Appendix 6b - Technical Specifiction Major Ovehaul T20 [PDF]

Zitiervorschau

Technical Specification for the

Major Overhaul of the

Steam Turbine Generator system T20 in

2014

Final

]

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Contents

1 Objective 2 Qualification and quality management 3 Present condition of the system 3.1 Operational and maintenance history 3.2 Known conditional shortcomings

4 Scope 4.1 Turbines, gear and auxiliary systems 4.2 Generator 4.3 Deliveries and scope by others

5 Applicable standards and contractor requirements 6 Performance and operational requirements after the overhaul 7 Enclosures 8 Authorization

Pagina 2 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

1. Objective: Inspection and repair of the steam turbine generator system T20 so that it is suitable for efficient, reliable, and safe operation for the next 20 years defined by: a) A time availability >= 98 %, excluding scheduled maintenance according: • The VGB R-115 M- Richtlinie (2-1993) “Empfehlungen für die Revision von Dampfturbinen“ code for the turbine with auxiliariess. • The VGB R 167 e: Guidelines for the overhaul of Turbo Generators b) API 612: 5 years of continuous operation, and design life of 20 years. c) Compliance with the performance and operational requirements mentioned in chapter 6 of this document

Pagina 3 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

2. Qualification and Quality management The inspection and repair of the HP rotor must be executed in compliance with API 687 The maintenance policy and the scheduled overhauls is bases upon the instruction manuals and the codes: Turbine and auxiliaries: VGB-R 115 M Revision 2 1993: Empfehlungen für die Revision von Dampfturbinen. A description of this overhaul is described in this code as “Große Revision” Generator: The VGB R 167 e: Guidelines for the overhaul of Turbo Generators. A description of this overhaul is described in this code as “Main Inspection” ”

Pagina 4 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

3 Present condition of the system 3.1 Operational and maintenance history. The turbine generator T 20 has been in almost continuously in operation at high to full load after commissioning in 1992 without major overhaul. • The HP turbine casing has never been opened. • For the LP turbine an exchange of the HP guide carrier and the rotor took place in in 2002. For the history of the exchange of the LP rotors and the First guide vane carrier of the LP turbine between T 10 and T 20 see enclosure E • The generator had a major overhaul in 2002 • In March 2013 an inspection stop of the turbine and the generator was made without opening the turbine casings or removal of the generator rotor. So in 2014 the operational time is 22 years or 195.000 hours including the effect of starts and stops according VGB-R 115.M

3.2 Known conditional shortcomings HP turbine The HP turbine has never been opened before, and operates without notable vibration issues or performance shortcomings . It has considerable steam leakage at the seals of the balancing cylinder. For the analysis of this experience see enclosure F.

The inspection of March 2013 concluded the following shortcomings and recommended actions: • The control valve stems and nuts showed considerable wear. They must be replaced • The control servomotor main piston and cylinder showed unacceptable wear. They must be repaired or replaced • Leakage test of trip valve not executed, to be executed during this overhaul • Control range of the spare E/H to be calibrated. LP turbine The LP turbine operates without notable vibration issues or performance shortcomings. The inspection of March 2013 concluded the following shortcomings: • •

The LP blades were inspected by means of endoscopy in 2013. There are considerable signs of water droplet erosion in the last stage. Therefore the LP rotor must be replaced by the spare rotor. The first guide vane carrier showed unacceptable wear (washing out) during the endoscopic inspection in 2013. It must be replaced. The HP gland of the LP turbine will likely have the same defect in that case it must be replaced.

Pagina 5 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

•

The main oil pump was completely overhauled in 2010. In 2013 the driving gear set showed considerable wear patterns. Replacement is of the gear is necessary • The bearing on the gear side showed a clearance increase of 0.41 mm. The bearing must be inspected , the cause must be estimated and repair or replacement to be executed. Generator The inspection of March 2013 concluded the following shortcomings: • By means of endoscopy and electrical testing ( partial discharge, insulation value and tang delta)there are no noticeable shortcomings. • It is recommended that the rotor is inspected, the rotor retaining rings must be removed and tested for cracks. High speed balancing is necessary • Replacement of the ceramic star point insulators by resinous material .

