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Case Study On BFP Mod.

This document summarizes a case study of a TDBFP failure at an NTPC power plant in Ramagundam, India. The failure was caused by the coupling between the turbine and booster pump detaching, which unloaded the BFP-A. This was compounded by a failure of the BFP's SH spray non-return valve, causing reverse rotation of the BFP, a rise in steam and metal temperatures, and loss of generation. Corrective actions included manually starting another BFP, closing the faulty BFP's SH spray isolating valve to stop reverse rotation, and engaging the turbine's braking gear. Recommendations included adding motorized valves for each BFP's spray lines and interlocks

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887 views

Case Study On BFP Mod.

This document summarizes a case study of a TDBFP failure at an NTPC power plant in Ramagundam, India. The failure was caused by the coupling between the turbine and booster pump detaching, which unloaded the BFP-A. This was compounded by a failure of the BFP's SH spray non-return valve, causing reverse rotation of the BFP, a rise in steam and metal temperatures, and loss of generation. Corrective actions included manually starting another BFP, closing the faulty BFP's SH spray isolating valve to stop reverse rotation, and engaging the turbine's braking gear. Recommendations included adding motorized valves for each BFP's spray lines and interlocks

Uploaded by

rajan_me083
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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TDBFP FAILURE

A case study

NTPC LTD, RAMAGUNDAM

TDBFP AN OVER VIEW

UMP IS DRIVEN BY TURBINE OF STAGES.

URBINE IS DIRECTLY CONNECTED WITH MAIN AIN PUMP BY HYDRAULIC COUPLING NIT AND TO THE BOOSTER PUMP HROUGH GEAR BOX

AIN PUMP CONSISTS OF 4+1 (KICKER) STAGE.

URBINE IS HAVING 5 Nos OF CONTROL VALVE WITH NE STOP VALVE AND ONE ACV.

STEAM SOURCES TO DRIVE THE TURBINE CRH STEAM AUXILARY STEAM IP-LP CROSS OVER LTD, RAMAGUNDAM STEAM NTPC

TDBFP AN OVER VIEW


TO FRS SH SPRAY RH SPRAY COUPLING TURBINE
BOOSTER PUMP

LP-IP CROSS OVER AUX STEAM CRH FROM D/A

HC
MAIN PUMP

GB
TO CONDENSOR
NTPC LTD, RAMAGUNDAM

CASE STUDY
UNIT STATUS BEFORE EMERGENCY: UNIT : 5 DATE : 09/03/2006 LOAD : 490 MW MILLS IN SERVICE : A B C D E F BFPs IN SERVICE : - TDBFP A ON EXTRACTION - TDBFP B ON EXTRACTION WITH CRH LINED UP. - ( MDBFP AUTO STANDBY )
NTPC LTD, RAMAGUNDAM

22:41:30 HRS

OBSERVATIONS:

1. ACV CHANGE OVER ALARM APPEARED. 2. BFP-A GOT UNLOADED. 3. FEED WATER FLOW DROPPED BY 400 T/HR. 4. BFP A SPEED INCREASED FROM 5387 RPM TO 5923 RPM AND MAINTAINED AT 5728 RPM.

NTPC LTD, RAMAGUNDAM

OBSERVATIONS (conti:):

5. TURBINE FRONT VIBRATION INCREASED FROM 44 TO 53 . 6. TURBINE ECCENTRICITY INCREASED FROM 32 TO 39. 7. GEAR BOX FRONT VIBRATION INCREASED FROM 8 TO 25 8. CV POSITION REDUCED FROM 41 TO 28 %.
NTPC LTD, RAMAGUNDAM

ACTIONS TAKEN : 1. MDBFP STARTED MANUALLY, LOADED AND DRUM LEVEL NORMALISED. 2.MEANWHILE BFP A R/C VALVE OPENED MANUALLY AS R/C VALVE DIDNT OPEN IN AUTO ON LOW FLOW. 3. IN LOCAL BFP-A TURBINE TO GEAR BOX COUPLING FOUND IN DECOUPLED CONDITION AND SPARK WAS COMING,IMMEDIATELY BFP-A HAND TRIPPED.
NTPC LTD, RAMAGUNDAM

