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El Paso MarriottEl Paso, TX
July 26-27, 2016
Plant Management, Engineering & Operations Conference and Roundtable
Instructed by:Mike Preston, Chemical Engineering Section Leader, Black & Veatch Corp.
Benjamin Franklin, Director, Technical Services, Headwaters Resources Anthony Tipton, Sr. Engineer, Thielsch Engineering, Inc.
Chad Kline, Superintendent, Generation Projects, El Paso Electric Company James Nyenhuis, Performance Consultant, Emerson Process Management
Power & Water SolutionsJohn Michael Harris, Consultant, R-Levels Power Partner LLC
Jackie Liu, Director, R-Levels Power Partner LLCAnthony “Tony” Carrino, Manager, Power Studies, Solomon Associates
Aubrey Johnson, VP, New Mexico Operations, PNM Resources
Brent Gifford, Manager, Major Project and New Generation, Arizona Public Service
RMEL ~ 6855 S. Havana, Ste 430 ~ Centennial, CO 80112 ~ (303) 865-5544 ~ FAX: (303) 865-5548 ~ www.RMEL.org
Tuesday, July 26, 20168:30 a.m. – 9:15 a.m.ELG ComplianceMike Preston, Chemical Engineering Section Leader, Black & VeatchThe CCR and ELG rules have been finalized and compliance plans are being prepared. These rules have profound effects on some power generating stations residuals management and water man-agement approaches. Now that the rules are final, it is helpful to reconsider compli-ance options in light of the established requirements and review holistic compliance approaches to reduce cost for affected power generators. This presentation will provide an overview of rules as they stand, integrated CCR and ELG compliance solutions with examples of implementa-tion, and impacts to operating philosophies.
9:15 a.m. – 10:00 a.m.The Effect of Sorbents on Flyash Quality and the Impacts to MarketingBenjamin Franklin, Director, Technical Services, Headwaters ResourcesThe presentation will cover, dry sorbent injection products and their potential impacts to fly ash quality and issues regarding marketing to the concrete industry and the various State Department of Transportation requirements.
10:00 a.m. - 10:15 a.m.Networking Break
10:15 a.m. - 11:00 a.m.Root Cause Analysis Collapse of 10th Stage Ip Diaphragm Steam Turbine Generator, Unit No. 2 Omaha Public Power DistrictAnthony Tipton, Sr. Engineer, Thielsch Engineering, Inc.On November 28th 2014 the Steam Turbine Generator for Unit #2 at Omaha Public Power District’s Nebraska City facility experienced a catastrophic failure in the HP/IP section while operating at full load. A root cause analysis revealed that the event was precipitated by the collapse of the 10th stage diaphragm into the 10th stage disk and rotating blades. The primary causal factor responsible for the collapse of the 10th stage diaphragm was identified as weld cracking at the vanes to outer and inner ring circum-ferential weldments which likely occurred during manu-facturing. The diaphragm integrity was therefore dependent on the remaining tack/seal welds between the vanes and outer/inner rings which eventually fractured due to creep or creep/fatigue during operation. The detailed results of the root cause investigation are presented.
11:00 a.m. - 11:45 a.m.Common Problems En-countered with Commis-sioning an LMS 100 PlantChad Kline, El Paso Electric Company
Noon – 1:00 p.m. Networking Lunch
1:00 p.m. – 4:00 p.m.Generation Vital Issues RoundtableRoundtable registration is limited to the first 40 members.Roundtables offer a unique forum for peer-to-peer shar-ing of experiences, critical issues and expertise. The roundtable is a discussion group, open only to RMEL members. Discussion is based on topics brought by attendees. Roundtables are focused on the open discus-sion period and provide each attendee the oppor-tunity for participation and dialogue on their particular issue. Roundtables are held in conjunction with a conference and many topics presented at the conference are discussed further in the roundtable setting. The roundtable is a good oppor-tunity to share experiences, troubleshoot problems and network with peers in a smaller, informal setting. Each participant is offered a chance to pose questions and share information. All attendees are encouraged to bring issues for discussion and materials for sharing.