4 Scope: Execution of all recommend actions mentioned in 3.2

4.1 Turbines, gear and auxiliary systems

Function Function Couplings

Part Coupling

Location HP turb/

Inspection VGB R 115 M

between

(Gear type)

gear of

Alignment

shafts

Pagina 6 van 40

Last Inspection 2013

2014 inspection

Code

Last inspection

Inspection

Location

Part

Function

Scope Major overhaul Turbine-Generator T 20 with auxiliaries on basis of VGB R 115 m

2014 Code VGB R 115 M

yes

2013

Manual

yes

2013

VGB R 115 M

yes

oil pump Coupling

HP turb/

VGB R 115 M

(Gear type)

gearbox

Alignment

no

Manual

yes

Coupling

Gear box/

VGB R 115 M

no

VGB R 115 M

yes

(Gear type)

generator

Alignment

no

Manual

yes

Coupling

HP turb/

VGB R 115 M

no

VGB R 115 M

yes

(Stiff)

LP turb

Alignment

no

Manual

yes

Coupling

Lp turb/

VGB R 115 M

no

VGB R 115 M

yes

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014 (Stiff)

Generator

Alignment

no

Manual

yes

Coupling

Generator/

VGB R 115 M

no

VGB R 115 M

yes

(Stiff)

Excitor

Alignment

Manual

yes

Alignment

Sliding system

HP turbine

Manual

no

Manual

yes

of bearing-

with keys

Front bearing

Manual

no

Manual

yes

Manual

no

Manual

yes

Manual

no

Manual

yes

Manual

2002

Manual

yes

Manual

2002

Manual

yes

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

pedestals

pedestal with

with casings

turbine casing HP turbine rear bearing pedestal with turbine casing LP turbine front bearing pedestal with turbine casing LP turbine rear bearing pedestal with turbine casing Generator front bearing pedestal with stator Generator rear bearing pedestal with stator

3

Rotor support

Journal bearing

(Bearings)

HP turbine front side

Thrust bearing

HP turbine front side

Journal bearing

HP turbine rear side

Journal bearing Pagina 7 van 40

gear box Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014 pinion driving side Thrust bearing

gear box

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

VGB R 115 M

2013

Manual

yes

2013

Manuals

yes

pinion

Journal bearing

gear box pinion n.d. side

Journal bearing

gear box wheel n.d. side

Thrust bearing

gear box wheel

Journal bearing

gear box wheel driving side

Journal bearings

Generator

VGB R 115 M

Casing support

Turbine casings

Keys and bolts

Manuals

no

Manuals

yes

and alignment

T. Bearing pedestals

Keys and bolts

Manuals

no

Manuals

yes

Gear casing

Keys and bolts

Manuals

no

Manuals

yes

Generator stator

Keys and bolts

Manuals

no

Manuals

yes

Generator pedestals

Keys and bolts

Manuals

no

Manuals

yes

Connection to

Turbine casings

Sliding plates

VGB R 115 M

no

Manual

yes

concrete

Bearing casings

Sliding plates

VGB R 115 M

no

Manual

yes

Gear casing

Sliding plates

VGB R 115 M

no

Manual

yes

Generator stator

Sliding plates

VGB R 115 M

no

Manual

yes

Bearing casing

Turbines (HP and LP)

All related parts

Manual

no

Manual

yes

sliding and

Generator

All related parts

Manual

no

Manual

yes

Turbines (HP and LP)

All related parts

Manual

no

Manual

yes

Turbines

Anchor bolts

Manual

no

Manual

yes

guidance system Connection of bearing casings with turbine casing Anchoring to Pagina 8 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014 concrete

