project stories plant 1. life assessment for hanllim ccpp … · 2018-11-30 · project stories...
TRANSCRIPT
PLANT ASSESSMENT
PROJECT STORIES
2. Sousse A Unit 2 Life Assessment (Tunisia)
3. Generator Test & Life Assessment in Western Sector (Saudi Arabia)
2.1 Summary2.2 Introduction 2.3 Inspection Activities 2.4 Proposed Work Scope
3.1 Summary3.2 Detailed Scope of Work
1. Life Assessment for Hanllim CCPP (Korea)
1.1 Summary1.2 Gas Turbine Part1.3 Steam Turbine Part1.4 HRSG, Duct, etc. 1.5 Generator
Copyright by Doosan Heavy Industries & Construction Co., Ltd. All Rights Reserved.
DOOSAN POWER SERVICES
1.1 Summary of Life Assessment for Hanllim CCPP (Korea)
PROJECT OVERVIEW
PLANT LOCATION
PJT title Life Assessment for Hanllim CCPPClient KOSPO (Korea Southern Power)
Contract year 2017PJT period 10 months
Jeju-do, Korea
∙ Gas turbine & Steam turbine - NDT, material/condition evaluation - Life assessment of rotor - Steam path audit of steam turbine∙ HRSG, duct, pipe, etc. - NDT, material/condition evaluation - Life assessment of high temp. header∙ Generator - Electrical and mechanical test∙ Impact assessment of fuel conversion
Output
- Residual life assessment report
- Existing facility impact assessment report for fuel conversion
∙ Residual life time assessment of existing power plant∙ Obtaining basic data in preparation for fuel conversion through detailed
diagnosis of each equipment
Plant Information
Scope of Supply
Customer Benefits
∙ OEM ∙ Plant Type∙ Configuration∙ Capacity∙ COD
TG: GE / HRSG: HanjungCombined cycle power plant2-2-1 (GT x 2, HRSG x 2, ST x 1)105MW (GT: 35MW, ST: 35MW)1997
PROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.2 Gas Turbine Part1) List of NDT
Item ComponentNDT Bore
ScopeVI PT MT UT ECT
Inlet Section
Inlet Duct ● ●
Inlet Plenum ● ●
Inlet Casing ● ●
Bearing Housing ● ●
Inlet Guide Vane ● ●
Journal Bearing ● ● ●
Thrust Bearing ● ● ●
Compressor Section
CompressorNozzle ● ●
Casing ● ● ●
Combustor Section
Casing (CDC) 1) ● ● ●
Inner CDC 2) ● ●
Turbine Section
Casing ● ● ●
Shroud Block Assembly Part ● ●
Item ComponentNDT Bore
ScopeVI PT MT UT ECT
ExhaustSection
Casing ● ● ●
Bearing Housing ● ● ●
Journal Bearing ● ● ●
Duct ● ●
RotorSection
Compressor Wheel ● ●
Distance Piece ● ●
Turbine Wheel ● ● ●
Spacer ● ●
Rotor Bolt ● ●
Compressor Bucket ● ●
Others
Accessory Gear ● ●
Load Gear ● ●
Load Gear Casing ● ●
Load Gear Bearing ● ● ●
Coupling Spacer ● ●
Coupling Bolt GEN Side ● ●
Coupling Bolt TBN Side ● ● ●
Main Piping of GT ● ● ●
Exhaust Plenum
1) CDC: Compressor Discharge Casing2) Inner CDC: Inner Compressor Discharge Casing
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.2 Gas Turbine Part1) Result Summary (Main Defects & Recommendations)
Crack on the compressor discharge casing[ADVICE] Replacement (Material change)
3 1 4 5
6
7
2
1 Cracks on the turbine casing[ADVICE] Drilling a hole to prevent further progress or repairing the welding
4 Exhaust plenum[ADVICE] Replacement with new part
6
Internal damage of the exhaust duct [ADVICE] Whole replacement or internal repair
7Exhaust casing cracks on the welded part[ADVICE] Existing welded part and re-welding
5Crack in the inlet duct at welded part / Peeling paint[ADVICE] Removing cracks (repair of welding, if required) / Repainting
2
Cracks on the inlet casing [ADVICE] Removing cracks (repair of welding, if required)
3
