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Contents
Upgrade to Guide for On-Line Testing and Monitoring of Turbine Generators .................................................................................. 2 Shutdown Protection of Steam Turbines Using Dehumidied Air ............. 3 Advanced Labyrinth Seal Project ...................................................... 3 Additions to Guidelines for Reducing the Time and Cost of TurbineGenerator Maintenance Overhauls and Inspections ............................ 4 EPRI Turbine-Generator Program Holds 2007 Steam Turbine-Generator Workshop/Vendor Expo and Summer 2007 Users Group Meeting....... 6 EPRI Turbine-Generator Users Group Holds Winter 2008 Workshop/ Meeting in San Diego ................................................................... 6 Tracking Laser Coordinate Measurement System Application Project Completed .................................................................................. 7 Boiler/Reactor Feedpump Turbine Rotor End-of-Life Project .................... 7 The Effect of Organics/Amines on Turbine Performance ....................... 7 Turbine and Generator Compliance to NERC Standards Interest Group Workshop ................................................................................... 8 Evaluation of Low-Pressure Turbine Stator Coatings to Reduce Erosion on Rotor Blades ............................................................................ 8 Reference Book for Steam Turbine-Generator Products ......................... 8 Generator High-Voltage Bushing Installation Guide.............................. 9 Non-Intrusive Methods to Validate NERC Standards: Steam Turbine Frequency Response (MOD-027)................................................... 10 Inspection Criteria for Generator Rotors Subjected to Abnormal Negative Sequence Current .......................................................... 10 New Turbine-Generator Projects Delivered in 2007 ...........................11 Fifth EPRI Turbine-Generator Program Technology Transfer Workshop and Summer 2008 TGUG Meeting ................................................12 Productivity Improvement Expert Reviews 2008 .................................12 Improving the Financial Risk of an Aging Turbine-Generator Fleet ..........12 Steam Turbine Valve Actuator Condition Assessment Guide .................13 Valve Metallurgy Guides for U.S. and International Turbine Units...........14 Additions to the Turbine-Generator Preventive Maintenance Database ...................................................................................15 Evaluation of Electrohydraulic Control Fluid ......................................15 Steam Turbine Bolting Maintenance Guide .......................................16 Looking Forward: Program 65 and NSTI ..........................................17 Stress Corrosion Cracking and Corrosion Fatigue Workshop to Be Held .....................................................................................18 2009 European TGUG Workshop and Meeting ...............................18 2008 Boiler and Reactor Feed Pump Turbine (B/RFPT) Workshop ........18 Turbine-Generator Supplemental Projects ..........................................19 Axial Entry Disk Blade Attachment NDE Performance Demonstration .....21 Determination of Parameter for 12% Cr Turbine Blades Using Fatigue Sensor Technology ............................................................21 Guide for Inspection of Low-Pressure Turbine Blades .......................... 22 Optimization of Fatigue Sensor Measurement for Curved Blade Surfaces .................................................................................... 22 Upcoming Events ........................................................................ 23 Program Staff ............................................................................. 23 Steam Turbine Blade Failure Root Cause Analysis Guide .................... 23
This technical report will detail basic MHC operation, inspection, setup, troubleshooting, and maintenance. It will help new systems engineers become familiar with the problems and corrective actions needed to keep MHC-related unavailability low. The intent of the report is to cover the MHC devices for the General Electric (GE) fossil and Westinghouse fossil steam turbine valve applications.