Gear box

Anchor bolts

Manual

no

Manual

yes

Genarator

Anchor bolts

Manual

no

Manual

yes

Safeguarding

Trip valves

All parts

Manuals

no

Manuals

yes

steam system

Non return valves

All parts

Manuals

no

Manuals

yes

Bypass valves

All parts

Manuals

no

Manuals

yes

Steam filtration

Steam strainers

All parts

Manuals

2013

Manuals

no

Steam blocking

All extraction lines

Valves

VGB R 115 M

no

VGB R 115 M

yes

All drains

Condensomates

VGB R 115 M

yes

VGB R 115 M

yes

system Condensate drain system Turbine casings

Steam inlet

and valves High pressure

All related parts

VGB R 115 M

no

VGB R 115 M

yes

Low pressure

All related parts

VGB R 115 M

no

VGB R 115 M

yes

Hp turbine control

All related parts

VGB R 115 M

no

VGB R 115 M

yes

valve chest Alignment inner

HP turbine

All related parts

VGB R 115 M

no

VGB R 115 M

yes

casings

LP turbine

All related parts

VGB R 115 M

no

VGB R 115 M

yes

Bolt relaxation

All bolting > 300 C

HP turbine

VGB R 115 M

no

Manual

yes

Steam seals

Rotors and casing

HP turbine

VGB R 115 M

no

Manual

yes

LP turbine

VGB R 115 M

2002

Manual

yes

Rotor

HP turbine

API 687

no

API 687

yes

Rotor with blades

LP turbine

To be replaced

2002

Manual

yes

Moving blades

All blades

HP turbine

API 687

no

API 687

yes

Erosion

Stationary Blades

VGB R 115 M

2002

VGB R 115 M

yes

LP Casing

LP turbine Support bars inner casings and drain holes

VGB R 115 M

no

VGB R 115 M

yes

Tip of moving blades

HP turbine

API 687

no

API 687

yes

Brushes

HP turbine

VGB R 115 M

2013

Manual

yes

LP turbine

VGB R 115 M

2013

Manual

yes

Generator

VGB R 115 M

2013

Manual

yes

Turbine rotor

Wear of stage shrouds Grounding

Pagina 9 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Oil supply

Control

Main oil pump

HP turbine

Driving gear pump

HP turbine

Flow control

HP turbine Stems and bushings

2010

Manual

yes

2013

Manual

VGB R 115 M

2013

Manual

yes Yes Yes

VGB R 115 M

2013

Valves and seats

VGB R 115 M

2013

Renewed in 2013 To be renewed

Several parts to To be renewed HP turbine

Manual

2013

Manual

Yes Yes

Mechanical, electric

LP turbine

Calibration

hydraulic, and

Generator

Functional

no

Manual

By others

Inspection

no

Manual

yes

HP turbine

Cracks

no

Manual

yes

LP turbine

Cracks

no

no

Manual

yes

Control servo Monitoring systems

VGB R 115 M

pneumatic

Condenser

Yes

Yes

testing

Pipes Pipe plates Water chambers Support plates Flash tank

Filthiness

Damage Tightness Vacuum system

Ejector (nozzles)

Complete

heat exchangers

vacuum and

Control valves

gland steam

Gland condenser

system

Control valves Steam piping

In turbine

( Incl. 6 Bellows) Steam piping

Piping support

To and from turbine

HP turbine

Cracks

bellows

LP turbine Cross over (incl. 4 bellows)

Cracks

Steam oil and

Condition

no

Manual

yes

Condition

?

Manual

yes

Removal of oil Reconditioning or

no

Manual

yes

All piping

Cracks

water Water injection

Complete systems

Bypasses seal steam export steam

Oil tank

Oil and tank

Pagina 10 van 40

Oil console

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014 renewal Clean tank and strainers

Oil filters

Lube and control

Suction non return valves

Inspection

Oil console

Filter Elements

filters Coolers

Lube oil coolers

no

Manual

yes

2013

Manual

yes

no

VGB R 115 M

yes

no

VGB R 115 M

yes

no

Manual

yes

2013

Manual

no

inspection Oil console

Inspection on water and oil Side. Water box repair or replacement

Oil piping

Lube and control

Complete system

Visual on leakage

Oil vapor

Ventilator and

removal

separator

Gear box and

Gear box

turning gear

Couplings

Oil console

Inspection cleaning

Complete train

Turning gear

Visual

no

In addition to the above mentioned standard scope the following actions and supplies are in the scope: • Commissioning and decommissioning • Inspections and certificates according VGB R 115 M (Anlage 2), see enclosure H HP turbine: The overhaul supplier is invited to quote improved HP gland designs and power limitation solutions • Inspection and repair of the HP rotor according API 687 including high speed balancing • Replacement of the steam seals in the casings • Replacement of the HP control valve stems bushings and nuts (Supplied by AEB) • Repair of the main oil pump driving gear • Overhaul of the HP control servomotor, replacement or repair of power piston, power piston bushing and actuator, no spares available at AEB LP turbine: • Replacement of the rotor by the spare rotor (Supplied by AEB) • Repair of the steam seals in the casing Pagina 11 van 40

