P0WLP

The Arnot Capacity Increase Project

An Integrated Boiler and Turbine
Retrofit by Alstom
Implementation and Operational
Experience
2





THE ARNOT CAPACITY INCREASE PROJECT
AN INTEGRATED BOILER AND TURBINE RETROFIT BY ALSTOM
IMPLEMENTATION AND OPERATIONAL EXPERIENCE


Mike Davies, Alstom UK Don Stephen, Alstom UK Glyn Rich, Alstom UK
Jeff Mills, Alstom UK Steve Allen, Alstom South Africa


1 Abstract....................................................................................................................................................4
2 Introduction .............................................................................................................................................4
3 Initial Upgrade Studies ............................................................................................................................5
4 Contracting, Guarantees and Commercial Issues ....................................................................................6
5 Equipment Requiring Retrofitting...........................................................................................................7
5.1 Turbine Plant ...................................................................................................................................7
5.1.1 High Pressure Turbine Retrofit................................................................................................7
5.1.2 Intermediate Pressure Turbine Retrofit ...................................................................................8
5.1.3 Low Pressure Turbine Modification........................................................................................8
5.1.4 Turbine Balance of Plant .........................................................................................................8
5.2 Boiler Plant ......................................................................................................................................8
5.2.1 Furnace ....................................................................................................................................8
5.2.2 Milling Plant ............................................................................................................................9
5.2.3 PA Fans....................................................................................................................................9
5.2.4 Burner Nozzles ......................................................................................................................10
5.2.5 Steam Drum Internals ............................................................................................................10
5.2.6 Economiser ............................................................................................................................11
5.2.7 Air Preheater..........................................................................................................................11
5.2.8 Superheater and Reheater Materials ......................................................................................12
5.2.9 Boiler Circulation system......................................................................................................12
5.2.10 Main Steam Strainer ..............................................................................................................12
5.2.11 Safety Valves .........................................................................................................................13
5.2.12 Reheater Spray System Integrity ...........................................................................................13
6 Requalification of Reused Equipment ...................................................................................................13
7 Project Implementation and Test Results ..............................................................................................14

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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8 Challenges and Solutions.......................................................................................................................15
8.1 Global Manufacture.......................................................................................................................15
8.2 Localisation....................................................................................................................................15
8.3 Project Management ......................................................................................................................16
8.4 Retrofit Integration ........................................................................................................................16
8.5 Safety.............................................................................................................................................17
8.6 Other Technical Challenges...........................................................................................................17
8.6.1 LP Rotor Vibration ................................................................................................................17
8.6.2 Silica Tile Adhesion ..............................................................................................................18
8.6.3 Mill Gearboxes ......................................................................................................................18
9 Operational Experience .........................................................................................................................18
10 Conclusions ...........................................................................................................................................18
11 Acknowledgements ...............................................................................................................................19
12 References .............................................................................................................................................19

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1 ABSTRACT
In cooperation with South African utility giant Eskom, Alstom has undertaken an ambitious project
to upgrade the six-unit Arnot Power Station, originally rated at 350 MWe per unit. The objective
was to retrofit major plant components in a cost effective manner, such that each unit would
produce a continuous gross electrical output of 400 MWe and plant life would be prolonged by
20 years.
The development of the Arnot Capacity Increase Project (ACIP) has been described previously
[1]
.
This paper will consider its implementation, including the challenges found and overcome, and the
operational experience subsequently gained with the retrofitted units. Lessons learned will be
identified. Conclusions will be drawn concerning the effectiveness of a comprehensive feasibility
study prior to project implementation and the ability of modern design and manufacturing
techniques to retrofit older machines, thus releasing latent potential.
2 INTRODUCTION
During the late 1980s and early 1990s, Eskom was forced to mothball capacity due to reduced
economic growth and the commissioning of new plant. However, the new millennium saw
considerable change with a rapid increase in the demand for electricity. Short-term delivery
requirements were essential to resolve the immediate shortfall and various opportunities were
investigated. Other projects were initiated including the building of a various mix of stations.
Eskom runs its plant according to a set of fundamental management policies that have been
developed to take into account best practice, sound engineering principles and experience in the
power generation industry. Amongst these are Life of Plant Plans", put in place to ensure sustained
running of existing generating plant. Arnot had passed its design life of 30 years and various large
items of plant needed replacement. This, combined with the demand for electricity, meant that
increasing the capacity of the existing station was clearly a favourable option.
Arnot would be the first station in Eskom to undergo such an increase in capacity. For it to be
successful, it was imperative that an integrated approach be taken to ensure that all aspects of the
generating plant were evaluated and engineered for the upgrade.

