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PLANT ASSESSMENT PROJECT STORIES 2. Sousse A Unit 2 Life Assessment (Tunisia) 3. Generator Test & Life Assessment in Western Sector (Saudi Arabia) 2.1 Summary 2.2 Introduction 2.3 Inspection Activities 2.4 Proposed Work Scope 3.1 Summary 3.2 Detailed Scope of Work 1. Life Assessment for Hanllim CCPP (Korea) 1.1 Summary 1.2 Gas Turbine Part 1.3 Steam Turbine Part 1.4 HRSG, Duct, etc. 1.5 Generator Copyright by Doosan Heavy Industries & Construction Co., Ltd. All Rights Reserved.

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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