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Presented by: Daniel Sculley, Manager Turbine, Generator & Piping Systems Engineering APP Site Visit October 30 November 4, 2006
Topics
Turbine Blading & Steam Path Upgrades Turbine Stop / Control Valve Upgrades Turbine Control System Modernization Generator Improvements
Glen Lyn 6 Series 235MW (GE) HP/IP Nine (9) Units (Subcritical, 1957 - 1961)
Integral control valve chest girth weld creep Purchased complete spare in 1990 Exchanged on other 8 units (1991 2004) New rotors replaced C grade materials New nozzles, diaphragms (Rows 1,9,10,12) Reassemble non-outage; 4-week reduction Cost = $8 Million (US) first unit installed, approx. Cost = $4 Million (US) subsequent units, approx.
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9 Results
9 Blading Efficiency > 92.0%, increase of 4.7% 9 20 MW and 28.5 kcal/kWh (113Btu/kWh) 9 Improved rotor stability against steam swirl 9 3 Units completed - - 1 with premature degradation
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Monoblock No Bore Rotor Rateau control stage 3-D Reaction Blades (ISB)
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Reliability
Tight shutoff, leaks
Maintenance
Weld repair to valve body, seats, bolt holes
Design Improvement
Improve O&M Reduce pressure drop
1 3 0 0 M W SV C V U p g r a d e
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Generator Improvements
Inspection Intervals (typical)
Field in-place ( 5 years) Field removed (10 years) Perform routine cleaning, testing, repairs 9Goal: Achieve high reliability through design life of insulation systems
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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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