PS 3.6.0

PROJECT STORIES
PLANT 1. Life Assessment for Hanllim CCPP (Korea)
ASSESSMENT
1.1 Summary
1.2 Gas Turbine Part
1.3 Steam Turbine Part
1.4 HRSG, Duct, etc.
1.5 Generator
2. Sousse A Unit 2 Life Assessment (Tunisia)
2.1 Summary
2.2 Introduction
2.3 Inspection Activities
2.4 Proposed Work Scope
3. G
enerator Test & Life Assessment in
Western Sector (Saudi Arabia)
3.1 Summary
3.2 Detailed Scope of Work
Copyright by Doosan Heavy Industries & Construction Co., Ltd. All Rights Reserved.
PROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA) DOOSAN POWER SERVICES
1.1 Summary of Life Assessment for Hanllim CCPP (Korea)

Plant ∙ OEM TG: GE / HRSG: Hanjung
PROJECT OVERVIEW Information ∙ Plant Type Combined cycle power plant
PJT title ∙ Configuration 2-2-1 (GT x 2, HRSG x 2, ST x 1)
Life Assessment for Hanllim CCPP ∙ Capacity 105MW (GT: 35MW, ST: 35MW)
Client ∙ COD 1997
KOSPO (Korea Southern Power)
Contract year
Scope of ∙ Gas turbine & Steam turbine Output
2017 Supply - NDT, material/condition evaluation - Residual life
PJT period - Life assessment of rotor assessment report
10 months - Steam path audit of steam turbine - Existing facility
∙ HRSG, duct, pipe, etc. impact assessment
- NDT, material/condition evaluation report for fuel
- Life assessment of high temp. header conversion
∙ Generator
PLANT LOCATION - Electrical and mechanical test
∙ Impact assessment of fuel conversion
Jeju-do, Korea
Customer ∙ Residual life time assessment of existing power plant
Benefits ∙
Obtaining basic data in preparation for fuel conversion through detailed
diagnosis of each equipment

1) List of NDT
NDT Bore NDT Bore

Item Component Item Component
VI PT MT UT ECT Scope VI PT MT UT ECT Scope
Inlet Duct ● ● Casing ● ● ●
Inlet Plenum ● ● Exhaust Bearing Housing ● ● ●

Section Journal Bearing ● ● ●
Inlet Casing ● ●
Inlet Duct ● ●
Bearing Housing ● ●
Section
Inlet Guide Vane ● ● Compressor Wheel ● ●
Journal Bearing ● ● ● Distance Piece ● ●
Thrust Bearing ● ● ● Rotor Turbine Wheel ● ● ●
Compressor Section Spacer ● ●

Compressor ● ●
Nozzle
Section Rotor Bolt ● ●
Casing ● ● ●
Compressor Bucket ● ●
1)
Combustor Casing (CDC) ● ● ●
Accessory Gear ● ●
Section Inner CDC 2)
● ●
Load Gear ● ●
Casing ● ● ●
Turbine Load Gear Casing ● ●
Section Shroud Block
● ● Load Gear Bearing ● ● ●
Assembly Part
Coupling Spacer ● ●
1)
CDC: Compressor Discharge Casing Others
Coupling Bolt
2)
Inner CDC: Inner Compressor Discharge Casing ● ●
GEN Side
Coupling Bolt
● ● ●
TBN Side
Main Piping of GT ● ● ●
Exhaust Plenum

1) Result Summary (Main Defects & Recommendations)
6
2
7
3 1 4 5
1 Crack on the compressor 4 Cracks on the turbine casing 6 Exhaust plenum

discharge casing [ADVICE] Drilling a hole to [ADVICE]Replacement with
[ADVICE]Replacement prevent further progress or new part
(Material change) repairing the welding
2 Crack in the inlet duct at 5 Exhaust casing cracks on the 7 Internal damage of
welded part / Peeling paint welded part the exhaust duct
[ADVICE] Removing cracks [ADVICE]Existing welded part [ADVICE] Whole replacement
(repair of welding, if required) and re-welding or internal repair
/ Repainting
3
Cracks on the inlet casing
[ADVICE] Removing cracks
(repair of welding, if required)

