25 156 2MB
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