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2010 GE Energy Customer Solutions Conference

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© 2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
Technical Information Letters (TILs)

Southern Region Conference


August 25, 2010
Houston, TX

© 2009
© 2010 General
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Technical Information Letters (TILs)
Published – After July 2008 - 2009

• TIL - 1616 – Combined SV-CV Balance Chamber Bolt Breakage


• TIL - 1618 – Recommendation for Overspeed Prevention
• TIL - 1627 R1– D11 Steam Turbine N2 Packing Head Main Fit Cracking
• TIL - 1629 – Combined Stop/Control Valve Seat Stellite Liberation
• TIL - 1632 – Journal Bearing Operating and Maintenance
Recommendations
• TIL - 1719 - Modification to DTP Bearing Geometry

© 2009
© 2010 General
General Electric
Electric Company.
Company. AllAll Rights
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Reserved. This
This material
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may not
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Technical Information Letters (TILs)
Published 2010
• TIL - 1712 - R1 - Main Steam/Reheat Pipe Thermowell Replacement
• TIL - 1721 - 207D-11 Thrust Bearing Clearance Recommendations
• TIL - 1722 – Hydraulic Oil Contamination of Medium Steam Turbines with
EHC Systems
• TIL - 1733 – D-10 Steam Turbine Unit Turning Gear Housing Cross Bar
Clearance Modification
• TIL - 1734 – Recommendations For A10 Fleet Axial Rubs at the N2
Packing Head
• TIL - 1735 - A10 Turning Gear Piggyback Motor Inspection and Potential
Retrofit
• TIL - 1738 – A14/A15 Outer Shell Pressure Tap Connection Inspection
• TIL – 1739 – Main Stop Valve Stem Solid Particle Erosion
• TIL – 1745 – Inspection & Maintenance Hydraulic Power Unit Flex Hoses
• TIL – 1748 – D11 N2 Shell Fit Modification
© 2009
© 2010 General
General Electric
Electric Company.
Company. AllAll Rights
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Reserved. This
This material
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TIL – 1627 - D11 N2 Packing Head Main Fit Cracking
Causes
• Higher than expected peak stresses in the packing head
Axial Force
fillet radius. from Pressure
• Less than desirable material properties; specifically low Shell
Loading from
HP to IP
rupture strength and low notch rupture ductility on some IP
Packing Head
packing heads.
• Over temperature operation increases the risk of cracking. HP

Differential Pressure Across Fit


Recommendations
• At scheduled major outage intervals, perform NDE
inspection of packing head fit
• Perform machining to remove indication if present.
• If cracking is extensive perform high strength weld repair
with torch tempering at GE Pittsburg Service Shop.
( Minimum 23 days for repair)
• Following the repair perform dimensional check of
packing head fillet and shell fit to restore design
clearances.
D11 N2 main fit cracking.
• Consider ordering replacement packing head due to
repair cycle.
©©2010
2009General
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Reserved. material
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TIL – 1719 – Modification to DTP Bearing Geometry
Causes
• Some 6-pad DTP bearings have been found with
damage to the leading edge of the upper half pads.
• Damage is due to the oil wedge not forming
sufficiently, resulting in the pad “fluttering”
• “Fluttering” leads to localized work hardening of the
Babbitt, which subsequently chip off.
• No operational deficiencies are associated with this
Leading edge Fluttering damage
damage.

Recommendations
• All DTP drawings have been updated with improved
geometry.
• During routinely scheduled bearing inspections the
leading edge should be examined.
• If “fluttering” damage is noted the bearing should be
repaired per the updated geometry. Taper on leading edge for Upper pads only

©©2010
2009General
GeneralElectric Company.
Electric Company. AllAll
Rights Reserved.
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Reserved. material
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may bebe
not copied
copied
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distributed in in
distributed whole oror
whole in in
part, without
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copyright owner. 5
TIL – 1712-R1 – Main Steam/Reheat Pipe
Thermowell Replacement
Causes
• During installaton, thermowells for main steam
thermometer (TI-200) and reheat steam thermometer
(TI-206)were identified as being an incorrect material
• The correct material for the thermowell is 316SS

Recommendations
• At next scheduled outage, the designated thermowells
should be removed.
• Install a replacement thermowell of the correct material. Thermowell Installation

©©2010
2009General
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Electric Company. AllAll
Rights Reserved.
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Reserved. material
This materialmay not
may bebe
not copied
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copyright owner. 6
TIL – 1721 - 207D-11 THRUST BEARING CLEARANCE
RECOMMENDATIONS
Causes
• 2 different specifications were published for thrust bearing clearances
• OLD: .024-.026”
• NEW: .016-.018”

Recommendations
• Record axial vibration levels prior to outages on units
built with OLD clearances
• If axial vibration > 4 mils, contact Service Manager
• If axial vibration < 4 mils, check clearances and set to
last as-left setting Thrust bearing.