1) List of NDT & Material Evaluation
NDT Material Evaluation

Item Location
MT UT PT VI Replica Hardness
HP 1st Stage Wheel Fillet ● ● ● ●
HP 1st & 2nd Stage Wheel Dovetail ● ● ● ●

HIP & LP Rotor/Bucket
Bucket Vane, Tenon & Cover ● ●
Bull Gear ● ●
L-0 Blade Pin, L-1,2 Notch Blade Pin ● ● ●

L-0, 1, 2 Bucket
LSB Vane ● ●
Casing ● ●
Casing
Casing Bolt ● ● ● ●
Nozzle & Diaphragm Nozzle Partition ●
Packing Inter-Stage/End Packing ●
MSCV Body ● ● ● ●
Valve
Body Seat ● ●
Bearing
Bearing Pad ● ● ●
(STG Journal & Thrust)
Main Steam Lead Pipe Lead Pipe Welding Part ● ● ● ● ●
Duct Steam Exhaust Duct ● ●


1) Result Summary (Main Defects & Recommendations)
1 Thrust BRG pad 2 HP 1st stage FOD1) fault 3 IP 1st & 2nd stage 4 Last stage DPH3) fault
babbitt fault (Polishing required) SPE2) fault (Completed repair)
(Process surfacing/ (Polishing required)
Re-babbitt)
3
8
2
1
5 7 7
1)
FOD: Foreign Object Damage
2)
SPE: Solid Particle Erosion
3)
DPH: Diaphragm
4)
BKT: Bucket
5 Turning gear tooth wear 6 MSCV body internal 7 End packing tooth wear 8 LSB BKT 4) wet erosion
(Gear replacement and crack (Tooth sharped repair
logic change required) (Repair and removal and replacement
required) required)

1) List of NDT & Material Evaluation
NDT Test Bore Material Evaluation

Item Component Remark
VI PT MT UT Scope Replica Hardness
Creep and fatigue
Header & Stub Welds ● ● ● ● ●
analysis
Manifold & Drum ● ● ● ● ● ●
Bellows ● ●
HRSG
Tube ● Tube sample test
Attemperator ● ●
Link Welds ● ● ● ● ●
Terminal & Pipe to Cast Welds ● ● ● ● ●
Branches, Tees, Y-Pieces ● ● ● ● ●
HP Piping Flange & Section Change Welds ● ● ● ● ●
Butt Welds, Bend, Drains ● ● ● ● ●
Hangers ●
Terminal & Pipe to Cast Welds ● ●
IP Piping Branches, Tees, Y-Pieces ● ●
Flange & Section Change Welds ● ●


2) Summary of Material Degradation and Creep Damage Inspection – HRSG
∙ The maximum life consumption rate is estimated to be around 50%. It is therefore recommended to conduct a re-examination within 8 to 10 years if the
current operation conditions are maintained.
Component Material Degradation 1) Creep Damage 2) Life Time Consumption Rate (%) Residual Lifetime 3) (Hr)
Drum Shell 2/3 1

HP Drum 25 176,805
Riser 2/3 1
Drum Shell 2/3 1
IP Drum 25 176,805
Riser 2/3 1
Header 4/5 1 50 58,935
HP HT SH
Tube 4 1 40 88,403
Header 4 1 40 88,403
HP IT SH
Nozzle 5 1 50 58,935
Header 2/3 1
HP EVP 25 176,805
Nozzle 2/3 1
Link Pipe 4 1
Attemperator 40 88,403
Nozzle 4 1
Upper Link Pipe-1 Pipe 4 1 40 88,403
Elbow 4 1
Upper Link Pipe-2 40 88,403
Reducer 4 1
Tee 4 1
Upper Link Pipe-3 40 88,403
Pipe 4 1
1)
Material Degradation: 1-6 Level
2)
Creep Damage: 1-5 Level
3)
Residual Lifetime: Consumption Rate = Operated Hours* / (Operated Hours + residual life time)
* 58,935 hours and 53,918 hours for the operated hours of 1st Unit and 2nd Unit, respectively based on the figures as of September 2017

