CORRUGATED LINER REPLACEMENT

OEM HAD SUGGESTED NTPC-ANTA TO REPLACE THE CORRUGATED LINER OF NIMONIC 300 AFTER 60000 VOH AT ONE OF THE STATIONS. THE OPERATION MANUAL INDICATED THE LIFE TIME OF HOT PATH COMPONENTS ON EOH BASIS WHICH DEPENDS ON TIT AND PEAK LOAD HOURS OPERATION WHEREAS VOH DEPENDS ON THE OPERATING HOURS PLUS A FACTOR OF 20 FOR EACH SUCCESSFUL START. NTPC MACHINES HAD CLOCKED ONLY 45000 EOH FOR 60000 VOH. SO NTPC DECIDED TO RUN THESE MACHINES & ADOPTED STRATEGY OF MONITORING THE MATERIAL CONDITION OF THESE LINERS IN EACH MINOR INSPECTION WHICH REVEALED THAT THE MATERIAL WAS BETTER ( BETWEEN LEVEL 2 & 3) WHICH WAS BELOW EVEN TO THE CAUTION LIMIT OF LEVEL 4. NTPC DECIDED TO RUN THESE LINERS UPTO 1 LAC VOH & THEN REPLACE THESE. NTPC ALSO ENSURED THAT THE AVAILABLE THICKNESS OF THESE LINERS WAS ABOVE 50% OF ORIGINAL THICKNESS. THIS HAD REDUCED THE COST BY 1.5 CRORES/GT

GAS TURBINE ROTOR OF M/S ABB GTs

THE GAS TURBINE ROTOR OF 13 D2 ABB MACHINES HAVE WELDED ROTOR CONSTRUCTION. COMPRESSOR AND TURBINE DISCS ARE WELDED, FURTHER THE TURBINE & COMPRESSOR ROTORS ARE WELDED. THE OEM HAD INDICATED THAT THE TURBINE ROTOR IS TO BE INSPECTED AFTER 80000 VOH. SINCE THE EOH WAS 25% LESS THAN VOH DUE TO OPERATION AT LOW TIT AND NO PEAK RUNNING, NTPC DECIDED TO FURTHER RUN THESE ROTORS UPTO 1 LAC VOH INSPITE OF OEMS RECOMMENDATIONS OF 80000 VOH. A USED SPARE ROTOR AVAILABLE AT SITE HAS BEEN SENT TO ABB WORKS FOR REFURBISHMENT / REPAIR OF TURBINE PORTION. THE ROTORS ARE BEING WITHDRAWN AFTER ONE LAKH VOH.

BLADES OPERATION BEYOND COATING LIFE

IN ONE OF THE GAS TURBINES, THE REFURBISHED AND RECOATED SET OF BLADES OF STAGE I WERE FALLING SHORT BY 6 NOS AND THE MANUFACTURER WAS REQUESTED TO EXPEDITE THE SUPPLY. SINCE THERE WAS DELAY IN THE SUPPLY FROM SUPPLIER AND GRID DEMAND WAS HEAVY, NTPC DECIDED TO CARRY OUT THE IN-HOUSE MATERIAL AND DEFECT TESTING AND INSTALL 6 NOS OF USED BLADES IN GAS TURBINES. THESE BLADES WERE ABLE TO SATISFACTORILY RUN UPTO NEXT OVERHAUL.

PART REPLACEMENT OF BLADES

IT HAS BEEN THE USUAL PRACTICE OF OEMs TO REPLACE COMPLETE SET OF BLADES WHENEVER A DEFECT OR DAMAGE IN BLADES WERE NOTICED EVEN IN FEW BLADES. THIS WAS RESULTING HIGHER COST OF REFURBISHMENT AND TRANSPORT. NTPC STARTED PART REPLACEMENT OF BLADES IN THEIR MACHINES AND ADOPT THE TRIM BALANCING METHOD TO OVERCOME ANY UNBALANCE IF NOTICED. IN MAJORITY THE MACHINE OPERATED SATISFACTORY WHILE ADOPTING THIS, IT IS NECESSARY TO KEEP THE OPERATING HOURS AND INSPECTION RECORDS OF EACH BLADE TO ENSURE THAT RELIABILITY BETWEEN TWO INSPECTIONS.