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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3 INITIAL UPGRADE STUDIES
As a pre-requisite to any decisions on modification and investment, a comprehensive study was
conducted to investigate the feasibility of an increase in capacity, up to a maximum gross output of
400 MWe per unit, and to estimate the costs.
Since the turbine was originally designed for a continuous load of 350 MWe, whereas the original
boiler design was for 500 MWe (down-sized for Arnot), a basic assumption was that the turbines
would be the potentially limiting element. Consequently, the study was structured in the following
format:
No modification of turbine centreline. What would be the maximum permissible continuous
load on the turbine?
Minor modification of turbine centreline. The maximum possible continuous output of the unit
was analyzed with regard to a steam path upgrade (reblading of the HP and IP turbine). All
other main equipment and systems were checked.
Major modification on turbine centreline. This case assumed retrofitting (new inner casing and
a new rotor) of the HP and IP turbine. As before, all other main equipment and systems were
checked to ensure operation at maximum output and to propose methods of resolution, if
necessary.

Lxistinq Jurbine 8 6eneratcr Shalt Line at Arnct Pcwer Staticn
The main components of the water steam cycle, cooling water systems, boiler and coal handling
were reviewed with respect to the operating boundary conditions, effects on heat rate and costs of
the necessary modifications to achieve the respective increase in continuous output power. The
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outcome of the study included information on the level of investigation performed on the individual
equipment, the degree of suitability of that equipment and the estimated price for the proposed
modification.
In summary, it was shown that the target output of 400 MWe could be achieved with an upgrade or
retrofit of the steam turbine but the preliminary assessment revealed that the boiler would be the
limiting element. Subject to confirmation, the study recommended limiting the increase in steam
flow to 105% BMCR (Boiler Maximum Continuous Rating). A subsequent more detailed analysis
substantiated the possibility of an increase in boiler load to 108% BMCR.
4 CONTRACTING, GUARANTEES AND COMMERCIAL ISSUES
Using the results of the initial studies, Eskom initiated a competitive tendering process, as a result
of which Alstom was awarded a single contract for the execution of the project in accordance with
the NEC (New Engineering Contract) Terms; an activity-based standard form. The complexity of
the project, and diversity of the scope, required the involvement and expertise of a number of
different divisions within the global Alstom Group to provide an integrated project, from both a
technical and managerial perspective.
Alstom had carefully positioned itself in the market and was able to respond to the unique nature of
contracting in South Africa. Considerations in terms of government policies for the development of
local competences, industrial capability and trading of high capital value equipment were critically
assessed and addressed by extensive involvement of Alstoms local companies. Devolution of a
significant portion of the scope to a local South African base was achieved and all contracting
criteria imposed were met.
Throughout the execution of the project, open dialogue ensured that issues critical to both parties
were adequately addressed and agreements reached. Of primary importance were:
Suitable equipment warranties were negotiated for the scope of hardware and services being
provided by Alstom together with adequate non-conformance resolution and remedy.