3) Summary of Creep and Fatigue Life Assessment – Header
∙ The minimum of high temperature header is about 16.6 million hours based on equivalent operating hour (EOH) standard.
1. Creep Analysis 2. Fatigue Analysis
Damage, % Total Damage, % Damage, % Total Damage, %

Unit Unit
(Operation data hours) (Operating time = EOH) (Operation data hours) (Operating time = EOH)
HRSG #1 0.0016 (240 hours) 0.8 (113,056 hours) HRSG #1 0.043 (240 hours) 20.3 (113,056 hours)
HRSG #2 0.004 (240 hours) 1 .8 (106,157 hours) HRSG #2 0.051 (240 hours) 22.6 (106,157 hours)
3. Creep and Fatigue Interaction Analysis
Item HRSG #1 HRSG #2
Total lifetime 416,046 hours (100.0 %) 272,316 hours (100.0 %)

Consumed lifetime 113,056 hours (27.2 %) 106,157 hours (39.0 %)
EOH basis 302,990 hours (72.8 %) 166,159 hours (61.0 %)
Residual lifetime
Keep lasting current operational condition 153,889 hours 86,618 hours

4) Test Result of the Superheater Tube Sample
∙ The sample test of HP HT SH tube has enabled it to maintain sufficient strength. According to the test, material deterioration recorded grade D,
which is the intermediate level, and creep damage stood at level 1.
Tube Sampling Micro Structure
1st Unit (Hardness: Average of 145Hv)
Tension Characteristics
Tensile Strength Yield Strength Elongation Rate

Description
(Mpa) (Mpa) (%)
ASME Code Min. 415 Min. 205 Min. 30

Specimen-1 492 240 29
1st Unit
Specimen-2 494 235 29
Specimen-1 478 238 30 2nd Unit (Hardness: Average of 152Hv)
2nd Unit
Specimen-2 494 257 30
1.5 Generator
1) Summary of Results: Electrical and Mechanical Test
Item Test GT#1 GT#2 ST Min. Requirement Remark
Insulation Resistance Pass Pass Pass Min. 1GΩ

C Phase
Polarization Index Pass Pass Min. 2 Restore after cleaning and drying
Fail
Partial Discharge Test Pass Pass Pass 10,000 pC below
Temp.: Room Temp. ±5℃
Instrumentation Test —
Pass Pass Pass Residual deviation Remaining RTD sensor
RTD Sensor Check
Stator (between sensors): 0.8Ω
7 Each 45 Each 31 Each
Wedge Tightness Test Min. 550 Leeb #GT: 60 each and #ST 20 each replace
Fail Fail Fail
EL-CID Test Pass Pass Pass Max. /100 /mA
Max. 2,200 mm/S2/N
Block and binder reinforcement
Bump Test Pass Pass Fail (Series Loop direction)
completed
Others, Max. 4,400mm/S2/N
Insulation Resistance Pass Pass Pass Min. 25MΩ
Rotor Polarization Index Pass Fail Pass Min. 1.1 Restore after partial re-insulation
RSO Test Fail Pass Pass Waveform Match Restore after whole re-insulation
PROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA) DOOSAN POWER SERVICES
2.1 Summary of Sousse A Unit 2 Life Assessment (Tunisia)

Plant ∙ OEM BLR: SGP / STG: KWU_Siemens
PROJECT OVERVIEW Information ∙ Plant Type Oil or gas-fired
PJT title ∙ Capacity 160MW x 2
Sousse A Unit 2 Life Assessment ∙ COD 1980
Client
STEG
Customer ∙
Safety of urgent power generation
Site inspection period Needs ∙
Stable and economical operations
2 weeks ∙
Continuous technical support
Execution year
September, 2017
Scope of ∙
Pre-study by using existing information Output
Supply on operations and maintenance - Test & inspection
∙
Site survey and interview report
- Check site status - Indicative proposal
- Interview with operators and for plant life
PLANT LOCATION maintenance engineers extension
Sousse, Tunisia ∙
Detailed site inspection for all
components in the power plant #2
- Visual inspection
- NDT and replication
- Review of all information, data and
manuals
Customer ∙ Checking life assessment of existing equipment
Benefits ∙ Checking the budget for life assessment projects