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.3 Steam Turbine Part1) List of NDT & Material Evaluation
Item LocationNDT Material Evaluation
MT UT PT VI Replica Hardness
HIP & LP Rotor/Bucket
HP 1st Stage Wheel Fillet ● ● ● ●
HP 1st & 2nd Stage Wheel Dovetail ● ● ● ●
Bucket Vane, Tenon & Cover ● ●
Bull Gear ● ●
L-0, 1, 2 BucketL-0 Blade Pin, L-1,2 Notch Blade Pin ● ● ●
LSB Vane ● ●
CasingCasing ● ●
Casing Bolt ● ● ● ●
Nozzle & Diaphragm Nozzle Partition ●
Packing Inter-Stage/End Packing ●
ValveMSCV Body ● ● ● ●
Body Seat ● ●
Bearing (STG Journal & Thrust) Bearing Pad ● ● ●
Main Steam Lead Pipe Lead Pipe Welding Part ● ● ● ● ●
Duct Steam Exhaust Duct ● ●
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1) Result Summary (Main Defects & Recommendations)
1.3 Steam Turbine Part
Thrust BRG pad babbitt fault(Process surfacing/ Re-babbitt)
Turning gear tooth wear(Gear replacement and logic change required)
HP 1st stage FOD1) fault(Polishing required)
MSCV body internal crack (Repair and removal required)
IP 1st & 2nd stage SPE2) fault(Polishing required)
End packing tooth wear(Tooth sharped repair and replacement required)
Last stage DPH3) fault(Completed repair)
LSB BKT 4) wet erosion
1
5
2
6
3
7
4
8
1) FOD: Foreign Object Damage2) SPE: Solid Particle Erosion3) DPH: Diaphragm4) BKT: Bucket
12
7 7
83
4
5
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.4 HRSG, Duct, etc.
Item ComponentNDT Test Bore
ScopeMaterial Evaluation
RemarkVI PT MT UT Replica Hardness
HRSG
Header & Stub Welds ● ● ● ● ● Creep and fatigue analysis
Manifold & Drum ● ● ● ● ● ●
Bellows ● ●
Tube ● Tube sample test
Attemperator ● ●
Link Welds ● ● ● ● ●
HP Piping
Terminal & Pipe to Cast Welds ● ● ● ● ●
Branches, Tees, Y-Pieces ● ● ● ● ●
Flange & Section Change Welds ● ● ● ● ●
Butt Welds, Bend, Drains ● ● ● ● ●
Hangers ●
IP Piping
Terminal & Pipe to Cast Welds ● ●
Branches, Tees, Y-Pieces ● ●
Flange & Section Change Welds ● ●
1) List of NDT & Material Evaluation
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.4 HRSG, Duct, etc.
Component Material Degradation 1) Creep Damage 2) Life Time Consumption Rate (%) Residual Lifetime 3) (Hr)
HP DrumDrum Shell 2/3 1
25 176,805 Riser 2/3 1
IP DrumDrum Shell 2/3 1
25 176,805 Riser 2/3 1
HP HT SHHeader 4/5 1 50 58,935 Tube 4 1 40 88,403
HP IT SHHeader 4 1 40 88,403 Nozzle 5 1 50 58,935
HP EVPHeader 2/3 1
25 176,805 Nozzle 2/3 1
AttemperatorLink Pipe 4 1
40 88,403 Nozzle 4 1
Upper Link Pipe-1 Pipe 4 1 40 88,403
Upper Link Pipe-2Elbow 4 1
40 88,403 Reducer 4 1
Upper Link Pipe-3Tee 4 1
40 88,403 Pipe 4 1
1) Material Degradation: 1-6 Level2) Creep Damage: 1-5 Level 3) Residual Lifetime: Consumption Rate = Operated Hours* / (Operated Hours + residual life time)
* 58,935 hours and 53,918 hours for the operated hours of 1st Unit and 2nd Unit, respectively based on the figures as of September 2017
2) Summary of Material Degradation and Creep Damage Inspection – HRSG
∙ The maximum life consumption rate is estimated to be around 50%. It is therefore recommended to conduct a re-examination within 8 to 10 years if the current operation conditions are maintained.
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.4 HRSG, Duct, etc. 3) Summary of Creep and Fatigue Life Assessment – Header
∙ The minimum of high temperature header is about 16.6 million hours based on equivalent operating hour (EOH) standard.