©©2010
2009General
GeneralElectric Company.
Electric Company. AllAll
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Reserved. material
This materialmay not
may bebe
not copied
copied
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distributed in in
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copyright owner. 7
TIL – 1733 - D-10 ST UNIT TURNING GEAR HOUSING
CROSS BAR CLEARANCE MODIFICATION
Observations
• Applies to all models with the Model
33F turning gear

Causes
• Inadvertent turning gear roll-off
occurring after initial engagement .
• TG successfully engages but as
soon as the rotor starts to turn TG Cross-Bar
139E3703

disengages

Recommendations
• Examine the TG cross bar for interference
with the clash pinion gear
• Machine the underside of the cross bar to
provide clearance

© 2009
© 2010 General
General Electric
Electric Company.
Company. AllAll Rights
Rights Reserved.
Reserved. This
This material
material may
may not
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be copied
copied
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in part,
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TIL – 1734 – Recommendations For A10 Fleet
Axial Rubs at the N2 Packing Head
Observations
• N2 packing teeth exhibiting rotor short or rotor
long axial damage.

Causes
• Original long rotor and short rotor calculations
used are below current design practice.
• Abnormal operation also serves as a catalyst to
axial issue.

Recommendations
• Inspect N2 packing during major outage.
107A-10 N2 packing indicating axial interference.
• Perform rotor N2 packing land re-
machining to incorporate latest design
practice clearances.
• Replace existing packing with offset axial
packing.
• Contact Service Manager or CPM for
consultation with Product Service on pre-
outage risk review.

© 2010 General Electric Company. All Rights Reserved. This material may not be copied
©
or2009 GeneralinElectric
distributed whole orCompany. All Rights
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prior Thisof
permission material may not
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owner.
or distributed in whole or in part, without prior permission of the copyright owner. 9
TIL-1735 - A10 Turning Gear Piggyback Motor
Inspection and Potential Retrofit

Cause
• Root cause analysis indicated dynamic
loading during the clash engagement leads to
excessive loads transmitted through the
hypoid gear set.

Recommendations
Turning Gear Failure at Ring Gear Hub
• During next major outage, a complete inspection of turning
gear assembly should be conducted to determine if gears
display indications
• Report all indications to determine scope of repair
• The clash turning gear replaced with pre-engagement
sequence, requiring a new piggyback motor configuration
and controls upgrade

©©2010
2009General
GeneralElectric Company.
Electric Company. AllAll
Rights Reserved.
Rights This
Reserved. material
This materialmay not
may bebe
not copied
copied
oror
distributed in in
distributed whole oror
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copyright owner. 10
TIL – 1738 A14/A15 Outer Shell Pressure Tap Connection
Inspection
Causes
• Due to a steam leak that resulted from a shell
pressure tap NPT connection. Confirmation is
required that seal-welded connections have been
utilized at all pressure tap locations on the outer
shell.

• The NPT connection is utilized for factory hydrostatic


testing only and this connection needs to be a seal-
welded connection to avoid potential steam leaks

Recommendations
• At the next scheduled outage we recommend visual
inspection of all outer shell pressure tap connections to
ensure seal-welded connections have been implemented
• If inspections confirm that these pressure tap connections
are not welded, they will require rework to properly seal-weld
per GE specification P8B-AL-1206.