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Mechanical Hydraulic Control System Maintenance Guide in Progress continued from page 1
Because just six nuclear units in the world still employ these types of turbine control systems (as opposed to the more modern electrohydraulic control systems), the initial report will contain only limited information about nuclear units. As the project progresses, we will investigate the possibility of adding more nuclear MHC information to the final report. Including nuclear information greatly expands the original scope of the project. The current outline of most of the information to be included in the report is as follows: 1. Technical Description. This section will include a general description of the GE, Westinghouse 300#, and Westinghouse 150# MHC systems, with an emphasis on front standard (pedestal) components, lube oil tank components specifically related to control functions (but excluding the lube oil system itself), valve hydraulic cabinet components, and mid-standard components. The components included are as follows: a. For GE units: speed/load changer, load limiter, speed governor, secondary speed relay, acceleration relay, secondary pilot valve, linkages, cutout governor, initial pressure regulator, stop valve bypass valve controller, intercept valve (IV) speed governor, IV dashpot breakdown link, overspeed trip, backup overspeed trip, main stop valve/reheat stop valve trip devices, trip anticipator, test devices, vacuum trip, thrust bearing trip device, electrical trip interface, steam seal regulator, main shaft oil pump, and control rotor (gear on a few units) b. For Westinghouse (150# and 300#) units: speed/load changer, auxiliary governor, load limit valve, oil impeller, throttle pressure regulator, governor emergency trip valve, throttle valve controller, throttle valve servomotor, overspeed trip valve, trip manifold, main oil pump, control valve (CV) servomotor, IV servomotor, multiple orifices and check valve, and control rotor
2. Inspection. This section will include inspection criteria for the GE and Westinghouse turbine control devices. Copies of data sheets used to record measurements and condition will be included. The criteria for inspecting the controls system will be given. Included will be common adjustments, such as setting (measuring) regulation, CV crack point, and overspeed set points. 3. Maintenance. The maintenance section will include preventive and corrective maintenance tasks for the GE and Westinghouse turbine control devices. Applicable procedures for disassembly, repair, and reassembly of the components will be included, and any special tooling will be listed. Any safety considerations for working on the control devices will be given. Included will be references to partial upgrades or modifications that have typically been performed. 4. Post-Maintenance Commissioning. This section will describe activities required to set up and perform preoperational checks on the controls system prior to starting the unit following a major outage, whether or not major work was performed on the controls system. 5. Troubleshooting. This section will include a guide to troubleshooting operational problems. Common operational problems, symptoms, causes, and solutions will be included. For more information on this project, contact Alan Grunsky, 704.595.2056, agrunsky@epri.com.
July 2008
A Dehumidication System
July 2008
Additions to Guidelines for Reducing the Time and Cost of TurbineGenerator Maintenance Overhauls and Inspections
Over a period of more than seven years, the EPRI Turbine-Generator (TG) Program accumulated information that can assist utilities/plants with TG maintenance. This information is contained in the seven-volume set Guidelines for Reducing the Time and Cost of Turbine-Generator Maintenance Overhauls. In 2007, new material was added to Volume 2, Repair Procedures, and Volume 4, Blade and Rotor Procurement Specifications. Any company that is currently in a multi-year (at least three years) contractual commitment to Program 65 can order the entire seven volumes as a four-CD set. If you meet this requirement, you can order the 2007 EPRI product 1014134. This four-CD set is also available to Nuclear Steam Turbine Initiative funders. Companies that are funding the TG Program on an annual basis (regardless of the number of consecutive years of funding) cannot order 1014134, but the additions for 2007 have been compiled into one supplemental document EPRI report 1016387that you can order. This supplement, combined with the sevenvolume set from 2006, is equivalent to the full and current set of Guidelines. The general content of each volume is as follows: CD 1 Volume 1: General Practices The first volume presents general practices for each of the fundamental maintenance activities that are usually associated with an outage: TG condition assessment (in-service), pre-outage planning and bidding, unit shutdown procedures, disassembly and recording clearances, foreign material exclusion (FME) process information, TG condition assessment (off-line), oil flushing, rotor alignment and balancing, pre-startup checks, and post-outage activities. Volume 1 also contains, as appendices, a sample TG outage report, more than 150 sample data sheets, and a TG FME program/process guidance document. Volume 2: Repair Procedures The second volume provides detailed repair procedures to guide the pre-bid, inspection, disassembly, and repair of critical turbine and generator components. Examples of these procedures are bearing spincasting/repuddling, diaphragm and nozzle block partition repair, blade tenon repair, hydrogen seal repair, horizontal joint casing repair, main steam stop valve cap repair, generator hydrogen seal inspection/repair, alterrex inspection/maintenance, inspection/testing/re-wedging generator stators, and collector ring/ brush rigging maintenance. Volume 3: Balancing and Alignment Specifications The third volume contains comprehensive alignment and balancing primers and high- and low-speed balancing procedures for turbines, generators, and exciters. Volume 4: Blade and Rotor Procurement Specifications The fourth volume provides detailed specifications for the procurement of turbine buckets, to include blade frequency testing and tuning guidance, high-pressure/intermediate-pressure/ low-pressure (HP/IP/LP) fossil rotors, HP/LP nuclear rotors, generator rotor rewind, a new generator rotor, generator stator rewind, new generator stator, generator excitation system, turbine insulation, complete turbine outage services, and turbine bolting. Volume 5: Turbine Directory and Database The fifth volume presents a directory and database of large (>75 megawatts electric) turbines that operate with last-stage buckets of 23 inches (58 centimeters) or longer. The list now contains U.S. and international units. Presented in this database are original turbine manufacturers and their equipment designations and plant/unit status (as of 2001). To further assist users of this directory in identifying operators who might have units that share common features, the data are sorted and presented by L-0 bucket length and the manufacturers design designation (where this could be identified). Included are plants/ units that have been shut down and plants/units that have been cancelled. A table listing North American and international units that have completed major component replacements/ modifications is also included. CD 2 Volume 6: HP/IP Blade/Disk Design and Inspection Specifications The sixth volume presents blade/ disk design audit and inspection procedures for HP and IP steam turbine blades/disks. This information aids turbine maintenance personnel in assessing solid particle erosion, high-cycle fatigue (HCF), low-cycle fatigue (LCF), and creep rupture damage to HP and IP blading.
