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TATA POWER
Time: 05:30 pm
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
Suction And Discharge Oil Line Checked With Compressed Air For Any Chockage ,Found Ok
Material
Workmanship
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
TATA POWER
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
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
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
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