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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Robust overall plant performance guarantees were provided by Alstom and verified by
extensive testing. This was a parameter of principal concern to Eskom in ensuring the
economic viability of the project.
Delivery times, particularly critical in the case of the hardware for the first unit to be
retrofitted, as well as outage duration periods for the works required, were also of paramount
importance to Eskom in terms of their economic models. Through discussion, and via the
contract regimes agreed, these items were suitably mitigated and addressed.
Functionality and integrity of key plant components not being retrofitted. Eskom required
assurance that the newly imposed conditions following the plant upgrade would not
compromise the operation of other components that were not being modified or replaced. A
system of categorisation of plant was devised which addressed the concerns of both parties.
5 EQUIPMENT REQUIRING RETROFITTING
5.1 Turbine Plant
The major retrofit required to the turbine plant was the
complete replacement of the high pressure (HP) and
intermediate pressure (IP) turbine inner cylinders. However,
the increased operational demand to achieve the project
objectives meant that much of the auxiliary equipment
associated with the turbine plant was also affected (as
highlighted during the studies) and the scope was therefore
extended to include modifications to the existing low
pressure (LP) turbines and other plant.
5.1.1 High Pressure Turbine Retrofit
The HP turbine retrofit consisted of one pre-assembled retrofit module per unit comprising a drum
type single flow HP rotor with integral coupling and reaction blading (over-speed tested to 120% of
nominal speed) and a new inner casing, with mounted blades, designed for shrink ring closure. New
steam seals and gland sealing elements were provided.
8
5.1.2 Intermediate Pressure Turbine Retrofit
The IP turbine retrofit consisted of one partly assembled retrofit
module comprising a welded double flow IP rotor (complete with
reaction blading and integral couplings, high speed balanced and
over-speed tested to 120 % of nominal speed) and a new inner
casing with mounted blades. The module was fully assembled on
site and new steam seals and sealing elements were provided.
Coupling bolts for the HP-IP and IP-LP coupling were also
supplied.
5.1.3 Low Pressure Turbine Modification
The LP turbines required modification to allow for a reduction in the crossover and heat extraction
pressure. The swallowing capacity of the turbines was increased by replacing the first stage
stationary and moving blades. As part of the overall retrofit project the LP rotors were fully
inspected and rebalanced.
5.1.4 Turbine Balance of Plant
As identified in the upgrade studies, the existing condensate extraction pump was not considered
suitable for operation at the higher load and a decision was made to replace it. It was also
considered necessary to replace the 50% electric and 100% steam boiler feed pumps.
5.2 Boiler Plant
The following description outlines the equipment upgraded or replaced as part of the project to
upgrade the boiler plant from a continuous output of 365 MWe to 400 MWe.
5.2.1 Furnace
Originally based upon a 500 MWe design, the furnace was liberally sized, making the boiler and
associated equipment ideal candidates for capacity upgrade. The existing furnace size was adequate
for the 400 MWe upgrade and the furnace plan and heat release rating were within allowable
maximums for the normally supplied coals. Furnace combustion conditions had been optimised for
low excess air operation.

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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5.2.2 Milling Plant
The existing coal mills were unable to meet the
requirements of the 400 MWe load without
modification to the mill classifier and gearbox.
Capacity was increased such that, while firing the range
of fuels specified, a throughput of 38.5 t/hr per mill
could be achieved.
A larger, high efficiency static classifier, providing
higher coal throughput with lower overall mill
differential pressure, replaced the existing
classifier.
The mill was fitted with a rotating throat
modification that was verified by CFD modelling.
The mill gearboxes were refurbished and upgraded
for a power rating of 400 MWe.
The existing coal feeders had sufficient capacity to meet the increased throughput.
5.2.3 PA Fans
The existing hot primary air fans were operating close to their
limit and were unable to meet the requirements of the new 400
MWe load.
New primary air fans were provided including shafts,
impellers, casings, electric motors, couplings and inlet louvre
dampers. White metal bearings were refurbished or replaced
so that, after the boiler upgrade, all bearings would be
common. The existing oil lubrication system was refurbished
or replaced as necessary. Suitably sized hydraulic lock-up
couplings were installed together with new electric motors.