Wednesday, July 27, 20168:30 a.m. – 9:15 a.m.Advanced Automation Strategies for Combined Cycle PlantsJames Nyenhuis, Performance Consultant, EmersonMarket and regulatory forces continue to change the op-erational profile of combined cycle plants. Plant owners and operators are constantly looking for ways to increase unit operational flexibility while maintaining plant reli-ability in an environment of
CONFERENCE AgENdAconsistent pressure on O&M costs. This environment is driving many plants to seek additional capabilities from their automation systems. This session will review some of the advanced technolo-gies and control strategies currently being deployed and how these applications have impacted dynamic plant performance capabilities.
9:15 a.m. – 10:00 a.m.New Generation Boiler Drum Water Level Instruments for Improved Boiler SafetyJohn Michael Harris, Consultant, R-Levels Power Partner LLCJackie Liu, Director, R-Levels Power Partner LLCTraditional boiler drum water level instruments simply do not work correctly. But don’t take our word for it ask your operators and instrument technicians three questions when you get back to your plant: 1) do the different theory drum water level in-struments (e.g. conductivity probe and DP transmitter) agree even when the level deviates from “zero”? 2) do the different theory instruments agree with one another during startup, shutdown, or large pressure changes? 3) when the drum is open during an outage, does the water mark inside match what the instruments have been reading?
10:00 a.m. - 10:15 a.m.Networking Break
10:15 a.m. - 11:00 a.m.Maintaining Reliability in Low Margin MarketsAnthony “Tony” Carrino, Manager, Power Studies, Solomon AssociatesLow margins and lower capacity factors don’t allow for the same level
Thank You RMEL Generation Committee
CHAIRJeff Karloff
Division Manager, Production Engineering & FuelsOmaha Public Power District
VICE CHAIRCurt Brown
Project Manager, Power Generation ServicesBlack & Veatch Corp.
David ArandaNewman Plant Manager
El Paso Electric Company
Ben CluffArizona Public ServiceEngineering Manager
Matt FergusonVP, Power & Energy Section Manager
HDR, Inc.
Darrel HensleySr. Director, Generation
Kansas City Power & Light
Richard ThreetDirector, Power Generation
PNM Resources
Kellen WaltersRegional Sales Director
Mitsubishi Hitachi Power Systems Americas, Inc.
Tom WosRegulatory Program Administrator
Tri-State Generation and Transmission Assn.
The RMEL Generation Committee plans all RMEL Generation events. If you’d like to send
information to the committee, email James Sakamoto at [email protected].
of maintenance spending as ‘the good old days’. Prioritization of scarce financial and human resources requires some better perspectives. A time-based and value-based spending framework is necessary to make better decisions around maintenance and reliability programs.
11:00 a.m. - 11:45 a.m.Engineering Resources/Workforce Management Panel
PNM’s Rotational Engi-neering ProgramPanelist #1: Aubrey Johnson, VP, New Mexico Operations, PNM ResourcesHow we developed the Program; how we admin-ister the program; results that we’re seeing.
Training Entry Level Engineers for a Career in Fossil GenerationPanelist #2: Brent Gifford, Manager, Major Project and New Generation, Arizona Public ServiceA solid foundation in operations makes for a better engineer and a solid foundation in engineer-ing makes for a better operator. APS’s New Engineering in Operations (NEO) program puts every new engineer through a set of rotations totaling 21 monthsin each of the vari-ous functions of an opera-tions crew. The 21 month rotations are followed by a 12 month assignment as a shift supervisor. After the 12 month assignment the engineer is free to choose to stay in operations or come to engineering. Regardless a more techni-cal, operations aware work force is created in Fossil.
11:45 a.m. - 1:00 p.m. Grab & Go Lunch and Transportation to Montana Power Station Montana Power Station is about 18 miles from the hotel. A shuttle will take you to the plant tour and return you back to the hotel.
1:00 p.m. - 3:00 p.m.Montana Power Station Plant Tour
PLANT MANAGEMENT, ENGINEERING AND OPERATIONS CONFERENCEConference, Roundtable and Montana
Power Station Plant Tour
ELG Compliance
Mike Preston Chemical Engineer Section Leader
Black & Veatch Corp.