Final

yes

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

• Replacement of the guide vane carrier by the spare guide vane carrier (Supplied by AEB) • Replacement of the HP gland casing by a spare casing (Supplied by AEB) • Replacement of 2 block valves to the LP heater 1 (Supplied by AEB) • Replacement of 3 compensators in the LP turbine. (Compensators supplied by AEB) Couplings • Coupling between LP turbine and generator: alignment check and eventual correction, reaming of new coupling bolts (Oversize bolts to be supplied by the contractor)

4.2 Generator The requested scope and type of inspection are a ‘Main Inspection (MI)’ or so called ‘Major Inspection’ according to code VGB R 167e ‘Overhaul Recommendations for Turbo Generators’. The following inspection Schedules are to be applied : • • • •

Schedule Schedule Schedule Schedule

Taking out of Service Disassembly and Reassembly Rotor Commissioning

All measured data ‘as found’ and ‘as installed’, should be reported. Regarding ‘visual inspections’ a digital photo record is requested for each inspected subject.

The rotor must be removed and inspected, the rotor retaining rings must be removed and tested for cracks. High speed balancing is necessary The rotor must be high speed balanced according to EN 11324 (balancing of flexible rotors) class Q2,5 or equivalent.

Pagina 12 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Pagina 13 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Pagina 14 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

4.3 Deliveries / Scope by others The following items are supplied by AEB

• • Pagina 15 van 40

Set of driving gears of the main oil ump Overhauled LP-rotor Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

• • • • •

First guide vane carrier of the LP turbine Control valves, nuts, bushes and seats. Addition of a redundant electronic over speed trip system Cleaning of oil console and supply of new oil Three (3) compensators (Supplied by AEB), to be mounted in the LP turbine by the contractor

The following works are carried out under the responsibility of AEB • • • • • • • • •

Pagina 16 van 40

Removal of insulation HP-turbine Removal of insulation steam piping Dismantling and storage of steam piping Dismantling and storage of control & shut-off valves Re-installation of piping and valves Removal and installation of the insulation of the HP and LP turbine Cleaning of condenser, inspection of pipes, pipe plates, pipe support plates water cambers, flash tank Correction of the cross over piping and bellow alignment Replacement of the star point insulators

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

5 Applicable standards and contractor requirements General In general the requirements as mentioned in this document and in this section in particular apply fully. In case Contractor does not meet the requirements or does not comply with rules as mentioned, any costs occurred by this non-compliance shall be for Contractor’s account and cannot be claimed by AEB. Applicable standards The following standards apply to the described Works in this document: • • • • •

• • • •

VGB r 115 M Empfehlungen für die Revision von Dampfturbinen VGB R 167 (5/2010) Powertech Richtlinie: Revisionsempfehlungen für Turbogeneratoren NEN-ISO 1940-1:2005 en Mechanical vibration - Balance quality requirements for rotors in a constant (rigid) state - Part 1: Specification and verification of balance tolerances ISO 7919-2 Land based steam turbines and generators in excess of 50MW with normal operating speed of 3000 rpm. ISO 10816-2:2009 Mechanical vibration - Evaluation of machine vibration by measurements on non-rotating parts - Part 2: Land-based steam turbines and generators in excess of 50 MW with normal operating speeds of 1 500 r/min, 1 800 r/min, 3 000 r/min and 3 600 r/min ISO 1940 Balancing, ISO 11324 ISO 4386-1 Ultrasonic bearing assessment ISO 4386-3 Dye penetrant bearing assessment EN 60034-1 For testing of electrical windings

