MINUTES OF THE MEETING HELD BETWEEN M/S KPCL & M/S VOITH TURBO PVT

LTD, HYDERABAD REGARDING VIBRATION PROBLEM OF BFP#3B VOITH

HYDRAULIC COUPLING TYPE R16K.1(S/N: 913157) AT RAICHUR THERMAL
POWER STATION ON 01.02.2006 .

M/S KPCL M/S VOITH TURBO

1. Sri C.B.Yallatti, EE(TM-1) P.Srinivasa Rao

2. Sri N.R.Kulkarni, AEE(TM-1) Sr.Engineer-Services
3. Sri Vijayananda Shavi, AE( M )

1. As per the KPCL fax message dt.27.01.2006, M/s Voith service engineer reported at site on
28.01.2006 to attend the reported problem.

2. De coupled trial run of the Voith coupling taken for 5minutes, abnormal noise and heavy
vibrations noticed. It was decided to go for thorough inspection and stopped the coupling.

3. Hydraulic coupling Completely dismantled and the following observations made:

a. While dismantling the runner, it was noticed that 10nos bolts of primary shaft & primary
wheel got sheared and 2nos were found in loose condition.
b. Maximum number of holes in primary wheel and some of the threaded holes in primary
shaft enlarged and become oval-shape.
c. Babbit lining in coupling shell and secondary wheel completely worn-out/damaged.
d. 2nos- Fusible plugs blown off.
e. All the bearings found in good condition and clearances are within acceptable limits.

Bearing clearences ,all values are in mm:

Brg. 1 2 3/4 5 6 7 8/9 10
Nos.
Design 0.17- 0.17- 0.2- 0.16- 0.16- 0.07- 0.2- 0.08-
value 0.23 0.23 0.33 0.23 0.23 0.12 0.31 0.13
Measure 0.21 0.21 0.25 0.19 0.2 0.12 0.2 0.11
d value

4. By considering the above failure i.e., shearing of bolts and followed by enlarged holes both in
primary shaft and primary wheel & worn out of babbit linings , M/s Voith engineer
recommended not to use the same, as above parts assembly may create abnormalities like
unbalance , vibrations and further damage to the complete coupling and requested M/s KPCL
to arrange spare set of gear stage for smooth running of the coupling.

5. Due to non-availability of new gear stage at KPCL, Considering the high cost involved and
long delivery period (10 months) of gear stage and considering the unit generation/urgency,
in order to have standby BFP, M/s KPCL requested M/s Voith Engineer to assemble the
coupling with same components and assembling carried out accordingly with new available
S.H.Screws ( M16x50-12nos) after weight balancing along with new fusible plugs.
 -2 -

6. De coupled Trial run of the Voith coupling taken for 30 minutes, found all the parameters &
vibration levels normal , given below.

(displacement in microns/velocity in mm per sec)

V H A
Motor NDE 6/1 8/1.4 7/1.7
Motor DE 7.7/2 6.5/1.5 5/1
Hy.Coupling input 8/2.4 18/5 7.6/3.3
At ¾ bearing 4.3/2.2 17/4.9 15/4
Hy.Coupling output 4.8/2.1 21/6.2 13.5/5

Load trial run could not be taken as the balance alignment under progress. M/s KPCL will
take the same & inform to Voith accordingly.

7. M/s Voith engineer informed that, from the above parameters coupling found normal, but in
long run the shearing of bolts and enlarged holes both in primary shaft and primary wheel &
worn out of babbit lining may create abnormalities, recommended M/s KPCL not to run the
particular BFP drive for a long period and requested to keep emergency standby to avoid any
further damage to complete Voith coupling.

8. M/s Voith engineer recommended to procure the following gear stage at the earliest to
change in above coupling for smooth and reliable running of the same.

a. Input shaft with herring bone gears- complete balancing set.

b. Primary shaft with pinion along with primary wheel and coupling shell- complete
balancing set.
c. Secondary shaft with secondary wheel- complete balancing set.

M/s KPCL requested M/s Voith to submit the budgetary offer for the above spares with
minimum delivery period.

9. M/s Voith engineer also recommended to go for inspection / Overhauling of all Voith
couplings in stage-1 (unit # 1,2&3) in regular intervals .