26 Ju
ly, 2
016
CHEMICAL ENGINEERING SECTION LEADER MIKE PRESTON, PE
ELG COMPLIANCE
AGENDA • Regulatory Overview • Solutions • Getting Started
2
REGULATIONS
3
Regulation 2011 2012 2013 2014 2015 2016 2017 2018
EGU MACT
Cross State Air Pollution
Coal Combustion Residuals
Water 316 (b) & Effluent
Guidelines
Greenhouse Gases (GHGs)
Comment Period
Final Rule
MACT Rule Pre-compliance Period for existing sources
MACT Rule Compliance for existing sources
Current Clean Air Interstate Rule (CAIR)
CSAPR Phase I Compliance
Cross State Air Pollution Rule (CSAPR) Phase II Compliance
EPA Developing Final Rule
Final Rule
CCR Rule Pre-compliance Period CCR Rule Compliance
Develop Final 316(b) Rules
Develop New Effluent Guidelines
Rules
Final Rule 316(b) Rule Compliance
Final Rule Effluent Guidelines Compliance
EPA GHG Reporting Rule Compliance Best Available Control Technology for Modified/New Sources (PSD/NSR/BACT) Smaller Sources Included by EPA
Proposed GHG Regulation for New Sources
Develop GHG Regulation for Existing Plants Possible Compliance with New GHG Rules
Proposed Rule
Proposed Rule
Develop Final Rule
Impacts: • Elimination of Non Compliant
CCR Impoundments and Landfills • Revised Ash Handling Systems • Monitoring and Reporting • Public Exposure Due to
Enforcement Mechanism • Plant Wastewater Treatment
COAL COMBUSTION RESIDUALS
4
STEAM ELECTRIC POWER GENERATING EFFLUENT LIMITATIONS GUIDELINES 40 CFR 423
5
Waste Stream BPT BAT NSPS PSES & PSNS
All Waste Streams pH 6.5-9 PCBs: Zero discharge PCBs: Zero discharge pH 6.5-9
PCBs: Zero discharge PCBs: Zero discharge
Low Volume Wastes TSS 100/30 Oil and Grease 20/15 No Limitation = BPT No Limitation
Fly Ash Handling TSS 100/30 Oil and Grease 20/15 No Limitation Zero Discharge
Zero Discharge (PSNS only) No limitation in PSES
Bottom Ash Handling TSS 100/30 Oil and Grease 20/15 No Limitation TSS 100/30 Oil and
Grease 20/15 No Limitation
Chemical Metal Cleaning TSS 100/30 Oil and Grease 20/15 Cu 1.0/1.0 Fe 1.0/1.0
Cu 1.0/1.0 Fe 1.0/1.0 TSS 100/30 Oil and Grease 20/15 Cu 1.0/1.0 Fe 1.0/1.0
Cu 1.0 max
Once Through Cooling FAC 0.5/0.2 TRC 0.20 max or = BPT if <25 MW
TRC 0.20 max or = BPT if <25 MW No Limitation
Cooling Tower Blowdown FAC 0.5/0.2 FAC 0.5/0.2 126 Pr. Pol. No. Detect Cr 0.2/0.2 ZN 1.0/1.0
FAC 0.5/0.2 126 Pr. Pol. No. Detect Cr 0.2/0.2 ZN 1.0/1.0
126 Pr. Pol. No Detect Cr 0.2 max Zn 1.0 max
Coal Pile Runoff TSS 50 max No Limitation TSS 50 max No Limitation
Concentrations are in mg/l. If daily maximum and 30-day average concentrations apply, they are given as “maximum/average”.
BCT is reserved for all waste streams.
Low Volume Wastes include: clarifier blowdown, makeup water filter backwash, lime softener blowdown, ion exchange softener regeneration, demineralizer regeneration, powdered resin demineralizer back flush, reverse osmosis brine, boiler blowdown, evaporator blowdown, laboratory drains, FGD bleed stream, and diesel engine cooling system discharge.