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Additions to Guidelines for Reducing the Time and Cost of Turbine-Generator Maintenance Overhauls and Inspections continued from page 4
CD 3 Volume 7: LP Blade/Disk Design and Inspection Specifications The seventh volume presents blade/ disk design audit and inspection procedures for LP blades/disks. This information aids turbine maintenance personnel in assessing stress corrosion cracking (SCC), HCF, and LCF damage to LP blading. CD 4 TGAlign and TGAlign-SI Computer Programs and User Manuals TGAlign software (available in English-unit and SI-unit versions) is a robust computer program that determines the optimum coupling alignment for a TG rotor system, thereby reducing the outage time for steam TGs. The utility technical advisory group (TAG) met in early 2007 through a web cast, and the TAG decided what would be added to the Guidelines CDs. The following additions were made to the seven-volume set in 2007: Addition to Volume 2: Collector Ring, Commutator, Brush and Brush Holder Rigging Maintenance Manual as a new Section 8.13 Additions to Volume 4: Specifications for purchasing a generator excitation system (new Section 10) and an example of a generator excitation system procurement request for quote (RFQ) as a new Appendix G
Specifications for purchasing new turbine bolting as a new Section 11 and an example of a turbine bolting procurement RFQ A new Appendix K, to supplement the existing purchase specifications for turbine blading that appear in Section 1, titled Guidelines for Blade Frequency Testing and Tuning Acceptance The TAG met again by web cast in March 2008 to discuss potential additions. The following information will be added to the Guidelines CD set in 2008 based on budget constraints and availability of the information: Best practices for hydrogen seal installation and long-term preventive maintenance for hydrogen seals Best practices for optimizing TG rotor centerline alignment
Boiler/reactor feedpump turbine (B/RFPT) blading purchase specification and sample RFQ Parametric analysis of TG vibration on bearing life Guidelines for purchasing a complete B/RFPT unit A list of original equipment manufacturer service bulletins and technical information/advisory letters A grit-blasting procedure For more information on Guidelines for Reducing the Time and Cost of TurbineGenerator Maintenance Overhauls and Inspections, contact Alan Grunsky, 704.595.2056, agrunsky@epri.com. You can also ask Alan about becoming a multi-year funder of Program 65 or about your companys current participation level.
July 2008
EPRI Turbine-Generator Program Holds 2007 Steam Turbine-Generator Workshop/Vendor Expo and Summer 2007 Users Group Meeting
10th Steam Turbine-Generator Workshop and Vendor Exposition On August 1315, 2007, the EPRI Turbine-Generator (TG) Program held its 10th Steam Turbine-Generator Workshop and Vendor Exposition at the JW Marriott Desert Ridge Resort & Spa in Phoenix, Arizona. Although the temperature reached 110F (43C) almost every day, the meeting was a huge success, with more than 250 attendees at the three-day workshop and 48 vendors participating in the vendor expo that was held Monday and Tuesday evenings. On Monday morning, two pre-workshop/vendor expo workshops were conducted. One was a tutorial on boiler/reactor feedpump turbine design, and the topic of the second was generator core testing. Multiple sessions were conducted in parallel over the three days, with the following topics discussed: Steam turbines Nondestructive evaluation for TGs Generator on-line monitoring and condition assessment Generator core, rotor ground, and stator cooling water leak monitoring Generator upgrades and maintenance Steam turbine R&D Generator rotor turns and grid disturbance detection Use of monitoring data Summer Turbine-Generator Users Group Meeting The summer 2007 Turbine-Generator Users Group (TGUG) meeting was held August 1617 in conjunction with the 10th Steam TurbineGenerator Workshop at the same hotel in Phoenix, Arizona. On Thursday evening, an additional session was conducted. This was the Generator Clip-to-Strand TGUG working group, led by Tom Phelan of Constellation Energy; the session had approximately 25 attendees. All information shared during the weeks meeting/workshop can be viewed on the EPRI web site through the following address: http://www.epri.com/tgug/pastmeetings.html. For additional information on the EPRI TG Program or the TGUG and its activities, contact Alan Grunsky, 704.595.2056, agrunsky@epri.com.
