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PROJECT : RAICHUR UNIT 3 PROBLEM : BALANCING OF LP ROTOR AT SITE

Generator rotor replacement was carried out on Unit 3 , 210 MW unit (Seimens Turbine Russian Generator ) of Raichur thermal power station during May 2006 due to rotor earth fault. The IP turbine rear shaft vibrations increased to alarm levels of 120 microns peak from earlier levels of 75 microns peak at rated load parameters. The control room vibration levels are given below as recorded on 06-06-2006. Load: 172 MW Freq : 49.28 Hz Shaft Vibrations Bearing Vibrations in in microns microns peak(pk) peak(pk) HP Front HP Rear IP Rear LP Rear 49.5 34.0 119.8 26.2 2.9 3.0 14.9 10.7

Vibration analysis of bearing and shaft vibrations indicated predominant presence of running speed vibration components. The LP front pedestal vibrations are given below.

1X- microns pk-pk Vertical Horizontal Axial 49 56 57

Phase 46 295 192

Overall 49 56 57

The LP front vibrations for Seimens turbine are normally in the range of 25 to 30 microns pk-pk. Here the pedestal vibrations were high and also the phase difference between vertical and horizontal directions were 111 degrees very near to 90 degrees which results in good vibration reductions to balance correction. Balance correction was carried out on LP rotor using LP front Plane. A total number of 11 balance weights of 90 grams were added at LP front plane to arrive at satisfactory shaft and pedestal vibration levels on turbine. The LP front pedestal vibrations after balancing are given below. 1X- microns pk-pk Vertical Horizontal Axial 26 27 24 Phase 58 283 136 Overall 26 27 25

The control room vibration levels at 180 MW load are given below as recorded on 07-06-2006.

Load : 180 MW Freq : 49.42 Hz Shaft Vibrations in Bearing Vibrations in microns pk microns pk HP Front HP Rear IP Rear LP Rear 22 21 72 46 2.8 4.5 9.2 5.2

The IP rear shaft vibrations coast up plots before and after balancing are given in figures 1 & 2. It is observed that there is no critical speed sharply reflected at IP rear . The coast up plot shows considerable reduction in shaft vibration levels after 2700 rpm

Bode plot IP rear shaft Coast up , Raichur Unit 3 - initial run

360 300 Phase degrees 240 180 120 60 0 600 900 1200 1500 1800 2100 2400 2700 3000 3300

140 120 microns pk-pk 100 80 60 40 20 0 600 900 1200 1500 1800 2100 2400 2700 3000 3300 RPM

Bode plot IP rear shaft Coast up , Raichur Unit 3-after balance correction

360 300 Phase degrees 240 180 120 60 0 600

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2700

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3300

140 120 microns pk-pk 100 80 60 40 20 0 600 900 1200 1500 1800 2100 2400 2700 3000 3300 RPM

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