• FGD wastewater
• Ash impoundments
• Wet ash handling systems • Metal cleaning wastewaters
• Landfill leachate
FOCUS OF UPDATED GUIDELINES
6
BASIS OF ELG
7
Waste Stream Technology Regulatory Option BAT NSPS PSES PSNS
FGD Wastewater
Chemical Precipitation x x x x
Biological Treatment x x x x
Evaporation x x
Fly Ash Dry Handling x x x x
Bottom Ash Dry Handling Closed Loop x x x
Leachate Chemical Precipitation Impoundment
x x
x x
Gasification Wastewater Evaporation x x x x
Flue Gas Mercury Control Wastes Dry Handling x x x x
PREFERRED TECHNOLOGIES
NEW FEDERAL REQUIREMENTS
8 Technology based limits
Waste Stream BAT Limits, Avg/Max NSPS, PSES, PSNS Limits, Avg / Max
FGD Blowdown
As – 8/11 ppb Hg – 356/788 ppt NO2-NO3 – 4.4/17 ppm Se – 12/23 ppb
As – -/4 ppb Hg – 24/39 ppt Se – -/5 ppb TDS – 24/50 mg/l
Non-Chemical Metal Cleaning No New Limits No New Limits
Ash Transport No Discharge No Discharge
Leachate Impoundment TSS - 30/100 ppm Oil and Grease - 15/20 ppm
As – 8/11 ppb Hg – 356/788 ppt
Anti Circumvention Provision (ACP)
• Requires a particular waste stream for which a zero discharge limitation has been established not be used in another plant process that results in a surface water discharge. The exception to this provision is use of ash transport water as FGD makeup water.
Legacy Provisions
• Ash transport water generated prior to the date established by the ELG as the control date (earliest November 2018; latest December 2023) would be treated under current BPT (settling ponds)
Combined Waste Streams
• Factored approach to limits where waste streams of different categories are combined for discharge
Removal Credits
• POTW’s may grant qualifying removal credits to indirect discharges. POTW must apply and receive authorization to offer credits.
ADDITIONAL PROVISIONS
9
TIME FRAME
10
Latest Compliance Deadline
4
Earliest Compliance Deadline
3 Final Regulations
2
Draft Regulations Published
1
2013 2014 2015 2016 2017 2018 2019 2020 2023
Takes effect upon next permit issuance or renewal
• More Stringent Effluent Limits to Existing Wastewater Discharge
• Less Flexible Water Management
• Segregation of Some Wastewaters
• Additional Internal Monitoring Points (IMP’s) • Additional Analytical Work and Reporting • Additional Treatment of Non-Compliant Streams
IMPACT OF UPDATED EFFLUENT LIMITATION GUIDELINES
11
EFFLUENT GUIDELINE SOLUTIONS
12
• Isolate and address water issues individually
• Take a holistic approach to water management
WATER MANAGEMENT APPROACH
13
Water management can greatly reduce the capital required to comply
Every 1 gpm of FGD wastewater discharge may cost as much as
$90,000+ to comply with regulations
COST OF TREATMENT
14
• Holistic water review
• Opportunities for reuse
• Minimize treatment
• New water management paradigm
• Understand • Regulatory impact • Treatment options • Cost of treatment ($, MW)
WATER MANAGEMENT GOALS
15
WATER BALANCE
16
CCR AND ELG INTERSECTION
17
Ash Impoundment
(Pond)
Ash Handling Systems
Low volume wastewater
FGD wastewater
Coal pile runoff
Metal cleaning wastewater Other wastewater
ASH SYSTEM SOLUTIONS
18
Replace non-compliant
impoundment with compliant
impoundment
Dewatering Bin System
Dewatering Basins System
Submerged Scraper Conveyor
Dry Ash Conveyor System
Remote Submerged Scraper Conveyor
WASTEWATER SOLUTIONS – LOW VOLUME WASTEWATER (LVW)
19
• Considering future regulatory changes
• Cataloging all the flows
• Understanding plant water balance
• Data collection and analysis
• Flexibility • Understand variable
water quality
• Sizing treatment systems
• Solids handling
• Oily water
• Schedule • Coordination with ash
system modifications • Permitting
CHALLENGES
20
Chemical Precipitation • TSS Reduction • Metals
Reduction
Biological Treatment • Denitrification • Selenium
Reduction
OR
Evaporation • Falling Film • Crystallizer • Solidification • Spray Drier
FGD WASTEWATER TREATMENT
21
FGD WASTEWATER TREATMENT
22
PHYSICAL-CHEMICAL TREATMENT
23
Equalization
Tank
Primary Clarifier
Desaturation
Tank
Sulfide Rxn Tank
Secondary Clarifier
Neut Tank (Optional)
Dewatering
Lime Sulfide
Polymer
FGD
Wastewater
Treated
Wastewater
Cake
To Landfill
Effluent Tank (and possibly
filters)
Filtrate
Sludge Tank
Sludge Recycle
Coagulation
Tank
Ferric Chloride Acid
BIOLOGICAL SELENIUM REDUCTION
• Create conditions that allow microbes to use selenate and selenite as an oxygen source, precipitating elemental selenium.
