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Project:

Karnataka power corporation, Bellary, unit 1, 500 MW

Problem: During start up of the unit on 25/12/09, HPCV-1 did not open and observed not responding to even maximum secondary oil pressure. Problem details: Bellary unit 1 (500 MW) is in continuous operation after completion of reliability run in march 2009. The unit was shut down on 23/12/09 for attending to the leakage developed in one of impulse line of HP Turbine. During restart it was observed that the HPCV 1 is not opening. It was reported that the valve is operating sluggish since commissioning. The auxiliary pilot valve was serviced recently by BHEL,Hardwar technicians. Operation of the control valve: (refer the figure) The servomotor consists of auxiliary pilot valve (14), pilot piston (4), main pilot valve (3), feed back linkages, servo piston (9) and disc springs (10). The secondary fluid pressure controls the auxiliary pilot valve (14) and directs control fluid to the pilot piston. The pilot piston operates the main pilot valve through lever (5). The main pilot valve (3) admits/drains the oil from underside of servo piston (9). Under steady state auxiliary pilot is in middle position. When the secondary fluid pressure varies, auxiliary pilot valve deflects from middle position and allow control fluid to pilot piston and moves in one direction. The connecting lever transmits the movement to the main pilot valve causing the oil flow to the servo piston. The movement of the valve is transmitted back to the aux pilot valve through linkages. The cam in the servomotor spindle returns the pilot valve to its middle position. The degree of proportionality of pilot control system can be adjusted by the feed back linkage pivot. The aux pilot valve is kept in rotation by the fluid jet from the tangential holes of the pilot
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disc. The spring above the linkages preload it to avoid slackness and play.

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Analy0sis/trouble shooting: The signal pressure (HP secondary fluid pressure) was varied and found no response of the valve. The rotation of the auxiliary pilot was ensured. To identify whether it is servomotor problem or valve problem, the servomotor was decoupled. The secondary fluid pressure was then varied and found again no movement of the servomotor spindle. To check the freeness of the auxiliary pilot, the linkage was moved manually (in addition to the secondary fluid pressure) and it was noticed that the main pilot valve is not moving at all. Also, there is no flow of fluid observed from the pilot valve. The movement of the linkage manually and pilot valve/main valve movement along with flow changes could be seen in the healthy control valve number 2. Suspecting jamming of the main pilot valve in one position, it was decided to dismantle and service the main pilot valve of HPCV 1. To remove the main pilot valve, the linkage assembly & helical spring was taken out of its position and the main pilot was pushed away from the control valve casing. The pilot came out by around 20 mm and got struck up. It was again taken back to original position and the process was repeated but the pilot never came out beyond 20 mm. After consulting with BHEL Hardwar it was decided to remove the main pilot along with the liner and bush. The whole assembly (pilot with liner) was then removed from position. For removal of the assembly, Liner it was pushed towards the control valve casing. After taking the assembly away, it was tried to remove the pilot by hammering with a wooden piece. In the process the pilot came out by 40 mm, but there was no further movement by this process. At this stage it was observed that for the last 20 mm there was a Black powdered soot type material deposited on the inside surface of the bush which is the cause for jamming. The sample of this material was
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collected for further examination. The photographs are attached along with this report. The problem was discussed telephonically with BHEL Hardwar and it was decided to apply force with a jack. A 40 MT jack was used for this purpose. The pilot came out by another 20 mm after applying this force and then a change of arrangement was needed to take it out further. After changing of the arrangement the pilot could not be moved any further as the force from the jacks was getting dissipated in other directions. Even after repeated attempts the pilot never came out beyond 62 mm.Then it was decided to resort to somewhat heavy hammering. Initially 5 hammer blows were given and the progress was measured by a vernier.It was observed that the pilot has moved by another 4 mm. So this process was continued till the pilot came out totally. During this process intermediate progress was being checked with a vernier. All this while, the black material kept coming out of the periphery of Bush. After removal of the pilot it was checked for damages and scoring marks and none were found on either the Pilot or Bush. The pilot and bush were then cleaned thoroughly and assembled together. The free movement of the pilot was ensured. The liner was assembled inside the servomotor. During assembly of the liner, the defective o rings were replaced with locally made rings, as there was no spare available (3 numbers -rings of 170X5.5mm were damaged during liner removal). After assembling the servomotor, control fluid lines were charged and the operation of the servomotor was checked. The servomotor was coupled with the valve and was checked for operation. Unit was started on 28/12/09 and is running without problem.

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Conclusion and suggestions: The black material was causing for jamming of the main pilot valve. As it was reported for sluggish operation since commissioning, this could have accumulated over a period. The samples of the material needs to be examined thoroughly for ascertaining the source of the material. It is suggested that sufficient care should be taken at works to ensure that no foreign material enters in between liner and pilot during its assembly. Control oil samples are to be tested for moisture and sediments regularly. Regenerative system should be kept in service continuously. Spare O ring shall be made available for servcing requirements.

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