2.2 Introduction
∙ With consideration on equipment conditions, Doosan’s proposal focuses on providing solutions to generate electricity
as soon as possible with following key values.
Customer’s Needs Doosan’s Value Proposal
Urgent power generation and ∙ Major overhaul which enables the production of electricity within a year
operational safety ∙ Replacement of aged critical items to achieve safe operations
Optimized target ∙ Optimization of the recovery target in consideration of current equipment conditions
∙ Optimal target: 80-85% of rated output
Economic benefit ∙ Reasonable and affordable price by engineering optimization to maximize

re-use of current equipment
- Unit #1 used as a spare part for unit #2 refurbishment
Continuous technical support ∙ Long-term service agreement (LTSA) for the future operation period
- Technical Advisor (TA) support
- Spare part supply for critical items
2.3 Inspection Activities

∙ Detailed site inspection was conducted for Sousse Unit #2 through close cooperation
between Doosan and STEG for two weeks.
Items Doosan STEG
Wall Tube VI / Replication VI / NDT

S/H Tube & Header VI / Replication VI / NDT
Boiler R/H Tube & Header VI / Replication VI / NDT
Eco. Tube & Header VI / Replication VI / NDT
FD FAN / Duct VI VI
Main Steam VI / Replication VI / NDT
Piping Hot Reheat VI / Replication VI / NDT
Feedwater VI / Replication VI / NDT
Turbine & Aux. System VI VI
Generator VI Megger Test
Condensate System VI VI
Feedwater System VI VI
Cooling Water System VI VI
Fuel Supply System VI VI
Transforme Megger Test (LV) Megger Test (HV)
Main Cable Megger Test VI
Electrical
Motor Megger Test (MV) Megger Test (MV)
System
Circuit Breaker Megger Test (MV) VI
IPB & GCB Megger Test VI
C&I VI VI
* VI for Visual Inspection; NDT for Non-destructive Test (MT, UTT, HT); and MV for Medium Voltage

1) Summary of Proposed Work Scope for Refurbishment
Items Scope
• Wall Tube: Replacement

• SH, RH Outlet HDR, Tube: Replacement
Boiler • Gas Recirculation Fan: Replacement
• GR Damper: Bearing and actuator replacement
• Air Preheat System: Replacement of the seal system
• Main & Reheat Steam Piping: Partial replacement or repair

Critical Piping • Feedwater Piping: Repair
• Hanger & Support: Partial replacement or repair
• Major Overhaul (including detailed NDT test)

Turbine • Main Valve (high pressure turbine): Complete repair
• TCS upgrade to a new system
• Major Overhaul (including NDT test)

Generator • Stator: Rewinding
• Rotor: Re-insulation (optional)
Electrical • Battery System: Replacement (DC220V 240 EA)
• MP Bypass Valve: Replacement

• LP Feedwater Heater: Replacement (#2, #3)
BOP • Air Ejector: Replacement
• CCW: Replacement of the cooler and booster pump
• Major Overhaul: Condenser, HP heater, safety valve, main pump, cooler, etc.
• Burner Management System (BMS): Replacement

C&I • Field Instrument: Partial Replacement
• C&I Cable: Partial Replacement

2) Boiler Part
(A) Drum (J) Air Duct

⋅ Replacement of the level gauge and safety ⋅ Partial repair of the casing B A
system ⋅ Overhaul for the driving part of the C
(B) Soot Blower
damper
⋅ Reuse of the expansion joint
⋅ Demolition or blinding
(K) Gas Duct
(C) HDR and Heating Surface
⋅ Partial repair of the casing
⋅ Replacement of the SH, RH outlet HDR and F
⋅ Overhaul for the driving part of the
tube
damper
(D) HFO/Gas System ⋅ Reuse of the expansion joint D E
⋅ Demolition or physical isolation

(E) Furnace Wall
⋅ Replacement of the wall tube
(F) Gas Recirculation System
⋅ Replacement of the fan
⋅ Replacement of the bearing and actuator
for the damper
(G) FD Fans System
G G
⋅ Retrofit for the FD fan (F) Gas Recirculation System
⋅ Replacement of the actuator
I
(I) Air Preheat System
⋅ Replacement of the seal system H
⋅ Retrofit for the driving shaft cooling
system
J
⋅ Replacement of the inspection wind
(I) Air Preheat System