• Same bio-mechanism as denitrification or perchlorate reduction.
24
SeO42- + organic carbon → SeO3
2- + organic carbon → Se0 + CO2 + H2O
BIOLOGICAL TREATMENT
25
GE’s ABMet® Process
Source: General Electric
ZERO LIQUID DISCHARGE (ZLD)
26
Source: General Electric
SPRAY DRYER
27
Source: Advatech
• Oasys Water
• Membrane Brine Concentrator (80 – 90 Percent Recovery)
• Process using Draw Solution
• Draw Solution is Regenerated
• Capable of Efficiently Concentrating High TDS Brine Solutions
• Unit In Service – Changxing Power Station
• Test Unit being Prepared for WRC
FORWARD OSMOSIS
28
• Blending Wastewater with Power Plant Residuals for Disposal
• Typically Fly Ash Blending
• GE Proposed Improved Process
SOLIDIFICATION
29
PIRONOX™ - EVOQUA • Zero valent iron (ZVI), Fe0, iron
filings
• Past results inconsistent
• Removal mechanism is complex
• 3 or 4 different pathways
• Iron passivates
• New method for maintaining reactive oxide coating developed at Texas A&M
• Evoqua + Texas A&M licensing agreement
Latest development in ZVI arena 30
ZERO VALENT IRON - EVOQUA
31
THE BENEFITS OF GETTING STARTED
32
• Make the best of difficult requirements
• Understand the potential scenarios
• Understand schedule issues • Prepare for possible outcomes
• Select best solution for your facility
• Prepare for regulatory discussions
LOOKING AHEAD
33
High Level Study
• Evaluate current water usage
• Determine options
• 3-6 months
Detailed Study / Permitting Engineering
• Determine optimal solution
• 6-12 months
Capital Project
• 2-3 years
ELG COMPLIANCE PROGRAM DEVELOPMENT
34 Don’t overlook permitting and regulatory approval
www.bv.com
The Effect of Sorbents on Flyash Quality and the Impacts to
Marketing
Benjamin Franklin Director, Technical Services
Headwaters Resources
Dry Sorbent Injection A marketers perspective.
RMEL workshop, El Paso TX 7/26/ 2016
Dry Sorbent Technologies
Dry Sorbent Injection (Trona) 40-75% reduction in SO2: Lime, hydrated lime, Sodium bi-carbonate
Selective Non Catalytic Reduction (SNCR) 35% reduction in NOx (Ammonia)
Selective Catalytic Reduction (SCR) 90% reduction in NOx
Powdered Activated Carbon (PAC) 90% mercury removal
DOT Specifications Alkali Content
Department of Transportation: ◦ AASHTO M295: 1.5% available alkali ◦ ASTM: optional on request 1.5
Fly ashes in the US:~1.5% or greater available alkalis.
DOT total alkali allowances:3.0 Proper QA/QC is key to marketing ash
with Trona.
Powdered Activated Carbon
PAC creating many air issues in the fly ash market, which creates a tight supply chain.
Many in the specifying agencies and ready mix/related industry do not understand PAC.
Will create entrained air issues, effect dependent on PAC utilized.
Does not effect specification at DOT.
Impacts to Concrete Quality
Trona: Raises alkalis. May effect set times.
