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Appendix 6b - Technical Specifiction Major Ovehaul T20 PDF
Appendix 6b - Technical Specifiction Major Ovehaul T20 PDF
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
4 Scope
4.1 Turbines, gear and auxiliary systems
4.2 Generator
7 Enclosures
8 Authorization
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
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
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 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
2014 inspection
Inspection
Function
Location
Code
Part
3 Rotor support Journal bearing HP turbine VGB R 115 M 2013 Manual yes
(Bearings) front side
pinion
driving side
Bearing casing Turbines (HP and LP) All related parts Manual no Manual yes
sliding and Generator All related parts Manual no Manual yes
guidance
system
Connection of Turbines (HP and LP) All related parts Manual no Manual yes
bearing casings
with turbine
casing
Steam blocking All extraction lines Valves VGB R 115 M no VGB R 115 M yes
system
Condensate All drains Condensomates VGB R 115 M yes VGB R 115 M yes
drain system and valves
Turbine casings 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
Steam inlet 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
Moving blades All blades HP turbine API 687 no API 687 yes
Erosion Stationary Blades LP turbine VGB R 115 M 2002 VGB R 115 M yes
Support bars inner
casings and drain
LP Casing holes VGB R 115 M no VGB R 115 M yes
Wear of stage Tip of moving blades HP turbine API 687 no API 687 yes
shrouds
Oil supply Main oil pump HP turbine VGB R 115 M 2010 Manual yes
Driving gear pump HP turbine 2013 Manual yes
Yes
Control Flow control HP turbine VGB R 115 M 2013 Manual Yes
Stems and
bushings VGB R 115 M 2013 Renewed in Yes
2013
To be
Valves and seats VGB R 115 M 2013 renewed Yes
By
Condenser Pipes Filthiness no Manual others
Pipe plates
Water chambers
Support plates
Flash tank
Damage
Tightness
Oil tank Oil and tank Oil console Removal of oil no Manual yes
Reconditioning
or
Pagina 10 van 40 Final
Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014
renewal
Clean tank and
strainers
Suction non return
valves Inspection no Manual yes
Oil filters Lube and control Oil console Filter Elements 2013 Manual yes
filters inspection
Coolers Lube oil coolers Oil console Inspection on no VGB R 115 M yes
water and oil
Side.
Water box
repair or
replacement
Oil piping Lube and control Complete system Visual on no VGB R 115 M yes
leakage
Gear box and Gear box Complete train Visual 2013 Manual no
turning gear Couplings
Turning gear no yes
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
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
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’.
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.
The following works are carried out under the responsibility of AEB
Applicable standards
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.
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.
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.
Contractor requirements
Contractor demands regarding competencies for the work scope of the Generator :
Project requirements
General
Contractor shall provide a project plan for the complete project, work scopes,
containing at least the next information:
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
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.
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:
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.
7 Enclosures:
B General arrangement
C1 HP turbine
C2 Gear box
C3 LP turbine
C4 Generator
D 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
8 Authorization
Revesion number:0
Document revision
Enclosure A
Generator
Serial number : 412911
Manufacturer : Alstom, Belfort, France
Type : T190-240, Three Phase Star configuration of windings
Year of manufacturing : 1991
Year of commissioning : June 1992
Operation mode and speed : Continuous, 3000 rpm, 50 Hz
Power : S =49725 KVA, U = 10500 V, I = 2734 A, cos φ = 0.8,
Erection : 281V, 580 A, Norm IEC, IP 54
Bearings : (2x) type EGXYQ 28-280, 44430401
Manufacturer Bearings : Renk, Hanover, Germany
Erector
Serial number : 412943
Manufacturer : Alstom, Belfort, France
Type : TKJ70-10
Pagina 25 van 40 Final
Technical Specification for the Major Overhaul of the Steam turbine generator system T20 in
2014
Gearbox
Commission Number : 724728
Manufacturer : Renk, Rheine, Germany
Type : TNA 500-1
Year of manufacturing : 1991
Year of commissioning : June 1992
Transmission ratio : 2,098
Power : 23470 kW
Speed : 6293 / 3000 rpm
Oil viscosity class : VG46
Oil quantity : 430 l/min / 1,9 bar
Enclosure B
General arrangement
Enclosure C1:
High pressure turbine
Enclosure c 2:
Gear box
Enclosure C3:
Low pressure turbine
Enclosure C 4
Generator
Enclosure D 1
P&I diagram, Steam
Enclosure D 2
Enclosure D 3
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.
T10 T 20
GGG40 g.v.c., rotor A no stellite ` GGG40 g.v.c., rotor B no stellite
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
Enclosure F
Enclosure G
?C
T 20 Generator inspection report March 2013
?C
ca 295C
400 T 10 317C
C T 20 343 C
Enclosure G
849000~1.PDF
Enclosure H