MIXING CHAMBER OF SIEMENS V 94.2

THE MIXING CHAMBERS OF V 94.2 GAS TURBINE WERE FOUND TO HAVE CRACKS NEAR COLLAR AND FRETTING MARKS ON COLLARS. OEM HAD INDICATED TO USE THESE AFTER CARRYING OUT THE SOLUTION HEAT TREATMENT. THE STUDY CONDUCTED BY NTPC INDICATED THAT THESE CHAMBERS CAN RUN ANOTHER CYCLE OF OPERATION. THE REPAIR WAS CARRIED OUT BY REMOVING THE CRACKED PORTION AND INSTALLATION OF NEW COLLARS. THESE CHAMBERS ARE NOW PERFORMING SATISFACTORILY

DEVELOPMENT OF INDIGENOUS EXPERIENCE

1)

COMPRESOR BLADE COATING AT HAL, BANGLORE.

REPAIR OF UNCOATED VANES & BLADES. REPAIR OF COMBUSTION LINERS, TRANSITION PIECES & FUEL NOZZLES.

2)

3)

4)

REPAIR OF HOT GAS CASING AT GUJRAT PERFECT ENGG.

WORKS IN BARODA.
5)

REPAIR OF HEAT SHIELD SEGMENTS.

DEVELOPMENT OF INHOUSE EXPERTISE

REBLADING OF TURBINE (ANGPP / AUGPP)

&

COMPRESSOR

ROTOR

REPAIR OF MIXING CHAMBER ( DADRI)

FUEL NOZZLE REPAIRS ( DADRI)

CORRUGATED LINER REPAIRS REPAIRS OF TILE HOOK CARRIER (ANGPP) REPAIR AND MODIFICATION OF AIR INLET SCREEN (KyGPP)

UPGRADATION OF MATERIAL / DESIGN

1)

MHI
-TURBINE BLADE ROW#1 UDIMET- 520 TO INCO 738 LC -TURBINE VANE ROW#1 2 CAVITIES COOLING(NO COATING) TO 3 CAVITIES COOLING(CoNiCrAlY = TBC COATING) THIS HAS INCREASED THE LIFE FROM 37,500 / 30,000(RESP) TO 50,000 EOH

2)

GE
IMPROVEMENT OF COMPRESSOR SEAL FROM LABYRINTH TO CUTTER TEETH( AT KAYAMKULAM) HAS NOW BEEN REPLACED TO BRUSH SEAL WHICH AS IMPROVED THE EFFICIENCY BY 0.6% AND 1% INCREASE IN OUTPUT. -TURBINE NOZZLE STAGE#2 FSX-414 TO GTD-222(ALUMIDE COATED) TURBINE NOZZLE STAGE#3 FSX-414 TO GTD-222 GTD-222 IS A NICKEL BASED SUPERALLOY WITH SUPERIOR CREEP RESISTANCE

UPGRADATION OF MATERIAL / DESIGN

2)

GE
-TURBINE BUCKET STAGE#2 IN-738(UNCOATED) TO GTD-111(GT29 IN-PLUS COATED) GTD-111 HAS 35 DEG F IMPROVED RUPTURE STRENGTH , GOOD CORROSION RESISTANCE & SUPERIOR LOW CYCLE FATIGUE TURBINE BUCKET STAGE STAGE#3 U-500 TO IN-738 IN-738 HAS SUPERIOR HOT CORROSION RESISTANCE AND BETTER STRENGTH AT HIGH UPRATE TEMPERATURE

SHROUDS THE SHROUD HAVING THE FACILITY OF EASY RECLAMATION

IMPROVEMENT IN O&M PRACTICES

A) B)

IMPROVEMENT OVER THESE SCHEDULE ADHERE TO INSPECTION SCHEDULE

JGGPP 13E1
MODIFICATION OF BLADE TIPS HAS BROUGHT OUT RESULTS INCREASE OF MINOR INSPECTION TO 5000 EOH MAJOR OVERHAUL TO 20000 EOH

FARIDABAD - V94.2

MAJOR OVERHAUL HAS INCREASED TO 33000 EOH

KAWAS - Fr 9E

OPERATION OF GTs ON LIQUID FUEL REDUCTION OF EOH IN LIQUID FUEL FIRING UPTO 10% WITH H2 FACTOR REDUCED FROM 1.5 TO 1.3