Professional Documents
Culture Documents
Presented by
Paul Roediger
Encotech, Inc.
encotec h,
h Inc.
1
Overview
3
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
4
The Outage Time-Line
TURBINE OUTAGE
Shutdown Startup
Disassembly Reassembly
5
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
6
Pow er Loss (kW)
1000
1200
1400
1600
1800
200
400
600
800
0
Interstage
Packings
End Packings
Miscellaneous
Leakages
Surface
Roughness
Cover Deposits
Trailing Edge
Thickness
7
Opening Audit Power Loss
Po w e r L o s s (k W)
-200
200
600
1000
1400
1800
2200
2600
3000
Inters tage
Pac kings
Mis c ellaneous
Leakages
Surf ac e
Roughnes s
Trailing Edge
Thic knes s
Closing Power Loss
Rec ov ery
8
Results by Category
Encotech STPE - Fossil 5.2....05/11/2000..................Turbine Audit Summary
9
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
10
Chronology
of a
Steam
Path Audit
11
Model
Create model using the Thermal Kit
12
Day 1
Plan around grit blasting schedule
Inspect horizontal joint
Measure packing clearances
Measure top half tooth heights
Inspect shell sealing surfaces
13
Day 2
14
Day 3
15
Day 4
Input data
Print Steam Path Audit reports
Present preliminary results
16
SPA - Flow Path Damage
17
Solid Particle Erosion
18
Solid Particle Erosion Pattern
19
Inlet to the Diaphragm
20
Mechanical Damage
21
Cover Deposits
22
Blade Deposits
23
Foreign Object Damage
24
SPA - Flow Path Damage
25
Surface Roughness
encotec h,
h Inc.
26
Surface Roughness
27
Horizontal Joint
encotec h,
h Inc.
28
Tip Spill Strip
29
Tip Spill Strip Measurements
C B A Gap
CLEARANCE
30
Clearance Calculation Method
GAP
Clearance (C)
STATIONARY
ELEMENT
ROTATING
Tooth FEATURE
31
Rubbed Teeth
32
Interstage Packing Burr
33
Burr Removal Tool
34
Martins Formula
HILO Packing Coefficient K
F 1
(N
25K
AP
/ln1P P
)2)vP
1v
80
SPRING
70
PACKINGRING
2 1
60
ROTOR CLEARANCE
Coefficient K
50
40
=c
30
20
0 10 20 30 40 50 60 70
ROTOR
FLOW AREA
TOOTH
INCORRECT CLEARANCE
DUE TO CASING SPRING
38
Elliptical Flow Area
Diameter
Diameter
tops - on
tops - off
Horizontal
Diameter
tops - on
ROTOR vertical
ELLIPTICAL
FLOW AREA TOOTH
INCORRECT CLEARANCE
DUE TO CASING SPRING
39
Balance Hole Measurements
RADIAL
POSITION AXIAL AXIAL AXIAL
LENGTH MINOR AXIS LENGTH RADIAL LENGTH RADIAL
POSITION POSITION
RADIAL
AXIAL MAJOR AXIS
POSITION
LENGTH
DIAMETER
40
Blade Geometry
BLADE
CARRIER
BLADE HEIGHT
TRAILING
EDGE
AXIAL
WIDTH
PITCH LINE
LEADING
EDGE
PITCH
DIAMETER
SEALING
ROTOR DIAMETE
R
ROOT DIAMETER
OF STATIONARY BLADE
41
Root Diameter Measurement
BLADE
CARRIER
STG
16 TIP SPILL
STRIPS STG
15
TRAILING
EDGE
STAGE 15
AXIAL WIDTH
PITCH LINE
LEADING
EDGE
STAGE 16
BLADE HEIGHT
DIAPHRAGM
TIP TENON
SPILL STRIPS
TIP
LEAKAGE
COVER OR
SHROUD
STEAM FLOW
ROTATING STATIONARY
SHELL BLADE BLADE
PRESSURE
BOWL
ROOT LEAKAGE PRESSURE
ROOT
SPILL STRIPS
DOVETAIL
BALANCE HOLE
FLOW
BALANCE HOLE
PACKING
WHEEL
SHAFT
43
Stationary Blading Root Dia
DIAPHRAGM
TIP
SPILL STRIPS
STEAM FLOW
ROOT RADIAL
SPILL STRIP
ROOT AXIAL
SPILL STRIP
BALANCE HOLE
WHEEL
INTERSTAGE PACKING
STATIONARY
BLADE ROOT
DIAMETER
44
Rotating Blade Axial Width
AXIAL WIDTH
AXIAL WIDTH
ADJUSTMENT AXIAL WIDTH
ADJUSTMENT
45
Cover Deposits
COVER DEPOSIT
DEPTH (INCHES)
46
Deposit & Throat Opening
PRESSURE (CONCAVE) SURFACE
LEADING EDGE
RESTRICTED OPENING
TRAILING EDGE
DEPOSIT DEPTH
47
Foreign Object Damage
48
Erosion Measurements
TRAILING EDGE
DEPTH
TRIANGULAR SHAPED
SOLID PARTICLE EROSION
TRAILING EDGE
HEIGHT
TAPERED 50%
49
Surface Roughness Measurement
CONVEX SIDE
LEADING LEADING SECTION
SECTION % OF SURFACE
CENTER WITH EMERY GRIT SIZE
SECTION
3 CENTER SECTION
2 3 % OF SURFACE
WITH EMERY GRIT SIZE
TRAILING 2
1 SECTION
TRAILING SECTION
% OF SURFACE
1 WITH EMERY GRIT SIZE
COMPARATOR
3
LEADING SECTION 2
CENTER SECTION
1
TRAILING SECTION
CONCAVE SIDE
50
Snout Rings
Steam
Leakage
Paths
(24) Outer
(23) Shell
8 Rings (22)
(21)
4 Inner (20)
4 Outer (19)
(18)
(17)
(16)
Typical
(15)
IP Inlet or
HP Exhaust (14)
(13)
(12)
4 Rings (11)
2 Inner (10)
Inner
2 Outer (9)
Shell
Locking Screw
(8)
Nozzle
Box
51
First Stage
Bowl
Questions?
1-888-Encotech
www.encotech.com
Phone (518) 374-0924
53
54
Computer Model
Create turbine model at Encotechs office
using the Thermal Kit
Design heat balance (VWO)
Turbine cross section
Clearance and steam seal system diagram
First stage shell pressure curve
55
Coordinate Activities
Coordinate activities with owner
Review safety procedures
Sign contract
Plan around grit blasting schedule
56
Coordinate Activities
Coordinate with outage crew
Place upper half of casing w/ horizontal joint up or
lay on ground w/ 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
57
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
58
Before Lifting Rotor
Chart rotor for actual radial clearances
Interstage packings
Shaft end packings
Root spill strip clearances
Tip spill strip clearances
59
After Lifting Rotor
Measure lower half tooth heights
Interstage packing and shaft end packing
Root and tip spill strips
61
Geometric Data
Geometric data for the steam path must be
obtained to properly model turbine
Blade heights and widths
Blade root diameters
Balance holes
62
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
63
Completion
Enter audit data into STPE computer model
Review results
64
STPE
Steam Turbine
Performance Evaluation
65