BFP-A SPEED CAME DOWN TO ZERO AND AGAIN STARTED ROTATING AT A SPEED OF 3360 RPM. SH SPRAY BECAME ZERO AND WAS NOT INCREASING WITH ALL VALVES IN FULL OPEN CONDITION. DUE TO NON AVAILIBILITY OF SH SPRAY, STEAM TEMPERATURE AND METAL TEMPERATURE STARTED RAISING. MS TEMPERATURE WENT UPTO 560C , SH / RH METAL TEMPERATURE HAS GONE UPTO 600C.

NTPC LTD, RAMAGUNDAM

TDBFP HAND TRIPPED

Speed dropped to 20 rpm


NTPC LTD, RAMAGUNDAM

Actions taken (conti: )

4. FIRST MILL- F AND LATER MILL- E HAND TRIPPED BUTSTILL TEMPERATURE WAS INCREASING HENCE LOAD BROUGHT DOWN TO 230 MW. 5. SINCE BFP-A SPEED WAS NOT REDUCING, SUSPECTED BFP REVERSE ROTATION DUE TO PROBLEM WITH SH SPRAY LINE NRV OF BFP.

NTPC LTD, RAMAGUNDAM

Actions taken (conti: )

6. BFP-A SH SPRAY MANUAL ISOLATING VALVE CLOSED. 7. WITH THIS SH SPRAY STARTED INCREASING AND BFPA SPEED CAME DOWN TO ZERO. 8. HYD COUPLING BETWEEN MAIN PUMP AND TURBINE DISENGAGED AND TURBINE PUT ON BARRING GEAR.
NTPC LTD, RAMAGUNDAM

OTHER OBSERVATIONS: WHILE CLOSING BFP-A SH SPRAY VALVE, BFP SPEED STARTED COMING DOWN AND SAME TIME ECC AND VIB GONE UP TO
ECC - 262 VIB (F) - 131 VIB ( R ) - 128 GB ( F )- 35 GB ( R )- 15

AND IT HAS CAME BACK TO NORMAL VALUES AFTER PUTTING TURBINE ON BARRING. TURBINE HAS NOT COME TO BARRING DURING COASTING DOWN

NTPC LTD, RAMAGUNDAM

MAIN CAUSES
BFP COUPLING FAILURE: RESULTED IN UNLOADING OF TDBFP. SH SPRAY NRV FAILURE: RESULTED IN 1. REVERSE ROTATION OF BFP. 2. STEAM AND METAL TEMP RISE. 3. GENERATION LOSS.

NTPC LTD, RAMAGUNDAM

BFP TURBINE TO BOOSTER PUMP COUPLING

POINT OF FAILURE
NTPC LTD, RAMAGUNDAM

COUPLING CROSS SECTIONAL VIEW T U R B I N E S I D E

G B S I D E

NTPC LTD, RAMAGUNDAM

BFP SH SPRAY NRV :

FAILED NRV

FROM BFP DISCHARGE

TO SH SPRAY COMMON HEADER

NTPC LTD, RAMAGUNDAM

RECOMMENDATIONS:
FOR INDIVUDAL BFPs SH AND RH SPRAY MOTORISED VALVES TO BE PROVIDED IN ADDITION TO MANUAL ISOLATING VALVE. IF BFP TRIPS, RESPECTIVE BFPS SH AND RH SPRAY MOTORISED VALVES CLOSING INTER LOCK TO BE PROVIDED. BFP FLOW LOW ALARM TO BE PROVIDED (LESS THAN 250 T /HR ).
NTPC LTD, RAMAGUNDAM

THANK YOU
NTPC LTD, RAMAGUNDAM

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