10
5.2.4 Burner Nozzles
Coal burner and secondary air nozzle changes were necessary to accommodate the increased fuel
and airflow requirements at 400 MWe. A full change of burner nozzles (coal and air) was required
in order to redistribute the secondary air within the windbox and to provide the correct relationship
between primary and secondary air velocities. The new air and coal nozzles improved turndown,
provided better control of furnace atmosphere and reduced furnace fouling.
The new nozzles are suitable for additional NOx reduction measures without major modification
should NOx reduction legislation be introduced in South Africa. The nozzle design incorporates
NOx reduction techniques that are not only environmentally friendly but also have positive impacts
on bag filter life and replacement cost.
The coal nozzle design incorporates a ceramic material
that had been on test at Arnot Power Station for over
four years. The existing test nozzle, whilst showing
extremely good wear capability, was not designed to
meet the maximum velocities required to maintain
flame stability when operating at 400 MWe load. A
new nozzle was, therefore, developed from Alstoms
existing design to incorporate the ceramic components. The newly developed inner nozzle
incorporates flame attachment tips designed to stabilise and ignite the coal stream close to the
nozzle to devolatilise the coal as quickly as possible. The outer secondary air nozzle is designed to
maintain a constant airflow around the nozzle throughout the burner tilt range.
The existing oil burner register was not suitable for operation at 400 MWe and modifications to the
oil compartments were necessary. New tilting oil nozzle and air registers were required to allow
secondary airflow through the compartment for coal combustion.
5.2.5 Steam Drum Internals
The steam drum was fitted with cyclone separators and secondary corrugated plates to provide high
purity steam. Based upon the increased steam flow (360 kg/s) at 400 MWe the drum steam cyclones
were slightly overloaded when compared to current Alstom standards. Additional cyclone separators

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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were installed and the secondary steam separators increased in length to compensate. The
modifications were designed for installation in the steam drum without the need to weld to the main
pressure vessel wall.
5.2.6 Economiser
To reduce the flue gas temperature leaving the boiler and improve the overall thermal efficiency,
two additional rows of extended economiser surface were added to the existing configuration. The
economiser profile was similar to that previously installed and the support structure was suitable for
the additional surface with only minor modifications.
To exploit the potential benefits of the economiser upgrade, aspects on boiler operation were
investigated.
The increase in the economiser duty and maximum allowable economiser outlet temperature
(i.e., margin to steaming).
The effect of the increased economiser water outlet temperature on steam drum sub-cooling,
circulation pump capability and circulation through the water walls.
The effect of a lower economiser flue gas temperature on the air heater performance.
The load carrying capability of the economiser support structure.
5.2.7 Air Preheater
The existing regenerative air preheaters on boiler 1 were of the Rothemuhle Bisector type with
rotating hood and stationary heating matrix, whilst on boilers 2 - 6 the air heaters were of the
Ljungstrom Bisector type, arranged with rotating heating surface matrix support from a shaft
orientated in the horizontal position.
Regenerative air preheater performance was enhanced by the application of additional measures to
reduce preheater air-in leakage. In order to meet the requirements of the specification and taking
into account the service life of some of the airheater elements, a solution was provided to Eskom
with assurances that the regenerative air preheaters would perform to expectations. The solution
included using new heater packs (provided by Eskom), and the refurbishment of existing seal
systems on all boiler units. After refurbishment, preheater air-in leakage was reduced to below 9%.
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5.2.8 Superheater and Reheater Materials
In order to accommodate the higher operating conditions imposed on the superheater and reheater
resulting from operation at the 400 MWe upgrade, the

fifth stage superheater and third stage
reheater were upgraded by installing enhanced 9%Cr material on the leading and trailing tubes of
the

elements. The new 9%Cr1%Mo tubing grade (BS3059-91) has considerably enhanced
properties when compared to the original materials and tube metal temperature design margins are
greatly improved. The replacement tubing was designed in accordance with the requirements of
BS1113: 1999 code.
5.2.9 Boiler Circulation system
The boilers at Arnot Power Station are of the controlled circulation type with individual orifices
located in front and rear distributor headers that control the flow of boiler water to the furnace
tubes. Correct selection of orifices sizes is of paramount importance to ensure that all furnace tube
circuits have sufficient flow to protect the tube under all conditions of operation and that circulation
pumps have sufficient capability to meet those requirements. For the boiler upgrade, all distribution
orifices and a number of orifice carriers were replaced.
The existing orifices were mounted in specially design orifice carriers that were indexed to
prevent the installation of the incorrect size of orifice on any given circuit. In order not to
compromise the circulation pump capability, the new orifices were carefully selected for the new
specific operating conditions at 400 MWe. To achieve this a new system of orifice carrier
indexing was developed to prevent orifices from being incorrectly located during installation and
to simplify any future removal / replacement effort.
5.2.10 Main Steam Strainer
The boiler design pressure could not be compromised and, therefore, to accommodate the increased
pressure drop through the superheater, the outlet header operating pressure was reduced. To
compensate, the pressure drop between boiler and the turbine was reduced by removing an existing
steam strainer between the superheater outlet header and the boiler main steam stop valves and
replacing it with a new pipe bend. The new piping was the same material and dimensions as the

