steam path audit -...
TRANSCRIPT
STEAM PATH AUDIT
February 19, 2009 New Delhi, India
Arun Kumar SarnaSteam path AuditorHead-BD/ EVONIK Energy Services India Paul F. RoedigerSteam path AuditorPresident/ Encotech Inc. USA`
3rd Thermal Power India 2009
Overview
• Brief about Evonik & its activities in India
• What is a Steam Path Audit?
• Benefits of SPA
• Specific Areas of Concern
• Steam Path Audit Experience
Seite 3
A new company
A new brand
Seite 4
Model of foundation
Evonik Industries AG
Chemicals Energy Real Estate
100 % 100 %
Evonik Industries AG
Seite 5
A global group
Evonik has production and distribution sites in 52 countries across the globe and operates in more than 100 countries.
Production and distribution sites
Seite 6
Immobilien 3%
Business Area Energy
Solid foundation for mastering the challenges of the future
Power District Heating
Power Minerals
Energy Services
Trading Renewable Energies
Seite 7
Business Line Power Power Plant Sites
Based on decades of experience…
… trading new paths in the energy business..
Köln-Godorf
211 MW
2004
Termopaipa
165 MW
1999
Infracor
600 MW Iskenderun
1,320 MW
2003
Mindanao
232 MW.
2006
Walsum
750 MW COD 2010
Walsum
600 MW Weiher
724 MW Fenne
502 MW Lünen
500 MW Voerde
2,234 MW Bergkamen
747 MW Herne
950 MW Bexbach
773 MW
Leuna
158 MW
1996
COD = projected commercial operation date
Seite 8
Energy Technologies Nuclear Technologies Plant Services System Technologies
Design, construction, decommissioning and disposal of nuclear plants
Design, site supervision and commissioning of power plants
Operation & Maintenance Measurement & Analysis
Energy Management Systems Operation Management Systems Communication Technologies Site IT
Evonik Energy Services Business Lines
Evonik Energy Services
• Sales 65,6 Mio. EUR *
• Employees 498* *data 2007
SUMMARY SHEET:
Renovation & Modernization studies: 16 Units of 110 to 210 MW fleet
Energy Audit studies: Various Units upto size 210 MW
Steam Path Audit studies: Various Units upto size 500 MW
Performance Testing: 3 Coal Fired Units upto size 210 MW 156 MW Gas fired CC Station
Energy Efficiency Solutions by Evonik in India
Ener
gy E
ffici
ency
Act
iviti
es
What is a Steam Path Audit?
• A detailed inspection of the stationary and rotating steam path components
• An accounting of performance losses on a stage-by-stage basis
• A presentation of losses in power and heat rate
Benefits of a SPA
• Provides detailed inspection of steam path
• Repair/replacement decisions, early in outage
• Aid decisions for future repair
• Provides excellent record/history of equipment condition for future reference
The Outage Time-Line
Disassembly Reassembly
The specific areas of concern addressed by the audit are:
1) Leakages: - past stationary stage blading - past rotating stage blading - past shaft end packings where rotors emerge from casings - across poorly fitting joints - other miscellaneous leakages
3) Flow blockages from: - deposits - foreign objects - mechanical damage
2) Surface finish degradation: - deposits - corrosion - solid particle erosion - mechanical damage
4) Flow path modification from: - solid particle erosion - water droplet erosion - mechanical damage
Results
• Quantification of losses measured in pre-outage test
• Quality check on maintenance performed during the outage
• Performance improvement resulting from individual maintenance actions
• Expected return-to-service performance
Opening Audit Power Loss
Closing Power Loss
Results by Category
Encotech STPE - Fossil 5.2....05/11/2000..................Turbine Audit Summary
County Unit 1 Turbine Totals
Open audit 05/08/2000
Change In Heat Rate
Power Loss Heat Rate Loss
Audit Section (KW) (BTU/KWH) (%)
--------------------------- ---------- --------- ---------
Interstage Packings 152.9 118.20 1.10
End Packings 282.4 220.37 2.05
Tip Spill Strips 329.3 257.87 2.40
Miscellaneous Leakages 8.7 6.62 0.06
Flow Path Damage Results 109.5 20.42 0.19
Surface Roughness 122.7 94.70 0.88
Cover Deposits 0.0 0.00 0.00
Trailing Edge Thickness 0.0 0.00 0.00
Hand Calculations 0.0 0.00 0.00
--------------------------- ---------- --------- ---------
Totals 1005 759.8 7.07
See Casing Totals For Flow Change Impact
Results by Stage
Interstage Packing Root Spill Strip
<---Clearance----> <--Clearance---> Change In
Location Design Measured Design Measured Power Loss Heat Rate
Descr. (IN.) (IN.) (IN.) (IN.) (KW) (BTU/KWH)
-------- ------ -------- ------ -------- ----------- ---------
