Beruflich Dokumente
Kultur Dokumente
Upgrades and
Maintenance
Presented by:
Daniel Sculley, Manager APP Site Visit
Turbine, Generator & Piping October 30 – November 4, 2006
Systems Engineering
Topics
• Turbine Blading & Steam Path Upgrades
• Turbine Stop / Control Valve Upgrades
• Turbine Control System Modernization
• Generator Improvements
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Steam Path Improvements
• More than 20 units in plan for upgrade
• Efficiency gain
– Aerodynamic blade profiles
– Improved inter-stage sealing
– Reduction of sidewall secondary flow losses
• Reduction in future O&M costs
– Extend time between overhauls
– Reduction of solid particle erosion damage
– Less coal burned
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Glen Lyn 6 Series 235MW (GE) HP/IP
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Glen Lyn 6 Series 235MW (GE) HP/IP
Results
Restored CV chest with improved girth weld
Improved HP efficiency by 1.5% - 2.0%
2.5 MW and 35.28 kcal/kWh (140 Btu/kWh) gain
Erosion minimized, reduced repairs
Extended inspection intervals to 10-11 years
Re-inspections begun in 2001 confirm benefit
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1300 MW Series (Alstom) HP
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Effect of Advanced Design Steam Path
MR#5
82
BS #2
ADSP
80 Original Design
Normal Overhaul
78 ML#2
BS#2
76 CD#1
MR#5
74 BS #2
0 2 4 6 8 10 12
Time (Years)
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Big Sandy Unit 1 HP-IP/SFLP
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Original Design Issues
Efficiency
Turn-around Curtis Stage
(Pressure Loss) (Poor Efficiency)
Monoblock
No Bore Rotor 3-D Reaction Blades
Rateau control stage (ISB)
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New IP/LP Section Design
25in ISB ACC Packing Separately-Supported
(Active Clearance Control) Blade Rings
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Big Sandy Unit 1 Expectations
Anticipated Results
– Improved reliability and design efficiency
– HP efficiency +4.1% to 88.9%
– IP efficiency +3.1% to 94.6%
– Expect +18 MW at original design steam flow
– Includes replacement throttle/governor valves
– Installed cost $18Million (US), approx.
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LP Turbine Performance Retrofits
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LP Turbine Performance Retrofits
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Stop/Control Valve Upgrades
• Material Damage
– Thermal fatigue, creep
• Reliability
– Tight shutoff, leaks
• Maintenance
– Weld repair to valve
body, seats, bolt holes
• Design Improvement
– Improve O&M 1300MW SVCV Upgrade
– Reduce pressure drop
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1300 MW Series SV/CV Upgrades
• Original Design
– Pressure drop across
combined valves = 5.1%
– Limited steam flow at VWO
+ 5% overpressure
– Significant solid particle
erosion damage
– Expensive repairs
performed every 2-3 years
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1300 MW Series SV/CV Upgrades
• New Design
– Separate stop and control
valve chambers
– Actual pressure drop
across valves = 2.08%
– Achieved 32 MW increased
generation capability
without changing boiler
conditions
– Updating valve actuators to
digital controls
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Turbine Control System Upgrades
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Turbine Control System Upgrades
Results
Smooth, rapid rollups to synchronous speed
CV position and load ramping optimized by stress
probe
CV stroke ramped according to test throttle pressure
Improved reliability during protective device checks
Lower peak speeds reached during turbine trip
Reduction in boiler tube leaks due to “soft” trips
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Generator Rewinds
• Rewinds Offer Opportunity for Improvement
– Required for reliability and maintenance purposes
– Efficiency improvements are small added benefit
• Stator Windings
– Asphalt stator bar insulation replaced with modern epoxy-mica
insulation
– Potential for increased copper cross-section in original slots
– Improved cooling gas or water flows reduce operating
temperature and extend design life
• Stator Cores
– Inspect and test for looseness, hot spots, resonance
– Several cores replaced (full, partial)
– Reference papers available in Breakout Session
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Generator Rewinds
• Fields
– Replace retaining rings with 18Mn 18Cr material
– Improve end turn blocking design and materials
– Restore/replace copper and replace all insulation
– Optimize cooling gas flow
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Summary
• AEP has been retrofitting turbine generator equipment with
efficiency improvements for more than 15 years.
• Experience with OEM and non-OEM solutions.
• Economic benefit drives the HP and IP turbine retrofits.
• Must consider design improvement vs. restoration improvement.
• Turbine valve design could provide upgrade potential.
• Turbine control integration can produce thermal benefits.
• Reliability benefit drives the LP turbine and generator retrofits
(typically). Some small efficiency improvements are possible.
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Breakout Session
• Two Sessions on Tuesday Afternoon
• Expert Attendees
– Steve Molick – Turbine Services Manager
– Jim Michalec – Staff Engineer, Generators
– Alex Manukian – Sr. Engineer, Turbines
– Jim Cable – Sr. Engineer, Turbines, Controls
– Dan Sculley – TG&PSE Manager
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Questions
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