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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existing. Stress analysis of the HP steam piping modification was undertaken using the existing
CAESAR model suitably amended to reflect the modified pipework arrangement.
5.2.11 Safety Valves
On existing boiler installations, changes in operating conditions resulting from capacity upgrades
can only be accommodated within the certified design pressure and the boiler code rules governing
the selection, capacity and operation of the safety valves.
The live steam pressure and flow requirements for the 400 MWe upgrade case required a
re-examination of the superheater and steam drum safety set pressures. This was to ensure that
adequate margins were available for proper operation of the safety valves. To accommodate the
increased superheater pressure drop, the superheater and steam drum safety valves were reset so
that adequate margins existed between normal operating pressures and the valve lift pressures. The
reheater safety valves were similarly reset.
5.2.12 Reheater Spray System Integrity
The existing reheater spray water system was de-commissioned many years ago. As part of the
upgrade procedure Alstom carried out a review of the system to establish suitability for operation at
the upgrade conditions. As a result, Eskom re-commissioned the equipment during the boiler
statutory overhaul period.
6 REQUALIFICATION OF REUSED EQUIPMENT
The requalification of re-used equipment started with a careful review of existing documentation,
for example, drawings, data sheets, diagrams, etc. Next, a review of performance test data was
performed, where appropriate. This data was compared with actual operational data to allow for a
plausibility check and discover potentially weak points or defects. A further element of the study
was the incorporation of updated data and feedback from plant staff. This data was then taken into
account when performing cycle calculations to predict future projected operation.
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7 PROJECT IMPLEMENTATION AND TEST RESULTS
The installation of the replacement and retrofitted hardware has been performed during routine
major outages of the six units over a three-year period. At the time of writing, five have been
successfully completed (units 3, 2, 6, 4 and 1) with the remaining unit (5) to be retrofitted in an
outage commencing in September 2010. In each case, the outage length is 13 weeks, principally
dictated by the significant amount of work required on the boiler. The most challenging timescale
was that for the first unit (3), as the outage start date was less than 16 months after Notice to
Proceed. Nevertheless, to date, all work has been completed within the contractual timescales by
virtue of close cooperation between Alstom and Eskom.
On completion of the retrofit of each unit, initial run-up was achieved with almost no trips. Results
of the performance tests carried out by Eskom on two units to date have been extremely
encouraging. Power output under calibrated steady state test conditions has been measured as
406.2 MWe for Unit 3 (against a target of 400) and 409.0 MWe for Unit 2. Informally, substantially
higher outputs have been observed under high load conditions.
Although more fuel is required to achieve the average 55 MWe increase in output, heat balance
calculations have shown that almost 30% (approximately 15 MWe) of the additional power is
free energy arising from increased efficiency by using modern design and manufacturing
techniques to optimise overall performance and release the latent potential of the plant. Initial heat
balance calculations had predicted an output of around 402 MWe, thus raising the possibility that
even modern design theory may still be conservative in comparison with what is possible.
The incorporation of modern technology and the consequent increased efficiency of the plant has
significantly reduced NOx emissions, showing that the project is environmentally sound as well as
providing increased capacity. Alstom have proposed further testing to establish the exact reduction
in order that Eskom can demonstrate their commitment to improving the environment.
On completion of the project, the station will have the capability of producing at least an additional
6 x 50 = 300 MWe of power virtually equating to the addition of an extra unit of the original
design to the six-unit plant. In this manner, the project has contributed significantly to bridging the
gap between supply and demand pending the construction of new power plants in South Africa.