EPRI Turbine-Generator Users Group Holds Winter 2008 Workshop/ Meeting in San Diego
The 17th Turbine-Generator Users Group (TGUG) meeting was held in San Diego, California, at the Marriott Mission Valley Hotel on January 2325, 2008 in conjunction with the associated workshop that took place January 2122 at the same location. More than 250 registrants and 30 vendors participated in the vendor fair that was held on Monday and Tuesday evenings of that week. Day 1 of the workshop was a turbine-generator (TG) combined session, North American Electric Reliability Corporation Validation Requirements/Regulations/Issues from the Turbine-Generator Perspective. On Tuesday, two workshop sessions were conducted; the title of the turbine session was TG Upgrades: Planning, Procurement, and Installation, and the generator session was Generator Rotor Stator and Exciter Preventive Maintenance (Overhauls/ Refurbishments): Strategy Versus Retrofit or Replacement. On Wednesday, an evening session continued the Tuesday turbine session called TG Upgrades: Issues and Experiences. The session was led by Danny Chlou (Exelon) and Paul Zayicek (EPRI). Another evening session was held on Thursday night with a meeting of the Generator Clip-to-Strand TGUG working group. All information shared during the weeks meetings/workshops can be viewed on the EPRI web site through the following address: http://www.epri.com/tgug/pastmeetings.html. For more information, contact Alan Grunsky, 704.595.2056, agrunsky@epri.com.
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Sealants A list of OEM technical information letters, service bulletins, and notices Removal and installation, including the following topics: Area preparation Work area egress Rigging and handling the weights of the bushings, current transformers, and neutral/isolated phase bus duct enclosures Foreign material exclusion considerations Tools and tool staging Proper handling of high-voltage bushings during removal and installation Electrical field testing of the replacement bushing; high-potential (Hipot) testing Mechanical (for example, pressure) field testing of the replacement bushing The amount of contact required on the connection between the bushing and generator lead Termination taping Replacement criteria and spares, including the following topics: Inspection frequency and scope Replacement criteria When to keep spares and how many to keep Recommendation for reinspection and bolt re-tightening intervals Storage requirement (for example, vertical storage) The report will be available no later than December 31, 2008. For more information, contact Jan Stein, 650.855.2390, jstein@epri.com.
July 2008
Non-Intrusive Methods to Validate NERC Standards: Steam Turbine Frequency Response (MOD-027)
MOD-027 requires the generator operator to verify the generator unit frequency response (that is, the megawatt response of the unit to deviations in system frequency) for use in models for reliability studies. Each North American Electric Reliability Council (NERC) region must maintain procedures for the verification of frequency response, including the following: The response time, to be modeled up to 30 seconds for steam units The verified manufacturer and type of turbine speed governor controls The verified model for each turbine speed governor control with any associated dead band, gains, time constants, and limits In 2007, three utilities funded a supplemental project to derive generator, excitation system, and governor parameters from off-line and on-line tests (see EPRI report 1015241, Power Plant Modeling and Parameter Derivation for Power System Studies). The Power Plant Parameter Derivation (PPPD) software allows engineers to derive parameters for standard (that is, Institute of Electrical and Electronics Engineers) generator and exciter models and for combustion turbine governor models. The objective of this project is to extend the PPPD software to calculate steam turbine parameters from staged tests and system disturbances (for example, loss of a major generator that results in system frequency deviations) that are automatically captured during ambient monitoring. The primary objective is to investigate and prove whether ambient monitoring can be used to capture disturbance data and thus be used with automated software to fit the parameters of the turbine-governor model for large steam turbines. The project includes the following tasks: 1. Model and method development for large steam turbines 2. A staged test of a large steam turbine at a host utility 3. Ambient monitoring for system events at a host utility (for the same unit tested in Task 2) 4. A comparison of models developed by both methods 5. Presentation at the Generation Advisory Meeting 6. Publication of the final report 7. Delivery of prototype software to the EPRI Software Engineering Team 8. Workshop 9. Software release in 2009 The report will be available no later than December 31, 2008. For more information, contact Jan Stein, 650.855.2390, jstein@epri.com.