Ammonia: May be a health concern in confined spaces, no issue with concrete performance.
All sorbents create marketing issues and may cause the material to be removed from the market.
Currently many utilities still trialing different PACs, as results differed during peak vs, off peak generation.
Fuel change, wet scrubber w/ additives and other options might be available.
Mercury and Air Toxics Standards (MATS) final rule went into effect in December 2011 requiring coal fired power plants to control mercury emissions within 3 years (April 2015):
− States may grant 4th year (2016) −USEPA administrative order would allow 5th year (2017) for critical units.
Activated Carbon Injection Post Fly Ash Collection
Fly Ash
Flue Gas
Electrostatic Precipitator Boiler
Stack Carbon Injected after ESP
Fly Ash Only
C + Hg
Baghouse
Activated carbon
9
Sorbent Vendors Top players vying for this $10 billion /year market
Mercury Control: • Cabot (Norit) – DARCO-Hg family of sorbents • Calgon – Flue PAC family of sorbents • ADA carbon Solution: Power PAC, Fast Pac • Albemarle: B-PAC, C-PAC, H-PAC, • BASF – Mercury Sorbent HX – Brominated mineral sorbent • Novinda: Amended Silicates • EM2C: Additive & PAC • ADA ES: coal additive, engineering solutions and consulting • Others: Shaw, Nalco (scrubber additives)
10
Foam Index/ Carbon Reactivity Testing
Foam Index
200ml: water 40gms: fly ash AEA, company standard or most prevalent 4:1 for C ashes/low LOI Full strength for high LOI/highly reactive.
12
Foam Index/Windows/Carbon not mitigated.
13
Foam Index/No Windows/Carbon mitigated
Cement or fly ash
AEA
Air Bubble
Activated Carbon
Chemical mitigation saturates the activated carbon surfaces with a sacrificial agent to prevent the adsorption of AEA’s.
Air Entrainment Agents (AEA’s) prefer powdered activated carbon.
Activated carbon in concrete attracts the AEA hydrophobic end and prevent it from entraining air.
15
0%
5%
10%
15%
20%
25%
30%
35%
1 1.3 1.6 1.9 2.2 2.5 2.8 3.1 3.4 3.7 4 4.3 4.6 4.9 5.2 5.5 5.8 6.1 6.4 6.7 7
Perc
en
t o
f ti
me a
t in
ject
ion
ra
te
ACI Rate lb per million acf of flue gas
1st Generation Less Consistent
Current Generation
More Consistent
Lower PAC injection rates and a tighter control range =
less PAC in ash + Improved consistency (AEA demand)
Improvements in Activated Carbon Technology
16
PAC Adsorption Capacity varies…….
The slope of the linear regression line indicates the foam index variability relative to changes in PAC % concentration in ash.
In this example, C-PAC is less adsorptive of MBVR than B-PAC.
0
5
10
15
20
25
30
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
Fo
am
In
dex (
MB
VR
Co
nc.
)
RA 2.2 Dosage lb/ton of ash
Chemical Treatment 2.2 Tamed Dose-Response
Class C ash samples containing variable levels of PAC treated to acceptable foam index level.
Sample Description Control C-Ash C-Ash with PAC
Cement No PAC Untreated Treated
Foam Index (conc MBVR) 3 18 5 AEA dosage (oz/cw) 1.2 1.4 4.2 1.7
Air Content (6%+1%) 7.0% 7.0% 6.25% 5.75% Bulk Density, lb/ft3 144.8 145.6 147.2 148.0
Slump, inches (6+1) 6.25 6.0 6.25 5.75 3 day, psi 2814 2858 3039 2907 7 day, psi 3433 3689 3592 3918 28 day, psi 4594 4802 4764 4908
Beneficiated ash with chemical treatment
Ash treatment restored the AEA dosage to same level expected with ash containing NO activated carbon.
Sorbent Sensor
•New State of the Art Patented technology. •Provides definitive data as opposed to Foam Index. •Significant cost to develop and produce. •Produced and used by one marketer
Plants in Service Meeting current Regulations.