3) Critical Piping
DESCRIPTION
∙ Define the condition of BOP piping, alloy piping in particular, such as main steam
and hot reheat system based on non-destructive test (NDT)
NDT Point #1: Completed

- Magnetic Test: No cracks were found
- Thickness Test: No cracks were found
- Hardness Test: No cracks were found
NDT Point #2: Completed

-A
ccording to the results of NDT on point #2, NDT points #3 to #8 will be tested
additionally.
CONCLUSION
∙ The material and welding point will be considered as in good condition if there is
no crack according to the NDT report on point #1 and #2.
∙ If there are some cracks found according to the NDT report on point #2, NDT point
#3-#8 shall be tested in order.
∙ If there is no problem according to the NDT reports on point #3 to #8, cutting and
replacing part on point #2 needs to be treated while other parts are considered as
in good condition.
∙ If there are cracks on welding point #3-#8 without a raw material problem, Doosan
will supply alloy piping for partial replacement.
∙ NDT, including bore-scope test, should be carried out at one point for cold reheat,
feed water and feed extraction piping.
∙ Small bore piping in the supply scope should be all replaced due to corrosion.
PROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA) DOOSAN POWER SERVICES
3.1 Summary of Generator Test & Life Assessment in

Western Sector (Saudi Arabia)
Plant ∙ OEM GE, ABB, Alstom, Brush
PROJECT OVERVIEW Information ∙ Plant Type Oil or gas-fired
PJT title ∙ Capacity 23-188MVA
Generator Test & Life Assessment in ∙ Subject Unit 96 units in total
Western Sector
∙ COD 1976-2002
Client
∙ Cooling Type Air or hydrogen
SEC (Saudi Electricity Company)
Contract year
2017 Scope of ∙
Test & inspection, diagnostic & life Output
Supply assessment for stators, rotors and - Test & inspection
PJT period exciters report
4 years ∙
Submission of life expectancy analysis - Life expectancy
program (LEAP) reports analysis program
∙ Inspection and reporting schedule (LEAP) report
PLANT LOCATION
- Preparation: 15 days
Jeddah, Makkah, Rabigh, Tabouk, - Test & inspection: 15 days
Madinah, Yanbu, Duba, Taif and - Final report submittal: 15 days
Alwajh in Saudi Arabia
Customer ∙ Preventing failure through the inspection and assessment in advance
Benefits ∙ Securing a stable operation and maintenance of generators


1) Subject Generator Specification
Generators of GE and Other Similar Manufacturers Generators of ABB Manufacturers
Generator Type/ Rated Available Generator type / Rated Available

No. Location No. Location
Serial Number MVA MW Serial Number MVA MW
01 GE ATB 23.0 18.0 Alwadj 01 ABB WY18L-066-LLT 108.5 51.7 PP3 Jeddah
02 GE ATB 29.6 16.0 Alwadj 02 ABB WY18L-066-LLT 108.5 46.3/48.5 Makkah
03 GE ATB 37.7 17.1 PP1 Tabouk 03 ABB WY18L-066-LLT 108.5 50.0 PP2 Madinah
04 GE ATB 29.6 16.8 PP1 Tabouk 04 ABB WY18L-066-LLT 108.5 54.7 Rabigh PP
05 GE ATB 29.6 18.0 Yanbu PP 05 ABB WY18L-059-LLT 98.0 54.7 Rabigh PP
06 Rode Knocar (S1726) 32.0 15.9 Taif PP 06 ABB WY18L-050-LLT 40.5 18.0 Makkah
07 AlstomKT174-160 22.6 18.0 Duba 07 ABB WY18L-050-LLT 40.5 18.0 PP1 Madinah
08 Brush BD AX7.145 PRH 23.9 18.0 Duba 08 ABB WY14L-061-LLT 46.6 22.0 Makkah
09 GE 6Az 40.8 27.0 PP2 Tabouk 09 ABB WY14L-061-LLT 46.6 20.0 PP2 Madinah
10 GE PW70000 67.5 44.6 PP3 Jeddah 10 ABB WY16L-044-LLT 57.9 203 Taif PP
11 GE7A3 73.1 44.6 PP3 Jeddah 11 ABB WY14L-061-LLT 46.6 19.5 Taif PP
12 GE7A3 78.1 40.0 Makkah 12 ABB WY16L-068 82.5 31.2 PP2 Tabouk
13 GE7A4 98.7 53.2 Makkah 13 ABB WX21L-071-LLT 166.2 133.0 Rabigh PP
14 GE7A6 107.5 61.6 Rabigh PP
15 GE7A6 88.7 57.0 PP2 Tabouk
16 GE7A6 84.5 60.1 PP2 Tabouk
17 GE7A6 108.8 56.4 PP2 Madinah
18 GE7FH2 188.0 145.5 Rabigh PP