Inspection Criteria for Generator Rotors Subjected to Abnormal Negative Sequence Current
Negative sequence heating of the rotor is induced by three things: asynchronous operation of the rotor, such as motoring; phase unbalance in the stator winding caused by unsymmetrical loads or faults; and harmonic currents introduced in the grid by, for example, static frequency converters. The objective of this multi-year project is to define the level of negative sequence current that will warrant rotor inspection for damage to the forging, retaining rings, and rotor wedges. The EPRI report Negative Sequence Effects on Generator Rotors (1014910), published in 2007, provides easy-to-use models for estimating the tooth and wedge temperature during a negative sequence fault. In 2008, work will continue on estimating heating of teeth, pole face, and retaining ring shrink fit and on the heating effects experienced during rotor motoring. Toshiba has agreed to validate this work by comparing it to the results obtained by full-blown analysis. Formulas and flow charts required for development of inspection criteria software will also be developed. User-friendly software will be developed in 2009. For more information, contact Jan Stein, 650.855.2390, jstein@epri.com.
Steam Turbine-Generator Notes 10 July 2008
New Turbine-Generator Projects Delivered in 2007 New Turbine-Generator Projects Delivered in 2007
Guide for Stator Winding Coil Insulation Repair Report 1014909 Sometimes stator winding insulation is damaged from mechanical impact during operation; more frequently, however, the insulation is mechanically damaged during wedge replacement or rewinding. Under certain circumstances, it is possible to repair the stator coils and bars in situ without having to replace the coils. This report, a CD, provides guidance about when such localized damage can be reliably repaired and outlines the basic repair methodology. Guide for Rotating Machine Stator Winding Hipot Testing Report 1014908 High-potential (Hipot) withstand testing, which indicates whether the stator winding insulation in a generator is fit for service, is a standard factory acceptance test for a new machine. The same test can be used on an existing generator to assess the machines condition. EPRI surveyed owners of generating facilities about Hipot testing on existing machines. This report answers questions raised during the survey, including when to test, the type of test to perform, and the proper test voltage. Generator Control Testing to Certify Reactive Power Capability, Excitation System Functions, and Frequency Response Report 1014911 Accurate simulation models of power system equipment are beneficial to all power system participants: such models maximize equipment availability, minimize losses, avoid interruptions, and protect equipment. This report summarizes various methods of obtaining the model data and describes the benefits and drawbacks of each. Negative Sequence Effects on Generator Rotors Report 1014910 See p. 10 for article. Steam Turbine Blade Failure Root Cause Analysis Guide Report 1014137 See p. 23 for article. Boresonic Inspection Primer Report 1014140 Turbine rotor reliability and remaining life prediction are areas of concern for utilities that are interested in component life extension and longer inspection outage intervals. Boresonic inspection of the highly stressed rotor bore area provides the nondestructive inspection data that are among the inputs used in determining rotor operability and remaining life. Determination of the boresonic systems performance is essential in establishing confidence levels for the boresonic data. The EPRI report Boresonic Inspection Primer (1014140) provides guidance on evaluating performance of boresonic inspection systems as well as guidance in the evaluation and selection of boresonic inspection providers. Inspection and Damage Assessment of Turbine Casing Cracks Report 1014138 This report presents guidance on determining run/repair/retire options for cracked casings. Nondestructive evaluation techniques and metallurgical evaluation for the assessment of cracking are addressed. Considerations to make when deciding when to initiate a crack repairrepair methods for turbine casing cracks include mechanical methods and weld repairas well as the conditions that preclude repair are also described. Utility experiences with repair methods are documented. Steam Turbine On-Line Blade Condition Assessment Report 1014143 This report evaluates commercially available and emerging technology for on-line condition assessment of large steam turbine blades, with concentration on technologies that can detect changes in blade vibrational characteristics associated with propagating cracks. Finite element modeling and analysis in combination with fracture analysis was used to assess the effects of crack propagation on measurable L-0 blade characteristics. Provided in the report are recommendations for appropriate monitoring technologies that are based on the analyses. Industry experience with currently available on-line blade monitoring technology is included. Steam Turbine Bolting Maintenance Guide Report 1013341 See p. 16 for article.
