SENSOPLAN-Service: Up to 200 green Kilowatts through improved
Process for Vacuum Sealing Oil System
ON TOP: Major Overhaul of a H 2 -cooled Turbo Generator
Condition Monitoring of Steam Turbine
Generator Set
Paipa/Colombia
They say an ounce of prevention is
worth a pound of cure, and the same
holds true for large power generating
equipment. Regularly scheduled main-
tenance can be planned for well in ad-
vance, but what about extended outa-
ges relating to unforeseen problems?
The best way to deal with unplanned
outages is to prevent them. Preventa-
tive maintenance begins with ques-
tions such as:
Have there been any changes in the
operating behavior?
Coal Power Plant Termopaipa, Colombia
New Service: SENSOPLAN Vacuum
Sealing Oil System generates up to
200 green Kilowatts
In line with our drive to provide customers with optimal efficiency,
SENSOPLAN introduces our patented Vacuum Sealing Oil System.
This system utilizes an innovative and improved process for vacuum
sealing oil systems and provides:
Very high H2 purity and long-
term stability
Significantly reduced H2 con-
sumption
Less H2 ventilation and friction
loss
Shaft sealing systems consist of two
main components: shaft sealing rings
with ring holders and a sealing oil
system. In large turbo generators, se-
parate gas and air-side oil circulati-
on frequently function together as a
duplex pressure line system, i.e. there
are two oil circulation systems opera-
ting against one another and against
the H2 in the generator through gra-
duated pressure. Ideally, the integrity
and purity of each substance within
the system is maintained.
However, despite the functional se-
paration, hydraulics makes it impos-
sible to entirely prevent leakage on
both sides of the system: H2-saturated
oil can leak into the air-side circula-
tion, and vice versa air saturated oil
can leak into the H2-side circulation,
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What are the root causes for these? Sochagota, a subsidiary
Is action required? of Evonik STEAG, recent-
Termopaipa, a coal-fired power plant
ly again commissioned
SENSOPLAN to do com-
in Colombia, first called
parison measurements
SENSOPLAN in for an
and endoscopic inspec-
ounce of preventative
tions at Termopaipa. The
medicine in 2004 to per-
purpose of this visit was
form an initial vibration
to evaluate the actual
measurement on their
condition of the turbo-set
165 MW turbo-set. This
and to identify potential
fingerprinting proce-
problems prior to the next
dure made it possible
scheduled major mainte- Visual Inspection of LP Turbine
to determine, analyze
nance outage.
and document the cur-
rent functionality of the Using innovative measurement and data acquisition equipment,
turbo-set under various SENSOPLAN collected and analyzed relevant vibration data for the
operating conditions as complete shaft line. Using the data previously collected in 2004 as
Steam Turbine well as to recommend a comparison, it was possible to rapidly and reliably diagnose any
corrective procedures needed to ensu- changes. With such an excellent basis for comparison, the value of
re reliable service. fingerprint measurements is even clearer.
In order to answer the questions men- Additionally, the plant operator also assigned this years steam tur-
tioned above, and specifically to mo- bine inspection to SENSOPLAN. Using endoscopic testing on the
nitor the steam turbine generating set, low, medium and high pressure turbines and valves,
SENSOPLAN engineers identified the points where
deposits, excessive wear and tear or damage had
occurred.
This analysis also led to the identification of under-
lying causes and their probable consequences.
SENSOPLAN made recommendations for the further
operation and timing of subsequent service activities
at that time.
The Plant Operator indicated he was completely sa-
tisfied with SENSOPLANs professionalism and skill
with comparison measurements and inspection of
the steam turbine generating set.
Final Stage of LP Turbine
causing rising operational costs through incre- gas-side and the air-side
ased H2 feeding as well as the loss of effective circulations in a vacu-
power through decreased H2 purity. um tank and returning In the next issue:
The SENSOPLAN Vacuum Sealing Oil Sys- the purified substances
tem implements a simple addition to the exis- to the two circulation
ting duplex pressure line sealing oil system systems.
POWER UPGRADE
without altering the rest of the system con- An example of the new OF THE
figuration or the shaft sealing rings. It works systems effectiveness is
GENERATOR
by degassing the runback oil from both the seen in calculations
on a 3000-rpm
generator with
a 450 mm dia-
meter shaft and 3.4 bar H2 pressure. From the actual H2
consumption, which was estimated at only 1 m3/24h, it
is clear that the feed is far below normal values.
An effective solution for leaking on both sides of the
duplex pressure line oil system, the SENSOPLAN Va-
cuum Sealing Oil System significantly reduces the hy-
drogen feed amount and ensures high and stable levels
of hydrogen purity. The result is a continuous process
that maintains hydrogen purity in the generator and
significantly reduces the need for costly H2 replenish-
ment.
Additionally, consistent H2 purity keeps ventilation and
friction losses to a minimum. Mid-sized generators de-
monstrate an increase of over 100 kWel per % point of
reduced H2 concentration.