2) Stator Assessment
∙ To find the damage or defect of stator winding resulting from long operating hours at high temperature and high speed
Insulation Tests
∙ Insulation resistance and polarization index test

∙ High potential test
∙ Partial discharge test
∙ End winding bump test
∙ El-CID test
EL-CID Test Hi-Pot Test Bump Test PI Test
V1 V2
Terminal Box
DIGITAL EL CID MODEL 601
◁ ◁
Chattock Coil
Reset zero cal.X cal.Y Reset Y phase Battery D.C External
Reference INPUT 1
Distance Signal Calibration Low Fuse Power

Computer AUX
Pulse X POWER
Analogue
(Recorder)
SIGNAL INPUT 2
Y INPUT X INPUT OUTPUTS
Trolley Laptop Computer


3) Rotor Assessment
∙ To find the damage or defect of rotor winding resulting from long operating hours at high temperature and high speed
Insulation Tests
∙ Insulation resistance and polarization index test

∙ High potential test
∙ RSO test
RSO Test Hi-Pot Test PI Test
Generator Rotor Shorted Turn Analysis
Nomal Inner
120 VAC
0.05A
Test Simulator Outer
Ground Wire Collector Rings


4.1) Condition Assessment
Conforming material radial ring
Glass roving tying Support ring

End Winding and Connection Ring
Nose ring
No. Issues & Concerns
01 White powder of connection for phase lead and cracks on epoxy painting area
02 White powder of series loop and end arm

Teflon hose
03 Looseness of block and tying
04 Protrude of pin or block
05 Contamination of oil, dust and others Axial support
06 Insulation damage
07 Relative movement between ring and support Flux shield
08 Deformation and discoloration of connection ring Phase connection ring Support bracket
End Winding
Journal
01 Surface finish condition
02 Dimensional inspection
08 PT
Phase Connection Ring


Stator Core and Inside of Stator
01 Damage and deformation on the teeth of stacked core

Wedge
02 Overheating, discoloration and/or decolorizing of coating area
Core
03 Looseness of core laminations
04 Blocked space blocks
05 Protrude of core laminations including step cores
06 Rubbing between key bars and cores

Core and Wedge in the Stator
07 Condition of gas gap baffle and core baffle
08 Rust and corrosion of core
09 Gap of wedges
10 Yellow powder of wedges or fillers


High Voltage Bushing & Current Transformer
01 Check on the cleaning of insulator surface
02 Damage and discoloration of porcelain bushing
03 Condition of sealing compound
04 Gap of flange for bushing
05 Tightness condition of bolt for bushing flange and lock washer
06 Overheating of lead connection

High Voltage Bushing
07 Gasket condition of manhole cover for terminal box
Inner and Outer End Shields
01 Contact of horizontal joint
02 Leakage of H2 gas H2 seal csg

Bearing End shield
03 Injection of tight seal compound

Oil deflector
04 Painting condition H2 seal ring
Phase Connection Ring


Bearings
01 Contact between casing and rings
02 Wearing and damage of babbitt
03 Damage due to shaft current
04 Oil feed hole Bearing

