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INCIDENCE REPORT

Occurrence Date: 18.07.2011 Incidence:

DOCUMENT NO: TPCL/IMS/MMD/RCM/08

TATA POWER
Time: 05:30 pm

Failure of Voith lube oil pump of ID fan#3A


Brief description of incident: An alarm LUB OIL PRESSURE LOW of Voith coupling of ID fan#3A was observed in control room on18.07.11 in B Shift. The same was inspected and abnormal sound from Voith coupling was reported. Initial observation indicated that the abnormal sound was being generated from Voith Coupling but later on it was observed that the lube oil pressure was also showing zero. Immediate Action taken: Since the oil pressure was showing zero, the control room was immediately informed to stop the ID fan#3A.Immediate information was conveyed to TISCO (LDC) through Operation Department seeking their clearance for Fan shut-down on 18.07.11.Man power was arranged near the Fan for constant monitoring of the sound and Fan running condition till Fan shut-down was taken. Corrective Action taken: The Fan Shut down was taken on 18.07.11 for inspection and rectification after necessary clearences. After thorough inspection the following points were noted: Observations: The voith coupling was too hot The voith top cover was opened for inspection Oil was observed to be too hot. The runner assembly of voith coupling was hot A play was observed in lube oil pump shaft

The runner of the Voith coupling along with new lube oil pump was replaced and finally the fan was made available on 19.07.2011 Analysis: As lube oil pressure was showing zero and an abnormal sound was also coming from the pump so there could be an abnormality in the voith pump itself. As the chockage of suction line and discharge line of the pump also could lead to zero discharge pressure. The same was inspected the suction and discharge line was found clean. The pressure gauge was also checked it was found ok. Now the lube oil pump was dismantled .The key and the key way of the pump spur gear was found damaged. All other parts like the plain bearings of DE and NDE side, gears were found in good condition.

Prepared By:
1.Prabhakar Kumar 2.Biswajit Dey 3.Gulshan Baral

Checked By (DH):
S.S.Chatterjee

Date of Preparation:
20.07.11

Rev :0
Page 1 of 5

INCIDENCE REPORT

DOCUMENT NO: TPCL/IMS/MMD/RCM/08

TATA POWER DECISION MATRIX


Lub Oil Press. Low

Problem in Press. Gauge

Pump not developing Press.

Press. Gauge Faulty

Press. Gauge Line Choked

Sump Oil Level Low

Problem In Oil Line

Problem In Drive Mechanism

Problem In Pump Itself

Sump level checked, found ok

Suction And Discharge Oil Line Checked With Compressed Air For Any Chockage ,Found Ok

No Evidence Of Internal & External Oil Leakage Was Found

No Problem In Drive Gear Tooth

Enlarged Key Way Found In Drive Shaft

Key Found In Sheared Condition

No Problem In Pump Internal

Material

Workmanship

Additional Mechanical Force

Visual Mark On Pastwelding Both On Key & Keyway

Proper Welding Not Done Though Possibility Of Additional Keyway Envisaged

Free Movement Of Pump Ensured

Wrong Selection Of Welding Material Or Electrode Incompatible With The Shaft Material

Prepared By:
1.Prabhakar Kumar 2.Biswajit Dey 3.Gulshan Baral

Checked By (DH):
S.S.Chatterjee

Date of Preparation:
20.07.11

Rev :0
Page 2 of 5

INCIDENCE REPORT

DOCUMENT NO: TPCL/IMS/MMD/RCM/08

TATA POWER

Damaged keyway of pump gear

Damaged keyway of pump shaft

The failure of key and key way led to relative motion between pump shaft and pump spur gear which resulted in zero discharge pressure of the pump. The close observation of key way showed the mark of welding mark. It implied that the key way was repaired in past. Because of poor bonding between the parent material and welding material it got failure at the welded position leading to failure of key way also.

Prepared By:
1.Prabhakar Kumar 2.Biswajit Dey 3.Gulshan Baral

Checked By (DH):
S.S.Chatterjee

Date of Preparation:
20.07.11

Rev :0
Page 3 of 5

INCIDENCE REPORT

DOCUMENT NO: TPCL/IMS/MMD/RCM/08

TATA POWER

Damaged key

In this condition, if the fan was kept in continuous running, there was a possibility of failure of the bearing of lube oil pump and main bearings of Voith coupling. This could have ultimately led to seizure of the voith coupling itself.

Corrective Measures : The runner and pump of the voith coupling were replaced. Fresh oil was topped up to the mark. A correction in the motor alignment was carried out. After box up, trial of the fan was conducted and found satisfactory.

Preventive Measures : To avoid repetition of the failure the following steps are taken : 1. Lub oil pumps to be thoroughly inspected during annual overhauling as well as opportunity maintenance. Recommendation:1. In case of similar failure keyway to be put in opposite side of the failed keyway. 2. OEM to be communicated about such failure and ask for any modification. Shift Personnel present during the occurrence : Shift in charge (Reporter) MMD Engineer
Vikrant Singh Biswajit Dey

MMD Technician
Suresh Kumar

Personnel present during job work out: MMD in charge MMD Engineer
S.S.Chatterjee Biswajit Dey

MMD Technician
Suresh Kr. Singh

Prepared By:
1.Prabhakar Kumar 2.Biswajit Dey 3.Gulshan Baral

Checked By (DH):
S.S.Chatterjee

Date of Preparation:
20.07.11

Rev :0
Page 4 of 5

INCIDENCE REPORT

DOCUMENT NO: TPCL/IMS/MMD/RCM/08

TATA POWER
Prabhakar Kumar Sandip Sahu

Loss of Revenue due to ID Fan Outage: Unit Potential Declared Capacity Generation Availability Availability Loss Potential Loss Average Unit Tariff W A of Regulated & Firm Sale Billing of Q1Revenue Loss MW MW % % MUs Rs/Kwh Rs. Crs 120 82.83 76.70 23.30 0.65 3.69 0.24
Consider 0.85 if calculating shortfall from Normative Availability W A of Regulated & Firm Sale Billing of Q1

Prepared By:
1.Prabhakar Kumar 2.Biswajit Dey 3.Gulshan Baral

Checked By (DH):
S.S.Chatterjee

Date of Preparation:
20.07.11

Rev :0
Page 5 of 5

INCIDENCE REPORT

DOCUMENT NO: TPCL/IMS/MMD/RCM/08

TATA POWER

Loss of Incentive due to ID Fan Outage Annual Fixed Charges (proposed in ARR) Loss in availability due to drop in pottential AFC allocated to regulated capacity Loss in Incentive due to the pottential loss Rs Crs % Rs Crs Rs Crs Rs Lakhs 94.71 0.09 47.355 0.0254 2.54

Assumptions: 1)AFC proposed to JSERC has been considered 2) Calculated only for regulated capacity 3) Assumed that Unit 3 will atleast maintain a year end availability of 85%

Prepared By:
1.Prabhakar Kumar 2.Biswajit Dey 3.Gulshan Baral

Checked By (DH):
S.S.Chatterjee

Date of Preparation:
20.07.11

Rev :0
Page 6 of 5