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Fifth EPRI Turbine-Generator Program Productivity Improvement Expert Technology Transfer Workshop and Reviews 2008 Summer 2008 TGUG Meeting
The EPRI Turbine-Generator (TG) Program will hold its Fifth Technology Transfer Workshop and a summer Turbine-Generator Users Group (TGUG) meeting the week of August 11, 2008 in Concord, North Carolina (near Charlotte, North Carolina) at the Embassy Suites Convention Center. The workshop will be conducted Monday and Tuesday, with three workshop tracks running in parallel. Track 1 will feature the presentations Steam Turbine Design 101, Steam Turbine Performance 101, Steam Turbine Chemistry 101, Turbine Water Induction 101, and Turbine Life Cycle Management/Remaining Life 101. Track 2 is the Conference on Generator Predictive Maintenance, Generator Stator Winding HighPotential Testing, and Generator DC High-Potential Ramp Testing. Track 3 will include presentations on the newly released Steam Turbine Bolting Maintenance Guide (1013341), Shutdown Protection of Steam Turbines Using Dehumidified Air (1014195), Steam Turbine Blade Failure Root Cause Analysis Guide (1014137), Inspection and Damage Assessment of Turbine Casing Cracks (1014138), and PM Basis Overview and Improved Steam Path Design Primer Guide (1014141). The TGUG meeting will include presentations by General Electric, Siemens, Toshiba, Hitachi, Mitsubishi, and Alstom, as well as presentations on topics such as electrohydraulic control retrofits, Detroit Edisons on-line monitoring program, and Electrobrs Termonuclear's overview of its TG program. On Thursday afternoon, the group will tour the nearby Pioneer Bearing Motor Company facilities and attend a dinner at the Lowes Motor Speedway hosted by Pioneer Bearing Motor Company. Complete meeting details can be found on EPRIs web site through the following address: http://guest.cvent.com/EVENTS/info/summary. aspx?e=9fe89618-724b-4828-8cb5-d28d0bffaaac. For more information about the upcoming workshop or TGUG meeting, contact Alan Grunsky, 704.595.2056, agrunsky@epri.com.
Access to the Productivity Improvement Expert Reviews (PIER) web site for 2008 is limited to companies participating in this project. EPRI, its technical staff, and its expert consultants have developed this web site to provide critically evaluated information of direct value in improving the availability, efficiency, and profitability of fossil steam power plants. Over the last 10 years, this site has become a valuable resource to generating companies by summarizing successful applications that have already proved to be of significant value to other operating units. Hundreds of critically assessed case studies are documented in the sites pages, and this has allowed others to duplicate these successes. Additionally, the site tracks creative new ideas that are very close to broad power plant use. These current items of interest alert readers to technology on the brink of commercial application. In critically evaluating and discussing these new advances, we look primarily backward rather than forward. This approach was the basis behind what became EPRIs Productivity Improvement Handbook. All printed copies of the first three editions of EPRIs Productivity Improvement Handbook for Fossil Steam Power Plants (TR-11217, TR-114910, and 1006315) quickly sold out. The contents of the third edition can be accessed instantly on this site. In addition to the web site, hardcover annual summary reports of Productivity Improvement Case Studies are available and have found their way into operating power plants for quick reference by plant staff. Every year, members of the PIER group are able to request copies of these annual summaries for all their operating power plants, and members have found these hard copies to be a useful supplement to the web-based versions. For more information, contact Tony Armor, EPRI Palo Alto, 650.855.2961.