©©2010
2009General
GeneralElectric Company.
Electric Company. AllAll
Rights Reserved.
Rights This
Reserved. material
This materialmay not
may bebe
not copied
copied
oror
distributed in in
distributed whole oror
whole in in
part, without
part, withoutprior permission
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the owner.
copyright owner. 11
TIL 1739 – Main Stop Valve Stem Solid Particle Erosion

Causes
• HRSG boiler tube exfoliation during thermal cycles
• Throttling of control valves increases erosion rate

Recommendations
• Inspect valves per recommendations (frequency)
• Perform recommended periodic stop and control valve
stroke tests
• Replace stems if erosion is found, spare stem(s) should be Main Stop Valve Stem Erosion Damage
on hand.
• Reduce / Eliminate control valve throttling.
• Work with HRSG OEM to establish proper chemistry
program to help reduce exfoliation.
• Valve stem coatings and flow configuration changes
currently being investigated to minimize erosion

©©2010
2009General
GeneralElectric Company.
Electric Company. AllAll
Rights Reserved.
Rights This
Reserved. material
This materialmay not
may bebe
not copied
copied
oror
distributed in in
distributed whole oror
whole in in
part, without
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copyright owner. 12
TIL 1745 – Inspection & Maintenance Hydraulic Power
Unit Flex Hoses
Causes
• Need to outline the application, use and inspection
requirements for flexible high-pressure hydraulic
hoses connecting the components within the on-
base HPU skids
Recommendations
• Proper use, application & inspection of hoses
•Fluid compatibility
•Temperature
•Bend radius / twisting
•Abrasions
• Used on HPU internal components
•Fluid reservoir fill
•Accumulators
•Pumping systems

©©2010
2009General
GeneralElectric Company.
Electric Company. AllAll
Rights Reserved.
Rights This
Reserved. material
This materialmay not
may bebe
not copied
copied
oror
distributed in in
distributed whole oror
whole in in
part, without
part, withoutprior permission
prior permissionof of
the copyright
the owner.
copyright owner. 13
TIL 1748 – D11 N2 Shell Fit Modification
Causes
• Higher than expected peak stresses in the packing head
fillet & shell radius. Shell

• Less than desirable material properties; specifically low


notch rupture ductility on some Shells.
Packing Head
• Over temperature operation increases the risk of
cracking.
Locations of Cracks

Recommendations:
• Machine out cracks or weld repair depending on
severity.
3
• Modifications to reduce stresses on both shell and
packing head to accommodate poor material properties. 1 Shell

Features of geometry modification include :


4
1 Reduce Shell Bending Moments 2
Packing Head
2 Packing Head Section Modulus
3 Reduce Stress Concentration
4 Reduce Packing Head Bending Moments
• Consider ordering a replacement packing head due to Packing Head Modifications
modification cycle time.

© 2009
© 2010 General
General Electric
Electric Company.
Company. AllAll Rights
Rights Reserved.
Reserved. This
This material
material may
may not
not be
be copied
copied
or distributed
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in whole
whole or
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in part,
part, without
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copyright owner.
owner. 14
Fleet Maintenance Experience

© 2009 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner. 15
Outage Observations

• Rotor Storage
• Stop Valve Stem Erosion
• Diaphragm Dishing

© 2010 General Electric Company. All Rights Reserved. This material may not be copied
or© 2009 General
distributed Electric
in whole Company.
or in All Rights
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Component Storage

Recommendations
GEK 110367 Protection during shipment and prior to start-
up.
GEK 94502 Care of the Turbine During Shutdown

Rotor Journal, Oil deflector and packing surfaces protection should be removed and journals
inspected within 3 weeks of arrival at site then every 3 months
Wooden skids are not suitable for long term storage

© 2009
© 2010 General
General Electric
Electric Company.
Company. AllAll Rights
Rights Reserved.
Reserved. This
This material
material may
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TIL-1739 Stop Valve Stem Erosion

Causes
• HRSG boiler tube exfoliation during thermal cycles
• Throttling of control valves increases erosion rate

Symptoms
•MSV may not fully close on shutdown or trip
•Hung at some intermediate travel
•MSV valve position indication may show abnormal during
shutdown
• Position will show closed to approximate –13% to -
17% ( Normal closed position is around 0% )
•Measure/validate valve stroke and feedback position for
suspect valve
• If measured stroke is drawing tolerance plus CEOT of
actuator, stem is broken

© 2009
© 2010 General
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Electric Company.
Company. AllAll Rights
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Reserved. This
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Diaphragm Dishing
Inspection Data

Stages 2, 3, 4, 10 & 11 – Excessive Dishing


Stages 5, 6, 9 & 12 – Need Observation
© 2009
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner. 19