Turbine/Generator Upgrades and Maintenance

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

Steam Path Improvements

More than 20 units in plan for upgrade Efficiency gain
Aerodynamic blade profiles Improved inter-stage sealing Reduction of sidewall secondary flow losses

Reduction in future O&M costs

Extend time between overhauls Reduction of solid particle erosion damage Less coal burned
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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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Glen Lyn 6 Series 235MW (GE) HP/IP 9 Results

9 Restored CV chest with improved girth weld 9 Improved HP efficiency by 1.5% - 2.0% 9 2.5 MW and 35.28 kcal/kWh (140 Btu/kWh) gain 9 Erosion minimized, reduced repairs 9 Extended inspection intervals to 10-11 years 9 Re-inspections begun in 2001 confirm benefit

1300 MW Series (Alstom) HP

Six (6) Units (Supercritical, 1973 1989)
Use of spare rotor/inner casing assembly Replaced all stationary/rotating rows (28) Reuse rotor and re-round inner casing Modified seal strips for steam swirl stability Cost = $6 Million (US) per unit installed, approx.

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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600,800 MW Series (GE) HP/IP

Eight (8) Units (Supercritical, 1967 1972) To date, four have been converted New nozzles, diaphragms, seals Reblade spare rotor; reuse shells Cost = $6.5 Million (US) per unit installed, approx. 9 Results 9 82.8% - 86.3% HP section efficiency 9 11MW gained on 800MW Series 600 MW Series HP fell short of expectations by up to 3.5% due to overstated recoverable losses by OEM.
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Effect of Advanced Design Steam Path

Efficiency Degradation of HP Turbines

88 86 Efficiency 84 82 80 78 76 74 0 2 4 6 Time (Years) 8 10 12
ML#2 BS#2 CD#1 MR#5 BS #2

ADSP Original Design Normal Overhaul ML#2

Big Sandy Unit 1 HP-IP/SFLP

One (1) unit, W design (Subcritical, 1963)
HP turbine complete and IP/SFLP turbine rotor and inner casing install 2008 Inefficient original design Internal components subjected to erosion and distortion Creep damage evident No spare blade rings or rotors

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Original Design Issues

Efficiency
Turn-around (Pressure Loss) Curtis Stage (Poor Efficiency)

Conventional Cylindrical Airfoil (Poor Efficiency)

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Existing Maintenance Issues

Reliability
L-0 Shrunk-on Disc (SCC Potential) IP/SFLP Rotor 44 years Old Large Dia. Inner Casing (CrMo casting) (Distortion, Rubbing) Stage 1 Blade Root Distortion Stages 2-4 Blade Untwist

L-0 Blade Fatigue Life (Blade Failure)

Large Blade Ring (Distortion, Rubbing, Blade Leaning)

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New HP Section Design

ACC Packing
(Active Clearance Control)

Integral Inner Casing

Separately supported blade rings and balancing ring

Monoblock No Bore Rotor Rateau control stage 3-D Reaction Blades (ISB)
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New IP/LP Section Design

25in ISB ACC Packing
(Active Clearance Control)

Separately-Supported Blade Rings

Mono block no bore rotor

No Shrink-fit

Integral Inner Casing

3-D Reaction Blades (ISB)

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Big Sandy Unit 1 Expectations

9 Anticipated Results
Improved reliability and design efficiency HP efficiency +4.1% to 88.9% IP efficiency +3.1% to 94.6% Expect +18 MW at original design steam flow Includes replacement throttle/governor valves Installed cost $18Million (US), approx.

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LP Turbine Performance Retrofits

AEP experience driven by reliability issues Stress Corrosion Cracking on blades, disks and Low Cycle Fatigue on blade attachments Flow limit for L-1 rotating blade causes curtailment LP turbine exhaust limit = 140 mm HgA (5.5 in HgA) Frequently caused summer time curtailments

Solution = LP Turbine Upgrade

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LP Turbine Performance Retrofits

Four (4) BB73 W LP steam paths ruggedized Improved material properties to resist SCC and LCF Aerodynamic improvements to blades and inlet / exhaust flow guides Improved seal design to reduce leakage Full load capable to 203 mm HgA (8 in HgA) backpressure 9 Improved performance: 3.4MW, 22.4 kcal/kWh (89 Btu/kWh)
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Stop/Control Valve Upgrades

Material Damage
Thermal fatigue, creep

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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1300 MW Series SV/CV Upgrades

Original Design
Pressure drop across combined valves = 5.1% Limited steam flow at VWO + 5% overpressure Significant solid particle erosion damage Expensive repairs performed every 2-3 years

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1300 MW Series SV/CV Upgrades

New Design
Separate stop and control valve chambers Actual pressure drop across valves = 2.08% Achieved 32 MW increased generation capability without changing boiler conditions Updating valve actuators to digital controls

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Turbine Control System Upgrades

Converting original MH and analog EH controls to digital Integrated into plant Distributed Control System Reuse or modify hydraulic systems Use fire resistant fluids Expectations Enhanced control Fewer unit trips Faster startup/ramp rates Online testing of turbine valves and protective devices

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Turbine Control System Upgrades

9 Results
9 Smooth, rapid rollups to synchronous speed 9 CV position and load ramping optimized by stress probe 9 CV stroke ramped according to test throttle pressure 9 Improved reliability during protective device checks 9 Lower peak speeds reached during turbine trip 9 Reduction in boiler tube leaks due to soft trips All contribute to improved reliability and performance
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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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