Motoring - 3
BOKARO, KAKINADA, OBRA, WANAKBORI-7

Machines started as induction motor


from standstill..
Rotor barrel ends got overheated and
winding insulation got damaged.
In Wanakbori GT also got damaged.
Stator windings were damaged.
CASES by AC ARON Feb 2012

25

Local Repair of a Lower Bar


After rewinding works, during final HV
lower bar failed at 70 mm from core end
in overhang.
Puncture point was filled with epoxy. On
top, a shape 4 mm thick insulation
125 mm long was tightly glued and tied.
Passed 21 KV. In operation for >25 yrs.
CASES by AC ARON Feb 2012

26

Repair of Lower Bar - 2


WANAKBORI - 1

Core

Puncture Point

70

Cap

Glue
Cord

CASES by AC ARON Feb 2012

27

Repair of Upper Bar


Core Iron
Wedge

Barrier
Db
Thick
=2Lb

Fault Point
Upper Bar
Lower Bar
CASES by AC ARON Feb 2012

28

THRI-210: Rotor Damage


Set

started without water in gas coolers


and loaded to 77 MW.
High gas pressure alarm comes. H2 gas
pressure seen 2.6 against 2 atg normal.
It was estimated that gas temp.went up
to about 129C and rotor hot spot temp.
went up to 200 C.
CASES by AC ARON Feb 2012

29

THRI Rotor Damage - 2


Set

resynchronized. Rotor current higher


by about 20%, confirming rotor inter-turn
insulation damage.
Advised to increase H2 pressure from 2
to 3 atg & restrict rotor current to rated,
giving 170 MW and 20 MVAR.
Rotor ran for 18 months in this condition.
CASES by AC ARON Feb 2012

30

THW TG Rotor Winding Low IR

Creepage
Path*

*About

2800 creepage paths in rotor


cause creepage resistance to fall.
CASES by AC ARON Feb 2012

31

Fire Around Slip Rings


In a 210 MW generator, slip rings had
depressions due to non uniform wear
They were not machined as required
and machine continued to run.
Fire broke out on brushes around the
rings. All the holders+brushes melted
causing a forced and long shut down.
CASES by AC ARON Feb 2012

32

Slip Rings
Brushgear centering, stagger of brushes,
mounting of brush holders, & alignment
and clearances, brush pressure & grade
are important.
Dust + oil vapours, give high sparking.
HM-100 grade, though softer had better
performance. Slightly higher pressure
reduces sparking and brush jumping.
CASES by AC ARON Feb 2012

33

Oil Starvation
210 MW set reached 570 rpm. Sound
heard from rear bearing. Coast down
was quick. Babbit had melted, shaft
journal dia 400 mm developed cracks.
Shaft had hardened to 315 BHN from
246, because of rubbing. Cracks upto
200 mm length and 1.75 mm depth
had developed.
CASES by AC ARON Feb 2012

34

Oil Starvation - 2
Damage To Bearing Journal
Machined to 320 mm, till all cracks
disappeared & normal BHN achieved.
160
400

175
200

115
Rotor

was reused after machining.


CASES by AC ARON Feb 2012

35

Damage to a THW-210 TG
During overhaul, old strip type cracked
lock washers were reused. As a result
during operation, M24 bolts came out,
releasing a 5 kg steel segment inside.
Plate fell on stator overhang and was
sucked by magnetic pull into the airgap
hammering stator and rotor surfaces &
damaging them.
CASES by AC ARON Feb 2012

36

THW-210 Damage - 2

CASES by AC ARON Feb 2012

37
A. C. ARON 3MAY 2002

THW-210: Thrust Seal Failure


Kolaghat-4, Bokaro-1

At 120 MW, abnormal sound is heard near


TS bearing. Press falls by 0.3 Kg.
TS seal-oil drain high. Hydraulic seal oil
level high. Overflow of oil from the damper
tank to hydraulic seal occurs. Babbit RTD
on TE not working.
Smoke comes out of Turb S seal area
momentarily. Mating surfaces of hole and
locking pin were damaged.
CASES by AC ARON Feb 2012

38

Thrust Seal Failure - 2


TS seal collar face damaged & was cut by
13 mm. Seal liner babbit was worn out,
parent metal damaged 5 mm deep. Pins
were loose and found shifted.
Collar face was machined to get 36.7 mm
collar thickness.
Seal body flange thickness increased by
13.5mm. Long bolts and new seal liners
used.
CASES by AC ARON Feb 2012

39

A-A
With Bush

THW-210: Thrust Seals


Locking Pin
Brass Bush

A
A

A-A
Without Bush
B

Seal Liner
Sec B-B

CASES by AC ARON Feb 2012

B
Damage
Here
40

A. C. ARON

Fire in a 500 MW TG
Six

LP last stage blades towards IP


side failed at roots in quick succession
after 11 years service. All bearings, H2
shaft seals damaged; H2 escaped.
Oil and leaking H2 catch fire. H2 fire
extinguished promptly by venting H2
out and CO2 feed. Oil fire stopped by
extinguishers. No damages due to fire.
PMG,exciter armature, generator rotor
compressor blades were damaged.
CASES by AC ARON Feb 2012

41

Explosion in Generator
110 MW TG fed O2 instead of H2 for make
up. Explosion occurred after 8 hours. Ten
cylinders of O2 were fed upto explosion.
Purity-meter having 90% low range, was
not working,purity unknown. TG end walls
welding broke, gas coolers axially pushed
A stator coil had flashover marks in its
overhang portion, copper had melted. Set
tripped on its protections.
ACA by
- OH
- 2ARON
/ 50 HOFeb 2012
CASES
AC

42

Best Wishes !
AFSHA CLASS 5

CASES by AC ARON Feb 2012

43

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