05 UT and/or PT if necessary
Inner and Outer Oil Deflector
01 Clearance of rotor
02 Leakage of oil
Oil Deflector
H2 Seal with Ring
01 Wearing of babbitted ring
02 Insulation resistance between end shield and seal casing
05 Tension of spring
H2 Seal Ring

Retaining Ring with Disassembly
01 Overheating of fitting area
02 Movement of retaining ring
03 Rust and contamination
Retaining Ring
Collector Rings
01 Wearing of ring surface
02 Dimensional inspection
03 Leak for collector terminal
04 Cleanliness of insulation wrapper

Collector Rings
Fan
01 Fixing of fan blade
02 Crack on the corner
Fan

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PROJECT STORIES

PLANT 1. Life Assessment for Hanllim CCPP (Korea)

2. Sousse A Unit 2 Life Assessment (Tunisia)

1.1 Summary of Life Assessment for Hanllim CCPP (Korea)

Customer ∙ Residual life time assessment of existing power plant

1.2 Gas Turbine Part

NDT Bore NDT Bore

Inlet Duct ● ● Casing ● ● ●

Inlet Plenum ● ● Exhaust Bearing Housing ● ● ●

Journal Bearing ● ● ● Distance Piece ● ●

Thrust Bearing ● ● ● Rotor Turbine Wheel ● ● ●

Compressor Section Spacer ● ●

1.2 Gas Turbine Part

1 Crack on the compressor 4 Cracks on the turbine casing 6 Exhaust plenum

1.3 Steam Turbine Part

NDT Material Evaluation

HP 1st Stage Wheel Fillet ● ● ● ●

HP 1st & 2nd Stage Wheel Dovetail ● ● ● ●

L-0 Blade Pin, L-1,2 Notch Blade Pin ● ● ●

Nozzle & Diaphragm Nozzle Partition ●

Packing Inter-Stage/End Packing ●

Duct Steam Exhaust Duct ● ●

1.3 Steam Turbine Part

1.4 HRSG, Duct, etc.

NDT Test Bore Material Evaluation

Terminal & Pipe to Cast Welds ● ● ● ● ●

Branches, Tees, Y-Pieces ● ● ● ● ●

HP Piping Flange & Section Change Welds ● ● ● ● ●

Butt Welds, Bend, Drains ● ● ● ● ●

Terminal & Pipe to Cast Welds ● ●

IP Piping Branches, Tees, Y-Pieces ● ●

Flange & Section Change Welds ● ●

1.4 HRSG, Duct, etc.

Drum Shell 2/3 1

1.4 HRSG, Duct, etc.

1. Creep Analysis 2. Fatigue Analysis

Damage, % Total Damage, % Damage, % Total Damage, %

3. Creep and Fatigue Interaction Analysis

Item HRSG #1 HRSG #2

Total lifetime 416,046 hours (100.0 %) 272,316 hours (100.0 %)

1.4 HRSG, Duct, etc.

Tube Sampling Micro Structure

1st Unit (Hardness: Average of 145Hv)

Tensile Strength Yield Strength Elongation Rate

ASME Code Min. 415 Min. 205 Min. 30

Item Test GT#1 GT#2 ST Min. Requirement Remark

Insulation Resistance Pass Pass Pass Min. 1GΩ

Insulation Resistance Pass Pass Pass Min. 25MΩ

2.1 Summary of Sousse A Unit 2 Life Assessment (Tunisia)

Customer ∙ Checking life assessment of existing equipment

Benefits ∙ Checking the budget for life assessment projects

Customer’s Needs Doosan’s Value Proposal

Economic benefit ∙ Reasonable and affordable price by engineering optimization to maximize

2.3 Inspection Activities

Items Doosan STEG

Wall Tube VI / Replication VI / NDT

2.4 Proposed Work Scope

• Wall Tube: Replacement

• Main & Reheat Steam Piping: Partial replacement or repair

• Major Overhaul (including detailed NDT test)

• Major Overhaul (including NDT test)

Electrical • Battery System: Replacement (DC220V 240 EA)

• MP Bypass Valve: Replacement

1 Crack on the compressor 4 Cracks on the turbine casing 6 Exhaust plenum

Economic benefit ∙ Reasonable and affordable price by engineering optimization to maximize