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Intercept/combined reheat-intercept valves The steam valve components to be covered in the reports include the following: Bushings Main and bypass valve disks Pressure seal heads Seats Stems The metallurgical topics to be covered for each of the components are the following: The alloy standards/materials used by different manufacturers, to include alternative materials Chemical composition Physical properties Mechanical properties: yield strength, tensile strength, hardness, fracture appearance transition temperature, and creep rupture
Metallurgy: microstructure, heat treatment, and coatings Damage mechanisms Life assessment Repairs: welding, coatings, and heat treatment It will be necessary to conduct extensive research into the valve materials used on the U.S. and international steam turbine valve components. A survey on valve materials will be sent to fossil and nuclear plants, manufacturers, and other valve part suppliers. We plan to include the following sections and content in the report: 1. Introduction: background, overview of report content, glossary,
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The PMBD Version 2.0 software is now available to order through the EPRI Customer Assistance Center, 1.800.313.3774 or 650.855.2121 or
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7. Inspection, Assessment, and Maintenance Planning. This section covers manufacturers recommendations, a life assessment approach, approaches to aid in selecting fasteners for destructive examination, inspection, and actions to take when a cracked fastener is found. 8. Appendices. The appendices include information on shaft coupling bolts, a maintenance procedure for tightening, a maintenance procedure for removal of broken or seized bolts or studs, metallurgical summaries, a summary of bolting information bulletins, procedures for tracking bolt operating hours and history, ultrasonic examination of studs and bolts from the bore surface, ultrasonic examination of studs and bolts from the end surface, resources,
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The EPRI Turbine Generator User Group (TGUG) is currently in the planning stages of conducting a workshop and vendor exposition for European utilities in Madrid, Spain, from June 8th-12th, 2009. The Madrid hotel has yet to be determined. Both EPRI member and non-member European nuclear and fossil utility representatives are encouraged to attend, and U.S./North American TGUG members are also invited to participate. Updates will be available as soon as more details are finalized. For additional information, contact Alan Grunsky, agrunsky@epri.com
B/RFPT concerns. The topics will include: Valves and Controls, Controls Upgrades, Rotor and Cylinder end of life, Purchasing and Replacement, Operation and Lay-up, Impact of steam path upgrades, Couplings (various designs, capabilities, and alignment processes), Auxiliary Systems (lube oil, steam seals, etc.), TSI, Balancing, Coatings and finally a discussion of generators and maintenance lessons learned. Please come prepared to discuss with the other attendees your specific experiences relative to the previously mentioned topics. This activity will occur during a roundtable discussion period of the workshop. To participate as a presenter, contact Gary Golden, 865.218.8111, ggolden@epri.com.
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inspection technologies are not able to predict cracking before it occurs. Fatigue sensor technology has been qualitatively proven as a technology for identification of fatigue damage accumulation and life consumption. This EPRI supplemental project provides quantitative benchmarking of this technology using fatigue test specimens of Jethete material to provide a detailed quantification of the fatigue damage measurements and its uncertainty using existing technology. This quantitative benchmarking will provide an important basis for interpretation of the results of field tests on turbine blades. Uniaxial and flexural fatigue specimens have been subjected to interrupted testing and periodic measurement using fatigue sensor technology to develop parameters for determination of accumulated fatigue damage. For more information on this activity, contact Paul Zayicek, 704.595.2154, pzayicek@epri.com.
Torsional Cracking in the Shaft Keyway of a Four-Pole Nuclear Generator Rotor
The EPRI supplemental project Detection of Shaft Keyway Cracking Under the Coupling on General Electric Co. Generator Rotors includes development of a linear phased array ultrasonic inspection technique for the detection of cracking in the generator rotor shaft keyway area under the shrunk-on coupling. This technique can be used without disassembling the coupling, thereby enabling timely
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inspection with minimal impact on unit availability. Linear phased array ultrasonic technology allows steering of the ultrasonic energy by phasing of the individual probe elements. Because of this feature, it is feasible to inspect the inboard portion of the shaft keyway by conducting the inspection from the accessible shaft surface adjacent to the inboard side of the shaft keyway. Mathematical modeling efforts of this inspection application using EPRI technology indicate
that this approach is viable. Verification of the modeling work will be completed on a full-scale mockup using a variety of manmade targets. The flaw detection and sizing capabilities of the developed technique will also be evaluated on the mockup. Retired generator rotor segments are being used for the full-size mockup. For additional information on this activity, contact Paul Zayicek, 704.595.2154, pzayicek@epri.com.
Valve Metallurgy Guides for U.S. and International Turbine Units continued from page 14
2. Valve Bushing Materials: alloy standards (including alternative materials), chemical composition, physical properties, mechanical properties, metallurgy, damage mechanisms, life assessment, repairs 3. Main Valve and Bypass Valve Disk Materials: alloy standards (including alternative materials), chemical composition, physical properties, mechanical properties, metallurgy, damage mechanisms, life assessment, repairs 4. Valve Seat Materials: alloy standards (including alternative materials), chemical composition, physical properties, mechanical properties, metallurgy, damage mechanisms, life assessment, repairs 5. Valve Stem Materials: alloy standards (including alternative materials), chemical composition, physical properties, mechanical properties, metallurgy, damage mechanisms, life assessment, repairs 6. Pressure Seal Head Materials: alloy standards (including alternative materials), chemical composition, physical properties, mechanical properties, metallurgy, damage mechanisms, life assessment, repairs 7. References 8. Appendices Work began on the U.S. report in April 2008, with a first draft expected October 2008. The final report on U.S. valves should be completed in the first quarter of 2009. For the international report, vendors are being solicited for development. It is anticipated that the international report will be completed at the end of 2009. For more information, contact Sharon Parker, 704.595.2164, sparker@epri.com.