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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8 CHALLENGES AND SOLUTIONS
8.1 Global Manufacture
Alstom manufactures equipment using its global network of factories in order to best match
capacity to current high levels of demand and allow client needs to be met. ACIP is an excellent
example of this in that manufacture of the turbine retrofit inner cylinders was undertaken in both
Europe (Units 3 and 2) and China (Units 6, 4, 1 and 5). Similarly, virtually all manufacture for the
boiler upgrades was devolved to South African facilities, both Alstom factories and local
subcontractors.
Rigorous and identical quality standards are applied throughout the global network but,
notwithstanding this, there can be a perception that equipment originating in some parts of the
world may not be of the same standard as others. To counter any such doubts, representatives of
Eskom were invited to visit all factories in which manufacture was being undertaken to observe for
themselves the quality of the work. Eskom also exercised their right to institute a more rigorous
regime of third party inspection in certain factories. To date, this has revealed no substantive
differences in the quality of manufacture and the client has professed his satisfaction with the end
product in each case. The lesson learned is that open dialogue and reassurance between client and
contractor can often forestall subsequent problems.
8.2 Localisation
Given that no new power stations had been built in South Africa since the early 1990s, much of the
local power industry had been dormant for some years, limited mainly to the maintenance of
existing plant. Changing demographics and a shortage of skilled labour also contributed to the
potential challenges of undertaking a major project such as ACIP.
Both Eskom and Alstom recognised this challenge from the outset and a number of measures were
instituted to mitigate the risks to the programme. Alstom deployed significant extra resource to
manage and support local subcontractors, both those nominated under the contract and others. This
included a particular emphasis on quality and expediting. Local Alstom personnel were of
particular value in this respect. Technical Field Advisers from Europe were also deployed during
each outage to guide the local installation workforce. So far as possible, the same personnel were
16
employed on each occasion to benefit from past experiences and ensure consistency of quality and
standards.
Under the terms of the contract, Alstom agreed to significant employment and skills transfer in
accordance with the South African governments Black Economic Empowerment (BEE)
programme and, wherever possible, work was localised to meet these obligations.
The lesson identified is again that open dialogue, close cooperation between all parties and
selective application of resources to critical areas can be of significant benefit to the project.
8.3 Project Management
Some initial difficulties arose in the management from Europe of communications with a
geographically remote client such as Eskom. Alstom took an early decision to locate the Project
Director in South Africa to ensure close liaison with all parties and efficient management of the
outages. The lesson identified was that the development of a substantial senior presence in South
Africa would enhance relationships with the client at a time when significant further work is
expected within the next few years.
8.4 Retrofit Integration
Alstom was the Original Equipment Manufacturer (OEM) for the major equipment at Arnot Power
Station. Copies of the original design documentation still existed and had been used for the initial
feasibility study. However, it was recognised that more than 30 years of operation and maintenance
would have meant changes for which documentation may or may not exist and which, where it did,
may be of variable quality for no other reason than changes in personnel over that length of time.
Eskom made access to its own records freely available to the project team and Alstom allowed in
its manpower estimates for contingencies to deal with some unknowns. Where possible, Alstom
arranged to speak with staff with long experience of the plant, which revealed some items
previously unknown to either party, particularly from the plants construction phase.
By means of close cooperation between all parties and judicious use of resources, the project was
able to cope without detriment to the overall programme with a number of surprises (most of them
relatively minor) that were revealed when the equipment was opened up for retrofit. Alstom also
has a formal system for recording such variances so that the lessons may be applied in future, both