Unit Damage, %(Operation data hours)
Total Damage, %(Operating time = EOH)
HRSG #1 0.0016 (240 hours) 0.8 (113,056 hours)
HRSG #2 0.004 (240 hours) 1 .8 (106,157 hours)
Unit Damage, %(Operation data hours)
Total Damage, %(Operating time = EOH)
HRSG #1 0.043 (240 hours) 20.3 (113,056 hours)
HRSG #2 0.051 (240 hours) 22.6 (106,157 hours)
Item HRSG #1 HRSG #2
Total lifetime 416,046 hours (100.0 %) 272,316 hours (100.0 %)
Consumed lifetime 113,056 hours (27.2 %) 106,157 hours (39.0 %)
Residual lifetimeEOH basis 302,990 hours (72.8 %) 166,159 hours (61.0 %)
Keep lasting current operational condition 153,889 hours 86,618 hours
1. Creep Analysis
3. Creep and Fatigue Interaction Analysis
2. Fatigue Analysis
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.4 HRSG, Duct, etc. 4) Test Result of the Superheater Tube Sample
∙ The sample test of HP HT SH tube has enabled it to maintain sufficient strength. According to the test, material deterioration recorded grade D, which is the intermediate level, and creep damage stood at level 1.
Description Tensile Strength (Mpa)
Yield Strength (Mpa)
Elongation Rate (%)
ASME Code Min. 415 Min. 205 Min. 30
1st UnitSpecimen-1 492 240 29
Specimen-2 494 235 29
2nd UnitSpecimen-1 478 238 30
Specimen-2 494 257 30
Tube Sampling Micro Structure
Tension Characteristics
1st Unit (Hardness: Average of 145Hv)
2nd Unit (Hardness: Average of 152Hv)
DOOSAN POWER SERVICESPROJECT STORIES LIFE ASSESSMENT FOR HANLLIM CCPP (KOREA)
1.5 Generator
Item Test GT#1 GT#2 ST Min. Requirement Remark
Stator
Insulation Resistance Pass Pass Pass Min. 1GΩ
Polarization Index Pass C Phase Fail Pass Min. 2 Restore after cleaning and drying
Partial Discharge Test Pass Pass Pass 10,000 pC below
Instrumentation Test — RTD Sensor Check Pass Pass Pass
Temp.: Room Temp. ±5℃Residual deviation
(between sensors): 0.8ΩRemaining RTD sensor
Wedge Tightness Test 7 EachFail
45 EachFail
31 EachFail Min. 550 Leeb #GT: 60 each and #ST 20 each replace
EL-CID Test Pass Pass Pass Max. /100 /mA
Bump Test Pass Pass FailMax. 2,200 mm/S2/N
(Series Loop direction)Others, Max. 4,400mm/S2/N
Block and binder reinforcement completed
Rotor
Insulation Resistance Pass Pass Pass Min. 25MΩ
Polarization Index Pass Fail Pass Min. 1.1 Restore after partial re-insulation
RSO Test Fail Pass Pass Waveform Match Restore after whole re-insulation
1) Summary of Results: Electrical and Mechanical Test
DOOSAN POWER SERVICESPROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA)
2.1 Summary of Sousse A Unit 2 Life Assessment (Tunisia)
PROJECT OVERVIEW
PJT title Sousse A Unit 2 Life Assessment Client STEGSite inspection period 2 weeksExecution year September, 2017
∙ Pre-study by using existing information on operations and maintenance
∙ Site survey and interview - Check site status - Interview with operators and
maintenance engineers∙ Detailed site inspection for all
components in the power plant #2 - Visual inspection - NDT and replication - Review of all information, data and
manuals
Output
- Test & inspection report
- Indicative proposal for plant life extension
∙ Checking life assessment of existing equipment∙ Checking the budget for life assessment projects
Plant Information
Scope of Supply
Customer Benefits
∙ OEM ∙ Plant Type ∙ Capacity∙ COD
BLR: SGP / STG: KWU_SiemensOil or gas-fired160MW x 21980
PLANT LOCATION
Sousse, Tunisia
∙ Safety of urgent power generation ∙ Stable and economical operations∙ Continuous technical support
Customer Needs
DOOSAN POWER SERVICESPROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA)
2.2 Introduction
Customer’s Needs Doosan’s Value Proposal
∙ Major overhaul which enables the production of electricity within a year ∙ Replacement of aged critical items to achieve safe operations
∙ Optimization of the recovery target in consideration of current equipment conditions∙ Optimal target: 80-85% of rated output
∙ Reasonable and affordable price by engineering optimization to maximize re-use of current equipment
- Unit #1 used as a spare part for unit #2 refurbishment
Urgent power generation and operational safety
Optimized target
Economic benefit
∙ Long-term service agreement (LTSA) for the future operation period - Technical Advisor (TA) support - Spare part supply for critical items
Continuous technical support
∙ With consideration on equipment conditions, Doosan’s proposal focuses on providing solutions to generate electricity as soon as possible with following key values.