With the already proven SENSOPLAN Hydrogen
Sealing Contour shaft sealing rings and the new
SENSOPLAN Vacuum Sealing Oil System,
SENSOPLAN now offers a superior and cost-effective
upgrade package for turbo generator shaft sealing sys-
tems.
Schematic diagram of a duplex pressure line sealing oil system with vacuum oil tank

ON TOP!
Frimmersdorf. Operated by RWE
Power AG in Grevenbroich, the Frim-
mersdorf Power Plant is among the
largest lignite-fired power plants in
Germany. Recently, the major outa-
ge of one of their 150 MW turbo gene-
rators, called for a complete overhaul.
SENSOPLAN competed for the con-
tract and was awarded the complete
service package including planning,
on site organization, disassembly, in-
spection, corrective maintenance, re-
assembly, startup and documentation.
Built in 1963, Frimmersdorf s type of
H2-cooled generator is no longer ma-
nufactured today. Accordingly, the job
required specialized expertise for the
successful disassembly and reassembly of
this type of generator. Frimmersdorf re-
cognized SENSOPLANs extensive expe-
rience with comparable units and awarded
the contract, in part, because of their con-
fidence in our skill and professionalism.
Frimmersdorf Power Plant
Generator Symposium II: Minimizing Risik in the Operation of Medium and
Peak Power Plants
Following the popularity of the first
SENSOPLAN Generator Symposium in
autumn 2005, a second symposium was
held in October 2007. The topic of focus
was Generators Minimizing the Risk of
Operation and Project Management. This
topic addressed a particular problem area
for operators of medium and peak load
power plants. These plants, which to a
great extent run on fossil fuels, experience
frequent service interruptions and require
careful consideration to meet their special
operational demands.
Twenty-five participants from Germany
and neighboring countries gathered at the
Hotel Vierjahreszeiten in the charming
southern Black Forest town of Schluchsee
to attend lectures, discuss the topics and
exchange information. The first day was
dedicated to technical presentations and
discussions led by SENSOPLAN experts as
well as three external lecturers from large
power plants. The second day of the sym-
SENSOPLAN deployed to the lignite-fired power plant
in Frimmersdorf, Germany, for the major overhaul of
a H 2-cooled, 150 MW turbo generator.
Turbo-Set with H 2-cooled Generator
The job began with the dismantling of the
generators essential components such as
the exciter, H2 coolers, bearing brackets,
bearings, rotor and H2 shaft sealing rings.
Then, SENSOPLANs Generator Specia-
lists moved into the thorough process of
evaluating, diagno-
sing and cleaning.
The rotor and stator
were given a visual
inspection before
extensive electrical
testing. Years of ex-
perience has made
our specialists aware
of weak spots com-
mon to this type of
generator and detai-
led attention was gi-
ven to these issues.
Worn parts on the
generators hydro-
gen supply and sea-
posium included a visit to SENSOPLANs
company headquarters located on the up-
per Rhine River.
This visit was of interest to many because
level of quality.
of numerous changes at the Headquarters
building over the past two years.
With the new production facility comple-
ted, SENSOPLAN has successfully expan-
ded its spectrum of services to include a
highly specialized and independent engi-
neering firm as well as a full range of com-
petitive services for generators in large
scale plants including: dismantling, repai-
ring, procuring parts and manufacturing
components, reassembly, commissioning
and documentation.
Participants also visited the recently
erected 1000 sq. meters components ma-
nufacturing hall where they observed
an inductive heat treatment unit and a
bending machine both in-house deve-
lopments as well as a water jet cutting
ning efficiently and without inter-
ruption. This project demonstrated
SENSOPLANs expertise and skill
as professional partners in overhau-
ling power plants of this size and
complexity. Even with unexpected
issues that required corrective ac-
tion, our efficient and accurate
program management process en-
sured the project was completed on
schedule.
We executed the job to the comple-
te satisfaction of the Plant Operator.
He commended our excellent per-
formance in the complete overhaul
and appreciates having SENSO-
PLAN as a reliable and competent
ling oil system were replaced and partner in turbo generator service.
tested.
Once all system
components had
been inspected,
cleaned and re-
paired/replaced,
they were expert-
ly reassembled.
Working with the
plant operator, we
successfully recom-
missioned the sys-
tem. All necessary
measures for opti-
mal system function
were performed by SENSOPLAN Generator Specialists at Work
SENSOPLAN di-
rectly on site.
Impressum
Since the recommissioning in Feb- Editor:
ruary of this year, the completely SENSOPLAN AG
overhauled generator has been run- Gewerbestr. 6
D-79801 Hohentengen a.H.
Phone: +49 7742 9298-0
Fax: +49 7742 92-98-10
VP Sales:
Thorsten Wasmuth
Phone: +49 7742 9298-16
Mail: info@sensoplan.com
www.sensoplan.de
machine. This equipment efficiently Symposium lecturers and partici-
performs the very difficult process pants alike found the exchange of
of manufacturing copper strands information extremely beneficial.
for rewinding rotors to the required The next symposium is planned for
2009.
Symposium Participants