Stage 2 0.010 0.075 0.000 0.000 56.7 43.52
Stage 3 0.010 0.024 0.000 0.000 14.9 11.42
Stage 4 0.010 0.019 0.000 0.000 16.6 12.71
Stage 5 0.010 0.014 0.000 0.000 8.8 6.76
Stage 6 0.010 0.021 0.000 0.000 17.4 13.29
Stage 7 0.010 0.010 0.000 0.000 3.4 2.57
Stage 8 0.010 0.014 0.000 0.000 8.4 6.43
Total Power Loss (KW)........................ 153
Total Change In Heat Rate (BTU/KWH).......... 118.2
Total Heat Rate Loss (%)..................... 1.1
Chronology of
Steam Path Audit
Computer Model
Create turbine model at Evonik’s office using the Thermal Kit
• Design heat balance (VWO)
• Turbine cross section
• Clearance and steam seal system diagram
• First stage shell pressure curve
Coordinate Activities
Coordinate activities with owner
• Review safety procedures
• Sign contract
• Plan around grit blasting schedule
Coordinate Activities
Coordinate with outage crew
• Place upper half of casing w/ horizontal joint up or lay on ground with trailing edges up
• Leave all packing (interstage & shaft end) in place until measured. This speeds SPA process significantly
• All stages must be inspected prior to grit blasting
Sequence of Events (Casing Lifted)
• Inspect casing horizontal joint for leakage paths
• Measure blade geometry
• Measure packing teeth, interstage, tip, root, and & shaft end
• Create a photographic record of the steam path
Before Lifting Rotor
Chart rotor for actual radial clearances
• Interstage packings
• Shaft end packings
• Root spill strip clearances
• Tip spill strip clearances
After Lifting Rotor
Measure lower half tooth heights
• Interstage packing and shaft end packing
• Root and tip spill strips
Inspect lower half diaphragms
• Surface roughness
• Solid particle erosion
• Mechanical damage
Rotor
Inspect rotating blades
• Surface finish
• Solid particle erosion
• Mechanical damage
• Cover deposits
Geometric Data
Geometric data for the steam path must be obtained to properly model turbine
• Blade heights and widths
• Blade root diameters
• Balance holes
Photographic Record
Photographs of the steam path document condition
• All packing teeth
• Trailing edges of stationary and rotating blading
• Specific damage associated with the steam path
Completion
• Enter audit data into eSTPE™ computer model
• Review results
• Present preliminary report to owner at site
SPA - Flow Path Damage
Solid Particle Erosion
Blade Deposits
Foreign Object Damage
Tip Spill Strip
Tip Spill Strip Measurements
Clearance Calculation Method
Martin’s Formula
Root & Tip ToothTypes
Interstage Tooth types
Casing Spring
Elliptical Flow Area
Balance Hole Measurements
Blade Geometry
Root Diameter Measurement
Impulse Blading
Stationary Blading Root Dia
Rotating Blade Axial Width
Cover Deposits
Deposit & Throat Opening
Foreign Object Damage
Erosion Measurements
Surface Roughness Measurement
Steam Path Audit Experience
Turbine Manufacturers Modeled with eSTPE software
AEG/ Siemens Allis-Chalmers Alstom Ansaldo Asea Brown Boveri DeLaval Doosan Dresser-Rand Elliott Escher Wyss GE/Doosan
GEC Alsthom Co. General Electric Hitachi LMZ Mitsubishi Parsons Siemens Siemens/Kraftwerk Siemens/Westinghouse Skoda Toshiba Westinghouse
Models by Size and Manufacturer
Under 51 MW 101 MW 251 MW 501 MW Above 50 MW 100 MW 250 MW 500 MW 750 MW 750 MW
AEG/ Siemens 1 Allis-Chalmers 1 1 2 Alstom 1 Ansaldo 1 Asea Brown Boveri (ABB) 1 1 4 1 DeLaval 2 1 Doosan 1 Dresser-Rand 3 Elliott 1 Escher Wyss 1 GE/Doosan 1 GEC Alsthom Co. 1 2 General Electric 12 16 30 13 20 5 Hitachi 1 LMZ 3 Mitsubishi 4 Parsons 3 1 Siemens 2 Siemens/Kraftwerk 4 Siemens/Westinghouse 2 Skoda 1 Toshiba 2 Westinghouse 1 7 13 11 8 4
Steam Path Audit experience in India (Joint experience of Evonik & Encotech Inc.)
Location Unit Manufacturer Generator Output (kW) Jhanor St 1 ABB 243,380
Kahalagaon 1 LMZ 210,000
Kawas St 1C Alsthom 122,600
Mettur 1 LMZ (Baughman Stage) 210,000
Ramagundam 3 Ansaldo 206,260
Ramagundam 5 Siemens Kraftwerk 500,000
Rihand 1 GEC Alsthom 534,000
Singrauli 6 Siemens Kraftwerk 532,072
Talcher 5 Skoda 110,000
Vindhyachal 2 LMZ 210,000
Vindhyachal 4 LMZ 210,000
Vindhyachal 7 Siemens Kraftwerk 500,000
Ropar 1 Siemens Kraftwerk 210,000
Ropar 2 Siemens Kraftwerk 210,000
Korba (West) 2 Siemens Kraftwerk 210,000
Kahalgaon 2 LMZ 210,000
RGCCPP, Kayamkulum BHEL 129,000
Ramagundam 2 Ansaldo 206,260
Steam Path Audit Experience
- A Case Study
Platzhalter Bild
Creativity means:Developing solutions that no one expects.
Evonik. Power to create
We let trees grow in the desert.
THANK YOU.