DOOSAN POWER SERVICESPROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA)
2.3 Inspection Activities
Items Doosan STEG
Boiler
Wall Tube VI / Replication VI / NDT
S/H Tube & Header VI / Replication VI / NDT
R/H Tube & Header VI / Replication VI / NDT
Eco. Tube & Header VI / Replication VI / NDT
FD FAN / Duct VI VI
Piping
Main Steam VI / Replication VI / NDT
Hot Reheat VI / Replication VI / NDT
Feedwater VI / Replication VI / NDT
Turbine & Aux. System VI VI
Generator VI Megger Test
Condensate System VI VI
Feedwater System VI VI
Cooling Water System VI VI
Fuel Supply System VI VI
Electrical System
Transforme Megger Test (LV) Megger Test (HV)
Main Cable Megger Test VI
Motor Megger Test (MV) Megger Test (MV)
Circuit Breaker Megger Test (MV) VI
IPB & GCB Megger Test VI
C&I VI VI
∙ Detailed site inspection was conducted for Sousse Unit #2 through close cooperation between Doosan and STEG for two weeks.
* VI for Visual Inspection; NDT for Non-destructive Test (MT, UTT, HT); and MV for Medium Voltage
Items Scope
• Wall Tube: Replacement• SH, RH Outlet HDR, Tube: Replacement• Gas Recirculation Fan: Replacement• GR Damper: Bearing and actuator replacement• Air Preheat System: Replacement of the seal system
• Main & Reheat Steam Piping: Partial replacement or repair• Feedwater Piping: Repair• Hanger & Support: Partial replacement or repair
• Major Overhaul (including detailed NDT test)• Main Valve (high pressure turbine): Complete repair• TCS upgrade to a new system
• Major Overhaul (including NDT test)• Stator: Rewinding• Rotor: Re-insulation (optional)
• Battery System: Replacement (DC220V 240 EA)
• MP Bypass Valve: Replacement• LP Feedwater Heater: Replacement (#2, #3)• Air Ejector: Replacement • CCW: Replacement of the cooler and booster pump • Major Overhaul: Condenser, HP heater, safety valve, main pump, cooler, etc.
• Burner Management System (BMS): Replacement• Field Instrument: Partial Replacement• C&I Cable: Partial Replacement
DOOSAN POWER SERVICESPROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA)
2.4 Proposed Work Scope 1) Summary of Proposed Work Scope for Refurbishment
Boiler
Critical Piping
Turbine
Electrical
BOP
C&I
Generator
(A) Drum⋅ Replacement of the level gauge and safety
system
(B) Soot Blower
⋅ Demolition or blinding
(C) HDR and Heating Surface⋅ Replacement of the SH, RH outlet HDR and
tube
(D) HFO/Gas System⋅ Demolition or physical isolation
(E) Furnace Wall⋅ Replacement of the wall tube
(F) Gas Recirculation System⋅ Replacement of the fan⋅ Replacement of the bearing and actuator
for the damper
(G) FD Fans System⋅ Retrofit for the FD fan⋅ Replacement of the actuator
(I) Air Preheat System⋅ Replacement of the seal system⋅ Retrofit for the driving shaft cooling
system⋅ Replacement of the inspection wind
(J) Air Duct⋅ Partial repair of the casing⋅ Overhaul for the driving part of the
damper⋅ Reuse of the expansion joint
(K) Gas Duct⋅ Partial repair of the casing⋅ Overhaul for the driving part of the
damper⋅ Reuse of the expansion joint
DOOSAN POWER SERVICESPROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA)
2.4 Proposed Work Scope 2) Boiler Part
(F) Gas Recirculation System
(I) Air Preheat System
B A
C
F
ED
G
H
I
G
J
DOOSAN POWER SERVICESPROJECT STORIES SOUSSE A UNIT 2 LIFE ASSESSMENT (TUNISIA)
2.4 Proposed Work Scope
∙ The material and welding point will be considered as in good condition if there is no crack according to the NDT report on point #1 and #2.
∙ If there are some cracks found according to the NDT report on point #2, NDT point #3-#8 shall be tested in order.