and bolts from the bore surface, ultrasonic examination of studs and bolts from the end surface, resources, a questionnaire to utilities, turbine valve bolting information, and bolting procurement guidelines. The report was made available through the EPRI web site on December 31, 2007, and hardcopy reports were mailed to members in March 2008. After the reports publication, a purchase bid specification for bolting was developed and added to the EPRI report Guidelines for Reducing the Time and Cost of Turbine-Generator Maintenance Overhauls and Inspections, Volume 4: Turbine-Generator Component Procurement Specifications (1016346), published March 2008. This bid specification was also added as Appendix L to the Steam Turbine Bolting Maintenance Guide (1013341) to produce the Steam Turbine Bolting Maintenance Guide Revision 1 (1016958). If you have any questions on Steam Turbine Bolting Maintenance Guide Revision 1, contact Tom Alley, 704.595.2066, calley@epri.com.
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For more information on this activity, contact Paul Zayicek, 704.595.2154, pzayicek@epri.com.
Determination of Parameter for 12% Cr Turbine Blades Using Fatigue Sensor Technology
The EPRI supplemental project Demonstration of Fatigue Sensor Technology for Steam Turbine Blades explored emerging technology for nondestructively measuring the fatigue life consumption of turbine blades using ultrasonic waves. Application of fatigue sensor technology for in-service turbine blades can reduce the risk of in-service failures, make measurements of consumed fatigue life without removing blades from the rotor, and optimize timing for blade row replacement. The original supplemental project was based on measurement of Jethete blades to establish parameters for subsequent field deployment. This project, an extension of previous work, will determine parameters for the 12% Cr family of turbine blades and establish consumed fatigue life for subsequent field deployment. For more information on this activity, contact Paul Zayicek, 704.595.2154, pzayicek@epri.com.
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Upcoming Events
2008 Meetings
Fifth Turbine-Generator Technology Transfer Workshop and Summer Turbine-Generator Users Group (TGUG) Meeting NERC Interest Group EMI Interest Group
Program Staff
Date
Aug. 1115, 2008
Location
Concord, NC Embassy Suites
Fossil and Nuclear Steam Turbine-Generator Program Gary Golden Performance, Testing, B/RFPT 865.387.5309, ggolden@epri.com Alan Grunsky Operations and Maintenance 704.595.2056, agrunsky@epri.com Sharon Parker Turbine Auxiliaries 704.595.2164, sparker@epri.com Linda Parrish Senior Administrative Assistant 704.595.2061, lparrish@epri.com John Shingledecker Materials 704.595.2120, jshingledecker@epri.com Jan Stein Electrical Equipment, Generators 650.855.2390, jstein@epri.com Paul Zayicek NDE, Condition Assessment 704.595.2154, pzayicek@epri.com
Detroit, MI DTE Headquarters Groveport, OH AEPs John E. Dolan Engineering Laboratory Nashville, TN Gaylord Opryland Hotel Nashville, TN Vanderbilt Marriott Hotel Location Savannah, GA Hyatt Regency TBD TBD
Stress Corrosion Cracking & Corrosion Fatigue Workshop Boiler/Reactor Feedpump Turbine Workshop 2009 Meetings Winter 2009 TGUG Workshop and Meeting with Vendor Fair
11th EPRI Steam Turbine Generator Aug. 1011, 2009 Workshop and Vendor Expo Summer TGUG Meeting Aug. 1214, 2008
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The
Electric
Power
Research
Institute,
Inc.
(EPRI, www.epri.com) conducts research and development for the global electricity sector. An independent, nonprofit organization, EPRI brings together experts from academia and industry as well as its own scientists and engineers to help address challenges in electricity generation, delivery and use, including health, safety and the environment. EPRI also provides technology, policy and economic analyses to drive longrange research and development planning, and supports research in emerging technologies. EPRIs members represent more than 90 percent of the electricity generated and delivered in the United States, and international participation extends to 40 countries. EPRIs principal offices and laboratories are located in Palo Alto, California; Charlotte, North Carolina; Knoxville, Tennessee; and Lenox, Massachusetts.
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July 2008
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