Beruflich Dokumente
Kultur Dokumente
Stefan Florjancic
05/03/2007
POWER SERVICE
Rotor Lifetime
Page 3
Testing Methods
Page 7
Planning
Page 11
Lifetime Extension
Page 17
Summary
Page 21
Rotor Lifetime
Considerations
Ageing
Monitoring
Planning
Lifetime Extension
Design Expected Lifetime of 120 kEOH ~40% of the fleet soon to reach 96 kEOH at next C inspection 9 units soon to reach 120 kEOH at next C inspection Forgings lead times increasing Early planning essential for optimal plant rotor retirement program
Rotor Lifetime
Risk Assessment
Ageing
Monitoring
Planning
Lifetime Extension
Rotor Lifetime
Mechanism of Limitation
Ageing
Monitoring
Planning
Lifetime Extension
Rotor Lifetime
A: Cyclic
Starts Load Driven by n of starts
B: Creep
Load Time Driven by operating time
C: Corrosion
Load Time Driven by operating time
Rotor Lifetime
Page 3
Testing Methods
Page 7
Planning
Page 11
Lifetime Extension
Page 17
Summary
Page 21
Testing Methods
Location of Interests
Ageing
Monitoring
Planning
Lifetime Extension
A1 Central & Radial Bore: LCF A2 Fir tree Blade Row 1-5: LCF A3 Turbine/Drum Transient Radii: LCF A4 Compressor Groove Rows 20 & 21: LCF A5 Compressor Groove Row 4: HCF
A5 Internal Relief Groove Radii: LCF B Fir tree Blade Row 3: Creep
Rotor Information 05/03/07 - P 7
ALSTOM 2007. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Testing Methods
Phased Array Technique
Ageing
Monitoring
Planning
Lifetime Extension
Testing Methods
Eddy Current Techniques
Ageing
Monitoring
Planning
Lifetime Extension
Testing Methods
Creep Measurement Device
Ageing
Monitoring
Planning
Lifetime Extension
Higher accuracy than off-the-shelf devices > 10 times higher accuracy Measurement accuracy: +/- 0.005 mm
Testing Methods
Alstom NDT Field Experiences
Ageing
Monitoring
Planning
Lifetime Extension
Rotor Lifetime
Page 3
Testing Methods
Page 7
Planning
Page 11
Lifetime Extension
Page 17
Summary
Page 21
Planning
Base Load and Peaking Units
Ageing
Monitoring
Planning
Lifetime Extension
Lifetime Drivers
Base Load
Main damage mechanism: Driven by: Plant specific evaluation required: Methods available: - Creep - Operating Hours - Yes - Visual Inspections - Creep Monitoring
Peaking
- LCF - Starts - Yes - Visual Inspections - Eddy Current Testing - Magnetic Particle Inspection (MPI) - Phased Array US Testing (PAT) - Design Lifetime - Assessment - NDT - Material Data
Retirement/Reconditioning criteria:
Planning
Testing Schedule
Ageing
Monitoring
Planning
Lifetime Extension
GT13E2 Fleet
General Recommendation Eddy Current & Phased Array Testing Creep Monitoring & Magnetic Particle Inspection Visual Inspection
Time C1 C2 C3 C4 C5 C6
Theoretical End of Life* * Figures may change according to Upgrade type and Operating Regime Critical Opportunity for Start of Tests
Rotor Information 05/03/07 - P 14
ALSTOM 2007. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Planning
Simulated Retirement Program for a 5 GT Plant New Reco. Reco. Reco.
Ageing
Monitoring
Planning
Lifetime Extension
Reco.
Approx. 15 months*
Approx. 15 months*
Approx. 15 months*
Approx. 15 months*
~ 5 years
End of Life
Early planning essential for optimal plant rotor retirement program with lowest risk. Early retirement and reconditioning of a rotor may result in the lowest plant maintenance costs.
* Figures may change according to raw material availability
Rotor Information 05/03/07 - P 15
ALSTOM 2007. We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Rotor Lifetime
Page 3
Testing Methods
Page 7
Planning
Page 11
Lifetime Extension
Page 17
Summary
Page 21
Lifetime Extension
Rotor Reconditioning
Ageing
Monitoring
Planning
Lifetime Extension
Rotor Reconditioning
Cutting Zone
Compressor Turbine
Lifetime Extension
Rotor Reconditioning
Ageing
Monitoring
Planning
Lifetime Extension
Rotor Reconditioning
All advanced processes established and available
Proven technology based on 50 years of experience
More than 20 GT-rotors reconditioned and in operation Throughput time approximately 15 months*
Rotor Lifetime
Page 3
Testing Methods
Page 7
Planning
Page 11
Lifetime Extension
Page 17
Summary
Page 21
Summary
Summary Rotor requires dedicated consideration
Ageing
Monitoring
Planning
Lifetime Extension
~40% of the fleet soon to reach latest monitoring start opportunity Long forging lead times Alstom offers partnership with the customer for optimal planning Latest calibrated monitoring technologies available at Alstom Detailed design integrity and critical locations known by the OEM Reconditioning processes based on 50 years of new manufacturing
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