Port Neal: Ammonia, PAC and Trona
Newton: PAC Baldwin: PAC Jeffrey's and Tecumseh: PAC
THANKS
Benjamin J. Franklin Director of Technical Services Mobile: 314-974-5095 Email: [email protected] www.flyash.com
Root Cause Analysis Collapse of 10th Stage Ip Diaphragm Steam Turbine Generator, Unit No. 2 Omaha Public Power District
Anthony Tipton Sr. Engineer
Thielsch Engineering, Inc.
Anthony Tipton Thielsch Engineering, Inc.
July 2016
Tandem Compound Train Combined HP-IP Two Double Flow LP’s
Design Rated Conditions 720MW 2460 psig 1050⁰F/1050⁰F Speed-3600 RPM
Began Operation-July 2009
Unit Operating at 720MW for 2 ½ Hours Was Ramped from
500MW High-High Vibration
Levels at #1 and #2 Bearings Instantaneous No Warning Unit Tripped
30 Minutes to Coast Down
0
5
10
15
20
25
30
35
40
3500
3520
3540
3560
3580
3600
3620
4:19:12 AM 4:33:36 AM 4:48:00 AM 5:02:24 AM 5:16:48 AM 5:31:12 AM 5:45:36 AM 6:00:00 AM 6:14:24 AM
Vibr
atio
n (m
ils),
Trus
t Bea
ring
Posi
iton
(in)
Spee
d (R
PM)
Time
Turbine Speed
#2 Bearing Vibration
#1 Bearing Vibration
Thrust Bearing
Majority of Damage Centered in IP Turbine at 9th-11th Stages
Damage to 8th, 9th ,11th Stage and 12th Stage Rotating
Blades and Diaphragms Deemed Secondary
Rub and Impact Damage
8th and 9th Stage Diaphragms were Dished
10th Stage Blade Airfoils Missing Blade Roots “Proud”
on Exit Side of Disk 10th Stage Disk
Rubbed on Inlet Side Thickness Reduced
50%
10th Stage Diaphragm All Vanes Liberated
from Inner/Outer Rings Fractured at Vane to
Inner/Outer Ring Weld Joints
Severe Rub Damage on Exhaust Side of Inner Ring
Primary Failure Identified as 10th Stage Diaphragm
Fracture of Vane at the Outer Ring and Inner Ring Weld Joints Allowed Diaphragm to Deflect Downstream
Severe Wear to 10th Stage Disk and Blades Eventual Liberation of All 10th Stage Diaphragm Vanes
Diaphragm Components Outer and Inner
Spacer Rings Profiled Vane Slots
Vanes Outer and Inner
Rings
Vanes are “Tack Welded to Outer and Inner Spacers Follows Vane Profile
Multipass Circumferential Welds Join Outer and Inner
Ring to Vane and Outer and Inner Spacers
All Vanes Separated at Outer Ring to Vane Weldments Leading and Trailing
Edges
Outer Ring to Vane Weldment at Leading Edge Weld Passes Evident Surface Heavily
Oxidized Fracture Morphology
Exhibits Melted Appearance Weld Directionality
Apparent
OUTER RING LEADING EDGE SECTION
METALLOGRAPHIC SAMPLE
Circumferential Weld Fracture (100X) Transgranular
Fracture Path Lack of Deformation
at and Adjacent to Fracture
Oxidation app. 0.003” Thick
No Evidence of Creep Damage
Outer Ring to Vane Weldment at Trailing Edge Weld Passes Not
Evident Surface Heavily
Oxidized No Fracture Features Melted Appearance
Lack of Fusion
Vane to Outer Ring
Weldment at Leading Edge Fracture Morphology
Mimics Mating Fracture on Outer Ring
“Tack Weld” Evident Rub Damage Consumed
Most Fracture Features Shear Evident in Select
Areas
Circumferential Weld Fracture (500X) Fracture Progressed
Through Weld Metal Oxidation Present on
Fracture Weld Metal on Vane
Surface App. 0.008” Thick
Small Areas Exhibit Lack of Fusion
Transgranular Fracture Path
All Vanes Separated from Inner Ring
Severe Rub Damage on Exhaust Side of Inner Ring Vane Trailing Edge
Weldment Consumed
Inner Ring to Vane Weldment at Leading Edge Fracture Morphology
Similar to Outer Ring Fracture
Oxidation on surface Rub Debris on
Surface
INNER RING LEADING EDGE SECTION