∙ If there is no problem according to the NDT reports on point #3 to #8, cutting and replacing part on point #2 needs to be treated while other parts are considered as in good condition.
∙ If there are cracks on welding point #3-#8 without a raw material problem, Doosan will supply alloy piping for partial replacement.
∙ NDT, including bore-scope test, should be carried out at one point for cold reheat, feed water and feed extraction piping.
∙ Small bore piping in the supply scope should be all replaced due to corrosion.
∙ Define the condition of BOP piping, alloy piping in particular, such as main steam and hot reheat system based on non-destructive test (NDT)
NDT Point #1: Completed - Magnetic Test: No cracks were found - Thickness Test: No cracks were found - Hardness Test: No cracks were found
NDT Point #2: Completed - According to the results of NDT on point #2, NDT points #3 to #8 will be tested
additionally.
CONCLUSION
3) Critical Piping
DESCRIPTION
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
Summary of Generator Test & Life Assessment in Western Sector (Saudi Arabia)
PROJECT OVERVIEW
PLANT LOCATION
PJT title Generator Test & Life Assessment in Western SectorClient SEC (Saudi Electricity Company)
Contract year 2017PJT period 4 years
Jeddah, Makkah, Rabigh, Tabouk, Madinah, Yanbu, Duba, Taif and Alwajh in Saudi Arabia
∙ Test & inspection, diagnostic & life assessment for stators, rotors and exciters
∙ Submission of life expectancy analysis program (LEAP) reports
∙ Inspection and reporting schedule - Preparation: 15 days - Test & inspection: 15 days - Final report submittal: 15 days
Output
- Test & inspection report
- Life expectancy analysis program (LEAP) report
∙ Preventing failure through the inspection and assessment in advance∙ Securing a stable operation and maintenance of generators
Plant Information
Scope of Supply
Customer Benefits
∙ OEM ∙ Plant Type ∙ Capacity∙ Subject Unit∙ COD∙ Cooling Type
GE, ABB, Alstom, BrushOil or gas-fired23-188MVA96 units in total1976-2002Air or hydrogen
3.1
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work
No. Generator Type/ Serial Number
RatedMVA
AvailableMW Location
01 GE ATB 23.0 18.0 Alwadj
02 GE ATB 29.6 16.0 Alwadj
03 GE ATB 37.7 17.1 PP1 Tabouk
04 GE ATB 29.6 16.8 PP1 Tabouk
05 GE ATB 29.6 18.0 Yanbu PP
06 Rode Knocar (S1726) 32.0 15.9 Taif PP
07 AlstomKT174-160 22.6 18.0 Duba
08 Brush BD AX7.145 PRH 23.9 18.0 Duba
09 GE 6Az 40.8 27.0 PP2 Tabouk
10 GE PW70000 67.5 44.6 PP3 Jeddah
11 GE7A3 73.1 44.6 PP3 Jeddah
12 GE7A3 78.1 40.0 Makkah
13 GE7A4 98.7 53.2 Makkah
14 GE7A6 107.5 61.6 Rabigh PP
15 GE7A6 88.7 57.0 PP2 Tabouk
16 GE7A6 84.5 60.1 PP2 Tabouk
17 GE7A6 108.8 56.4 PP2 Madinah
18 GE7FH2 188.0 145.5 Rabigh PP
No. Generator type / Serial Number
RatedMVA
AvailableMW Location
01 ABB WY18L-066-LLT 108.5 51.7 PP3 Jeddah
02 ABB WY18L-066-LLT 108.5 46.3/48.5 Makkah
03 ABB WY18L-066-LLT 108.5 50.0 PP2 Madinah
04 ABB WY18L-066-LLT 108.5 54.7 Rabigh PP
05 ABB WY18L-059-LLT 98.0 54.7 Rabigh PP
06 ABB WY18L-050-LLT 40.5 18.0 Makkah
07 ABB WY18L-050-LLT 40.5 18.0 PP1 Madinah
08 ABB WY14L-061-LLT 46.6 22.0 Makkah
09 ABB WY14L-061-LLT 46.6 20.0 PP2 Madinah
10 ABB WY16L-044-LLT 57.9 203 Taif PP
11 ABB WY14L-061-LLT 46.6 19.5 Taif PP
12 ABB WY16L-068 82.5 31.2 PP2 Tabouk
13 ABB WX21L-071-LLT 166.2 133.0 Rabigh PP
1) Subject Generator Specification
Generators of GE and Other Similar Manufacturers Generators of ABB Manufacturers
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work
PI TestBump Test
2) Stator Assessment
∙ Insulation resistance and polarization index test∙ High potential test∙ Partial discharge test∙ End winding bump test∙ El-CID test
Insulation Tests
EL-CID Test Hi-Pot Test
Terminal Box
Chattock Coil
Trolley Laptop Computer
Reference
SIGNAL
Y INPUT
INPUT 1
INPUT 2
X INPUT
Reset zero cal.X
Distance
cal.Y Reset Y phase