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
17
on other units on the same project and on similar plant elsewhere. The lesson identified was, once
again, that the cooperation of all parties is vital, particularly when work is being carried out on
existing infrastructure.
8.5 Safety
Alstom and Eskom agreed at an early stage that safety was of paramount importance to both
organisations and a joint team was established to promote this aspect of the project. It was
recognised that this was made more complex by the diverse nature of staff working concurrently
during the outages and their proximity to other live machinery. Nevertheless, safety has been a
major success of the project, with a record established of one million man-hours (two man-years)
without a Lost Time Incident. The lesson identified is that, even on such a complex project, safety
can be successfully applied to the benefit of all parties.
8.6 Other Technical Challenges
Overall, the project has been adjudged technically as a great success. However, some issues were to
be expected in a project of this complexity. Examples of the challenges that were met and resolved
include:
8.6.1 LP Rotor Vibration
The two LP rotors were modified as described earlier (see 5.1.3) and refitted to the machines. In
one case, a higher than expected level of vibration was experienced upon initial run-up. Eskom
advised that similar issues had been experienced previously with the same equipment. Further
investigation revealed that there was a minor balance problem with the rotor, which may have been
exacerbated by the replacement of the generator during preparatory work for the upgrade in an
earlier outage. The problem was resolved and the lessons learned were applied in subsequent
modifications on other units. The further lesson identified was that a full integrated retrofit of the
plant, including replacement or retrofit of the generator, would be more likely to avoid such a
problem.
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8.6.2 Silica Tile Adhesion
Coal burners on the boilers were fully refurbished using modern silica tiles. On the first two units
(3 and 2), it was subsequently noted that a small percentage of these became detached in use.
Investigation revealed the problem to be with insufficient quality control of the fixing and assembly
process. Quality control was strengthened and additional supervision of the application process was
employed. This has been successful in resolving the problem.
8.6.3 Mill Gearboxes
The mill gearboxes were refurbished by a South African subcontractor and successfully returned to
service following each outage. However, subsequent examination revealed pitting on some of the
gears. This was traced to quality assurance problems with both the material used and the
manufacture of the gears at a second tier overseas subcontractor. Stricter quality control measures
were instituted to prevent a recurrence on subsequent units and the affected components are being
replaced. The lesson learned is a reminder that good quality control is necessary throughout the
supply chain.
9 OPERATIONAL EXPERIENCE
Whilst the project has yet to be completed, Eskom have now had the opportunity to gain some
operational experience with the units retrofitted to date. That experience has generally been very
positive and the units have provided dependable capacity much needed in South Africa. A retrofit
of this complexity will, by its very nature, often cause changes in the operating characteristics of
the plant and Alstom has provided training for engineering and operations staff and maintenance
personnel. This will be repeated annually over the life of the project to ensure that all personnel are
adequately trained in the new equipment and to cater for turnover in personnel.
10 CONCLUSIONS
The Arnot Capacity Increase Project is a good example of a contractor working with clients to
optimise existing plant and exploit latent potential giving enhanced plant performance well into the
future.

The Arnot Capacity Increase Project An Integrated Boiler and Turbine Retrofit by Alstom
Implementation and Operational Experience
February 2010
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The project has demonstrated a number of important facets of working within existing
infrastructure facilities. Firstly, a comprehensive feasibility study conducted in advance will often
reveal both unexpected benefits and potential problems. In the case of Arnot, a study of the entire
system revealed not only the possibility of realising additional power by matching the retrofit of the
shaftline to upgrades of the steam plant but also showed that, contrary to the accepted view,
substantial work on the boiler was necessary to generate the steam required for that additional
power. Separate studies of the individual elements would not necessarily have considered this
interface and thus may not have identified both benefits and problems. In this case, the sum of the
whole exceeds that of the parts.
Secondly, when working in the area of live plant on a complex integrated project, it is vital that all
parties subscribe and adhere to a fully integrated programme to make best use of common facilities.
Failure to do so can have a significant impact upon the timely completion of the work.
Finally, challenges will inevitably arise when upgrading facilities that are over 30 years old.
However, proper advance planning, contingencies and cooperation between all parties can mitigate
such risks and provide solutions.
11 ACKNOWLEDGEMENTS
The principal author of this paper is indebted to his co-authors for permission to reproduce parts of
their original paper
[1]
and to others who have willingly given of their time to describe the
challenges encountered and the solutions found in the execution of the Arnot Capacity Increase
Project.
Photographs 2007 www.photoworks312.com (ALL RIGHTS RESERVED)
12 REFERENCES
1. Arnot Power Station An Integrated Boiler and Turbine Retrofit Project to Increase Unit Output
and Efficiency; Stephen, Baldwin, Rich, Boneham, Mills & Kienzle; May 2007
1. Stephen, D., An Alstom Integrated Boiler and Turbine Retrofit Proj ect to Increase Unit Output and Efficiency, PowerGen Europe Conference, May 2007.
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