HSE Requirements Contractor shall provide a project specific Health and Safety Plan (Dutch : VGWM-plan ) for the work scopes at the site of AEB, according to an example plan available at AEB. The Contractors Health and Safety plan must be sent to the project leaders of AEB at least 1 month before work starts at AEB site. The Health and Safety plan will be judged by the Safety department and project leaders of AEB. In case of missing information or questions, the contractor should make improvements to the Health and Safety Plan. Contractor shall not start the works prior to approval of the HSE-plan. It is Contractor’s responsibility to obtain an approved HSE-plan. Contractor shall hold required toolboxes at a minimum of once a week with all assigned personnel. The signed toolbox form shall be handed over to AEB HSE department. AEB HSE department an d project leader may attend these toolbox meetings. Hoisting qualification for staff on site, for use and operation of gantry cranes for lifting works in the turbine hall.

Pagina 17 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Quality and reporting requirements Contractor should have ISO 9001 : 2000 for the following activities : • Repair, overhaul, re-engineering of steam turbines • Repair, overhaul, re-engineering of high-voltage power generators (10 KV, 50MVA) The Quality Department of AEB plans to verify the conduction of works in workshops and on site versus the contractor ISO 9001 documents applicable for these work scopes. Contractor shall provide a project specific: • A commissioning and decommissioning plan • Inspection & test plan for the whole works. The inspection and test plan shall indicate hold, witness, review points related to the work. Preliminary (eventually hand written) inspection reports Must be made on site, in suppliers workshops or sub suppliers workshops on daily basis, Copies of these preliminary inspection results must be made available to the owner immediately after the execution of each inspection Some work scopes contain witness points. In case of witness points AEB want to be invited to inspect / discuss finding resulting from inspections, measurements which can lead to more / less work. In case AEB does not respond to invitation, contractor should continue with the work. Some work scopes contain holding points. In case of holding points the contractor should wait for consent of AEB to proceed with further works. Prior to start of works Contractor shall send the inspection and test plan for review. Contractor shall incorporate comments given by AEB . Contractor shall not start the works prior to approval of the inspection and test plan. It is Contractor’s responsibility to obtain an approved inspection and test plan. Prior to start of works, a pre-inspection meeting shall be held. The following attendees from AEB shall be present: • AEB project leader • AEB Quality engineer • AEB Rotating equipment specialist

Documentation requirements All components supplied by the contractor (bolts, nuts, parts etc,) must be accompanied by material certificates according EN 10204. All re-engineered drawings created during this project are property of AEB and must be supplied to AEB on paper and digital as DWG (AutoCAD) file. Reports must be supplied to AEB on paper and digital as MS WORD or MS Excel file. Pagina 18 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Contractor requirements Contractor fabrication / shop requirements turbine scope Contractor demands regarding competencies for the work scope • •

In-company dedicated workshop and suited machinery for repair, overhaul and re-engineering of turbine parts. Experienced project leader on site for the duration of the work, with ability to fluently communicate in Dutch, English or German. Project leaders should demonstrate a project list of major overhauls which were performed under their leadership.

Contractor fabrication / shop requirements Generator scope Contractor demands regarding competencies for the work scope of the Generator : • • •

In company dedicated workshop and suited machinery for repair, overhaul and re-engineering of generator rotors and generator stators with a power of 50 MVA and larger. In company high speed balancing facility for generator-rotors of 50 MVA and larger. Experienced project leader on site, with ability to fluently communicate in Dutch , English or German. Project leaders should demonstrate a project list of major overhauls which were performed under his leadership.

Contractor shall provide the following: • •

Pagina 19 van 40

Reference list with comparable projects, containing the names of the customers, year of the project and size (Power in MW) of the machinery for overhaul of Overhaul of HP- and LP turbines Reference list with comparable projects, containing the names of the customers, year of the project and size (Power) of the machinery for overhaul of high voltage generators of 50 MVA and larger

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Project requirements General Contractor shall provide a project plan for the complete project, work scopes, containing at least the next information: • • • • • • •

Health & Safety (VGWM) Plan Risk Assessment for critical or dangerous handlings for this project Work scopes Overall planning Day-to-day planning Quality documents relating to the work scopes List of names and telephone numbers of responsible persons

Contractor shall provide, as minimum: • Project manager, primary contact and overall responsible • 24 hours per day on site supervision during execution of works • Quality inspectors for in view of Contractors works • All other required personnel to meet safety and quality requirements Contractor shall participate in AEB overall work preparation in view of this project. As such Contractor shall attend all requested: • Planning meetings • Clarification meetings • Alignment meetings • Kick-off meetings During execution of the works daily coordination meetings shall be held to monitor: • Safety • Progress of works • Quality

Pagina 20 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Project planning To reduce downtime to a minimum during turbine generator shutdown works shall be carried around the clock in either 2 or 3 shifts, as per contractor’s preference. Estimated time frame is 4 weeks . Contractor is challenged to reduce overall downtime as much as possible without consequences to safety, quality and overall performance.