C.B.Yallatti, EE(TM-1) P.Srinivasa Rao, Sr.Engineer-Service.

N.R.Kulkarni, AEE(TM-1)

Vijayananda Shavi, AE( M )

 Sub: Attending to the problem of abnormal sound and high
vibrations in hydraulic coupling of BFP-3B.

Ref:- 1)CE(O&M)/RTPS/R4TM-1/3971 dtd 24-01-2006

2) Fax Offer of M/s Voith dated 24.01.2006 and offer
No. SMQS-06-014 dtd 25-01-2006
3) CE(O&M)/RTPS/R4TM-1/3989 dtd 27-01-2006

-o0o-

Abnormal humming sound and high vibrations were noticed in hydraulic coupling of Boiler
feed pump – 3B. The pump was stopped and Service Engineer of M/s Voith was called to attend the
defect.

The service engineer reported at RTPS on 28-01-2006. The hydraulic coupling was
dismantled for inspection. Ten nos. of bolts of primary shaft & primary wheel were found sheared
and Two nos. in loose condition. Two nos. of fusible plugs were found blown off. However all the
bearings were found in good condition and clearances within acceptable limits.

The service engineer recommended for replacement of complete Gear stage. However, due
to non-availability of spare gear stage and considering the high cost of about Rs. Fifty lakhs , in
order to have standby BFP the hydraulic coupling was assembled with new bolts after weight
balancing and new fusible plugs. Trial operation of the hydraulic coupling was taken on 01/02/2006
and found satisfactory.

In this connection, the firm has submitted the invoice for Rs. 58,253.30 ( Rupees Fifty eight
thousand two hundred fifty three and paise thirty only) towards the service charges as detailed
below.

1. Service charges at Rs 4900/- per day : 46550.00

2. Service tax @ 10.2% : 4748.10
3. Travel expenses and accommodation : 6955.20
TOTAL 58253.30
____________________________________________________________________________________

The claim made by the firm is in order. Your kindself is requested to accord approval and
place a regularising job order on the firm to process the invoice.

EETM-1

Encl: Copies of the invoices of the firm in original.

 To: SEMM-3/CE(O&M) No. EETM-1/
Date: 10.02.2006

From: EETM-1
Our Ref: Your Ref: Receiving Office Seal
Date: Date:
Brief Note and
instructions of receiving
Sub: Attending to the problem of abnormal sound and high officer.
vibrations in hydraulic coupling of BFP-3B.

Ref:- 1)CE(O&M)/RTPS/R4TM-1/3971 dtd 24-01-2006

2) Fax Offer of M/s Voith dated 24.01.2006 and offer
No. SMQS-06-014 dtd 25-01-2006
3) CE(O&M)/RTPS/R4TM-1/3989 dtd 27-01-2006

Abnormal humming sound and high vibrations were noticed in

hydraulic coupling of Boiler feed pump – 3B. The pump was stopped and
Service Engineer of M/s Voith was called to attend the defect.

The service engineer reported at RTPS on 28-01-2006. The hydraulic

coupling was dismantled for inspection. Ten nos. of bolts of primary shaft &
primary wheel were found sheared and Two nos. in loose condition. Two
nos. of fusible plugs were found blown off. However all the bearings were
found in good condition and clearances within acceptable limits.

The service engineer recommended for replacement of complete

Gear stage. However, due to non-availability of spare gear stage and
considering the high cost of about Rs. Fifty lakhs , in order to have standby
BFP the hydraulic coupling was assembled with new bolts after weight
balancing and new fusible plugs. Trial operation of the hydraulic coupling
was taken on 01/02/2006 and found satisfactory.

In this connection, the firm has submitted the invoice for Rs.
58,253.30 ( Rupees Fifty eight thousand two hundred fifty three and paise
thirty only) towards the service charges as detailed below.

1. Service charges at Rs 4900/- per day : 46550.00

2. Service tax @ 10.2% : 4748.10
3. Travel expenses and accommodation : 6955.20
TOTAL 58253.30
_________________________________________________________________
The claim made by the firm is in order. Your kindself is requested to
accord approval and place a regularising job order on the firm to process
the invoice.

EETM-1
Encl: Copies of the invoices of the firm in original.
Encl: Copies of the invoices of the firm in original.