METALLOGRAPHIC SAMPLE
Circumferential Weld Fracture (100X) Transgranular
Fracture Path No Evidence of Gross
Deformation No Evidence of Creep
Damage
Vane to Inner Ring Weldments Rub Damage
Consumed Trailing Edge Weldment
Majority of Leading Edge Weldment Fracture Damaged by Rubbing
Circumferential Weld Fracture at LE (500X) Fracture Progressed
Through Weld Metal Oxidation Present on
Fracture Transgranular
Fracture Path No Evidence of Gross
Plastic Deformation No Evidence of Creep
Damage
Fracture Through Vane to Outer Ring Weldment at Leading Edge Likely Occurred During Manufacturing
Weld Metal had Limited Ductility Prior to PWHT Significant Shrinkage and Transformational Stresses Highly Restrained Weld Joint
Fracture Through Vane to Outer Ring Weldment at Trailing Edge Could Not be Determined Due to Secondary Damage
Significant Lack of Fusion/Penetration Evident
Some Fractures Through Vane to Inner Ring Weldment at Leading Edge Likely Occurred During Manufacturing
Similar to Vane to Outer Ring at Leading Edge Fractures
Some Fractures Through Vane to Inner Ring Weldment at Leading Edge Were Due to Tensile Overload
Probably Occurred During Turbine Incident
Cause of Vane to Inner Ring Separation at Trailing Edges Could Not be Determined from Evidence Available.
Vane to Outer Ring Joint Strength was Reliant on the “Tack Welds” (Seal Weld)
Component Materials are Typical Materials of
Construction for High Temperature Steam Turbines Hardness of Components and Weldments Indicates
they were Properly Heat Treated and/or PWHT’d
Reported Excursions 30 minutes at 1148°F 130 minutes at 1182°F 10 minutes at 1142°F
IP Inlet Temps Not Affected Reduced Effectiveness of IP Rotor Cooling
Lower Creep Rupture Life of Diaphragm Minor Effect at Diaphragm Outer Rings
Primarily to Cool Disks and Blades Will Cool Diaphragm
Inner Ring Much Less Effective at
Cooling Vanes and Outer Ring
Erratic Operation of Cooling Steam Valve Reported Diaphragm will
Experience Higher Temps Lower Creep Rupture
Life
IP Diaphragm Collapse at Major Southern Utility Same Turbine Manufacturer Similar Design
Attributed to “Cold Cracking” of Vane to Outer/Inner Ring Weld Joints
Fracture Characteristics Similar to OPPD Failure
Lack of Penetration/Fusion Evident No Evidence of Global Creep
Primary-Manufacturing Reduced Weld Joint Strength Welds Joining Vanes to Outer Ring at Leading Edge
Appear to Have Cracked During Fabrication Welds Joining Vane to Outer Ring Trailing Edge
Exhibited Significant Areas of Lack of Fusion/Penetration
Secondary-Operation
Erratic Operation of IP Rotor Cooling Steam Valve High Main Steam Temps Reduced Effectiveness of IP Rotor
Cooling Steam
10th Stage IP Diaphragm Inner Ring Deflected Downstream and Contacted the 10th Stage Disc and Blades
Severe Rubbing Separation of Vanes from Diaphragm Damage to 10th Stage Disc and Blades Secondary Downstream Damage
Imbalance Resulted in High Vibration Unit Tripped
Deflection of Inner Ring Occurred When The Vanes Fractured at the Outer Ring and Inner Ring Weldments
Likely Occurred at the Outer Ring Leading Edge and Inner Ring Trailing Edge First
Circumferential Welds between Vane and Outer
Ring/Inner Ring Cracked During Diaphragm Fabrication
Weld Joint Integrity/Strength Compromised
Common Problems Encountered with Commissioning an
LMS 100 Plant
Chad Kline Superintendent, Generation Projects
El Paso Electric Company