Project execution As soon as main components like the generator , HP turbine, LP-turbine, regulator valve and lubrication oil pump are dismantled, contractor should deliver as soon as possible an engine condition status report to AEB, giving information about the engine technical condition and expected more / less work to be conducted, and time needed for execution of the more works. Contractor shall not conduct any additional works other than described in this document prior to AEB approval. In such case AEB shall not be held accountable for the occurred costs by Contractor. Extra work forms should include the naming and description of the extra works, the sum of the extra work made up of unit rates x (man) hours and costs of extra materials used.

During the scheduled overhaul, contractor must have available immediately sufficient capability of facilities and qualified human resources, to execute adequate corrective actions that must be made as a result of the inspections executed. Contractor should give AEB the number of expected staff on site for the project. AEB uses this number to organise sufficient clothing and sanitary facilities for the contractors at its site. Before start of the project, contractor should inform the project leaders of AEB with the names of all staff working on site.

Pagina 21 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

6 Performance and operational requirements after the overhaul. After commissioning the turbine generator must have or give: a) The same or better specific steam consumption, flow capacity, feed water temperature and generator power as it had before the execution of the overhaul in compliance with the complete operational range as described in the operation manual b) Vibratory behavior: a. Absolute vibration according ISO 10816 for new turbines b. Shaft vibration according API 612 rev 5: 25 micron peak-peak c) Control stability in compliance with DIN 45635 d) All supervisory instrumentation ( Bearing temperatures, shaft position etc.) indicating values below the original lowest alarm settings e) Startup times and load fluctuation capabilities in compliance with the original indications of the manual f) Noise that is not higher than the values before the overhaul g) Absence of steam, water, oil and other fluid leakages inside and outside the machinery. Internal steam leakage is only allowed to the magnitude related with the clearances as indicated by Traupel.

Pagina 22 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

7 Enclosures: A

Technical specifications of the installed equipment

B

General arrangement

C

Cross sectional drawings

D

C1

HP turbine

C2

Gear box

C3

LP turbine

C4

Generator

P&I diagrams D1

Steam

D2

Lube oil

D3

Machine system

E

History of the exchange of the LP rotors and the First guide vane carrier of the LP turbine between T 10 and T 20.

F

Steam leakage and power limitation of the first reaction part of the HP turbine

G

Generator inspection report 2013

H

Specification of the scope turbine inspections and certificates

Pagina 23 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

8 Authorization

Revesion number:0 Name

Signature

Date

Author

J.Schrieken

2013

Checked

P.Lensen

2013

Authorised

M.Krikke

2013

Document revision Revision number

Pagina 24 van 40

Name

Signature

Final

Date

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure A Technical specifications installed equipment

Low Pressure (LP) –Turbine Serial number Manufacturer Type Year of manufacturing Year of commissioning Speed Over speed trip speed Year of manufacturing Year of commissioning Inlet Steam Pressure Inlet Steam Temperature Working pressure Power

: : : : : : : : : : : : :

452336 MAN Turbo (Blohm + Voss), Hamburg, Germany KR 120/310-2 1991 June 1992 3000 rpm 3300 rpm 1991 June 1992 4,24 / 4,8 bar (norm / max) 168 / 189 ºC (norm / max) P abs = 0,05 /0,06 bar (norm / max) 19400 kW / 19810 kW (norm / max)

High Pressure (HP) Turbine Serial Number Manufacturer Type Year of manufacturing Year of commissioning Speed Over speed trip speed Inlet Steam Conditions Outlet Steam Conditions Power max Power max

: : : : : : : : : : :