Signal Calibration
Battery D.C External
Low Fuse PowerComputer
Pulse X(Recorder) Analogue
AUXPOWER
OUTPUTS
DIGITAL EL CID MODEL 601
◁ ◁
A
V1 V2
∙ To find the damage or defect of stator winding resulting from long operating hours at high temperature and high speed
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work 3) Rotor Assessment
RSO Test Hi-Pot Test PI Test
∙ Insulation resistance and polarization index test∙ High potential test∙ RSO test
Generator Rotor Shorted Turn Analysis
Insulation Tests
120 VAC 0.05A
Test Simulator
Ground Wire Collector Rings
Nomal Inner
Outer
∙ To find the damage or defect of rotor winding resulting from long operating hours at high temperature and high speed
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work 4.1) Condition Assessment
No. Issues & Concerns
01 White powder of connection for phase lead and cracks on epoxy painting area
02 White powder of series loop and end arm
03 Looseness of block and tying
04 Protrude of pin or block
05 Contamination of oil, dust and others
06 Insulation damage
07 Relative movement between ring and support
08 Deformation and discoloration of connection ring
No. Issues & Concerns
01 Surface finish condition
02 Dimensional inspection
08 PT
End Winding and Connection Ring
Journal
End Winding
Phase Connection Ring
Glass roving tying
Nose ring
Teflon hose
Axial support
Phase connection ring Support bracket
Support ring
Conforming material radial ring
Flux shield
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2
4.2) Condition Assessment
No. Issues & Concerns
01 Damage and deformation on the teeth of stacked core
02 Overheating, discoloration and/or decolorizing of coating area
03 Looseness of core laminations
04 Blocked space blocks
05 Protrude of core laminations including step cores
06 Rubbing between key bars and cores
07 Condition of gas gap baffle and core baffle
08 Rust and corrosion of core
09 Gap of wedges
10 Yellow powder of wedges or fillers
Wedge
Core
Stator Core and Inside of Stator
Core and Wedge in the Stator
Detailed Scope of Work
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work 4.3) Condition Assessment
No. Issues & Concerns
01 Check on the cleaning of insulator surface
02 Damage and discoloration of porcelain bushing
03 Condition of sealing compound
04 Gap of flange for bushing
05 Tightness condition of bolt for bushing flange and lock washer
06 Overheating of lead connection
07 Gasket condition of manhole cover for terminal box
No. Issues & Concerns
01 Contact of horizontal joint
02 Leakage of H2 gas
03 Injection of tight seal compound
04 Painting conditionOil deflector
BearingH2 seal csg
H2 seal ring
End shield
High Voltage Bushing & Current Transformer
Inner and Outer End Shields
High Voltage Bushing
Phase Connection Ring
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work 4.4) Condition Assessment
No. Issues & Concerns
01 Contact between casing and rings
02 Wearing and damage of babbitt
03 Damage due to shaft current
04 Oil feed hole
05 UT and/or PT if necessary
Bearings
No. Issues & Concerns
01 Clearance of rotor
02 Leakage of oil
Inner and Outer Oil Deflector
No. Issues & Concerns
01 Wearing of babbitted ring
02 Insulation resistance between end shield and seal casing
05 Tension of spring
H2 Seal with Ring
Bearing
Oil Deflector
H2 Seal Ring
DOOSAN POWER SERVICESPROJECT STORIES GENERATOR TEST & LIFE ASSESSMENT IN WESTERN SECTOR (SAUDI ARABIA)
3.2 Detailed Scope of Work 4.5) Condition Assessment
Retaining Ring with Disassembly
No. Issues & Concerns
01 Overheating of fitting area
02 Movement of retaining ring
03 Rust and contamination
Fan
No. Issues & Concerns
01 Fixing of fan blade
02 Crack on the corner
Collector Rings
No. Issues & Concerns
01 Wearing of ring surface
02 Dimensional inspection
03 Leak for collector terminal
04 Cleanliness of insulation wrapper
Retaining Ring
Collector Rings
Fan