452336 MAN Turbo (Blohm + Voss), Hamburg, Germany GR 36/70 1991 June 1992 6293 rpm 6930 rpm 40 Bar abs, temp 415 ºC (norm) / 430 ºC (max) 4.24 Bar abs (nom) / 4.8 Bar abs (max) 19550 kW at 415 ºC 19970 kW at 430 ºC

: : : : : : : : : :

412911 Alstom, Belfort, France T190-240, Three Phase Star configuration of windings 1991 June 1992 Continuous, 3000 rpm, 50 Hz S =49725 KVA, U = 10500 V, I = 2734 A, cos φ = 0.8, 281V, 580 A, Norm IEC, IP 54 (2x) type EGXYQ 28-280, 44430401 Renk, Hanover, Germany

Generator Serial number Manufacturer Type Year of manufacturing Year of commissioning Operation mode and speed Power Erection Bearings Manufacturer Bearings

Erector Serial number Manufacturer Type Pagina 25 van 40

: 412943 : Alstom, Belfort, France : TKJ70-10 Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Power Type Power assistant erector Operation mode

: : : :

S = 163 kW, U = 281 V, I = 580 A, 3000 rpm Multi Phase (5 phase), Frequency = variable 42 V, 67 A, Class F continuos, code IEC, IP54

: : : : : : : : : :

724728 Renk, Rheine, Germany TNA 500-1 1991 June 1992 2,098 23470 kW 6293 / 3000 rpm VG46 430 l/min / 1,9 bar

Gearbox Commission Number Manufacturer Type Year of manufacturing Year of commissioning Transmission ratio Power Speed Oil viscosity class Oil quantity

Pagina 26 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure B General arrangement

Pagina 27 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure C1: High pressure turbine

Pagina 28 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure c 2: Gear box

Pagina 29 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure C3: Low pressure turbine

Pagina 30 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure C 4

Generator

Pagina 31 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure D 1 P&I diagram, Steam

Pagina 32 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure D 2 P&I diagram, Lube oil

Pagina 33 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure D 3 P&I diagram, Machine System

Pagina 34 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure E History of the exchange of the LP rotors and the first guide vane carriers of the LP turbine between T 10 and T 20.

Low pressure turbines rotors and guide vane carriers (g.v.c.)

T10

T 20

GGG40 g.v.c., rotor A no stellite

`

1993 Start of operation

GGG40 g.v.c., rotor B no stellite Start of operation

2000 Installed new 13 % Cr g.v.c. Installed new rotor AB, 2 rows stellite 2002

GGG 40 g.v.c. emergency repaired by (Elbar) T 10 rotor A stellited 3 rows by Elbar

2010 Rotor B stellited 3 rows by Sulzer Rotor AB becomes spare rotor

2013 The present spare rotor is AB was 10 years in operation with 2 rows stellited Rotor B is in T 10 is in 2013 8+3=11 years in operation, the stellite is 3 years in operation Rotor A is in T 20 is in 2013 7+11=18 years in operation, the stellite is 11 years in operation The guide vane carrier is emergency repaired in operation for 11 years

Pagina 35 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure F Steam leakage and power limitation of the first reaction part of HP turbine 420C

Enclosure G

?C

T 20 Generator inspection report March 2013

?C

ca 295C

400 C

T10 /T20 Leak flow kg/h Real power kW Measured kW Limit kW kW

Pagina 36 van 40

T 10 317C T 20 343 C

The Hp gland leakage is at design clearance of 0,6 mm: 2.245 t/h The flow to A 1 is 1.045 t/h T 10 This is confirmed by tests of T 10 this year T 20 Has a tested leakage of 2 t/h. This is caused by an increased clearance to about 1,2 mm Recommended is to repair the seal of T 20 in order to avoid operational problems ( Thrust bearing overload, blowing gland) Modern reaction turbines have for the balance piston brush seals.

1000/2000 9800/10300 7980/6082 8800

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure G Generator inspection report

849000~1.PDF

Pagina 37 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Enclosure H Specification of the scope turbine inspections and certificates

Pagina 38 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Pagina 39 van 40

Final

Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in 2014

Pagina 40 van 40

Final