Engineered Improvements for Feed Pump Turbines FSRUG 2015 Presented by Jim Chalker
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Definitions Revamps or Re-Rates u Change in Power u Change in Rotating Speed u Change in Steam Conditions u Resulting in a change in Nameplate Upgrades u Modernization u Reliability u Efficiency u Operability u Maintenance u Address Technical Concerns Confidential & Proprietary Information
Revamps or Re-Rates u Re-design of hardware for the new conditions of service. u Manufacture new steam path components using modern methods l l Quality Assurance l u Engineering Manufacturing Technology “Cookie cutter” vs. custom design Confidential & Proprietary Information
Upgrades u Address technical concerns discovered through operation or maintenance turnarounds. u Technical advisements from OEM or shared experiences from organizations like FSRUG Confidential & Proprietary Information
Nuclear Power Project Example 3 Revamps and 3 New units for an EPU Project u Six GE Model DRV-631’s u Upgrade 3 surplus casings u Reactor feed-pump drives u Manufacture 3 new casings u Revamp for greater pump flow u 6 New D-R PRV Flow-paths u Increase in power & speed Confidential & Proprietary Information
Nuclear Steam Turbine Engineering casing and rotors mapped out to ensure interchangeability 5 -axis CMM with Laser Scanning Head used to gather data Confidential & Proprietary Information
Solid Models Created for design & analysis Confidential & Proprietary Information
Engineering & Analysis The Solid models were used for design and analysis u Unit layout and design “form, fit & function” u Structural & Finite Element Analysis (FEA) u Aerodynamic / Computational Fluid Dynamics (CFD) u Manufacturing CNC codes “Art to part” u Improve the castings Mechanical design * Rotor dynamic analysis and design * Stress and vibration engineering * Thermodynamic engineering * Aerodynamic engineering * Metallurgical laboratory services * Manufacturing engineering Confidential & Proprietary Information
Turbine Casing - S. S. Weld Inlays Confidential & Proprietary Information
Improved Stainless Steel Casings Confidential & Proprietary Information
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Steam Product Improvements u Profile Ring and Vane (PRV) Diaphragms l Aero Performance improvements l Advanced manufacturing methods l Ability to hold tight tolerances l Less-Heat / Distortion Confidential & Proprietary Information
PRV and Modified PRV Design Confidential & Proprietary Information
Steam Turbine Revamps Cylindrical end-walls develop secondary flows in a cylindrical stator end-wall. Profiled end-walls develop a considerable reduction in secondary flows and pressure gradients in a profiled ring and vane (PRV) Note the old and new design construction stator end-wall. comparison. Confidential & Proprietary Information
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Bolted diaphragms Confidential & Proprietary Information
Confidential & Proprietary Information
Turbine Casing - Upgraded packing cases Original packing relied on casing fits. New design has an inner-carrier for bolting Confidential & Proprietary Information
Improved bearing cases Capability for 2 out of 3 trip system Confidential & Proprietary Information
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Original turning gear (field pictures) Original turning gear Coupling Tight space between the exhaust end & containment wall along with the location of the turning gear made it very difficult to align during turnarounds Confidential & Proprietary Information
Improved clutch type turning gear includes the shaft grounding brush Confidential & Proprietary Information
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Confidential & Proprietary Information
Upgraded turning gear (test stand pictures) Upgraded from the old linkage to a modern clutch design & moved outboard to help reduce alignment time in the field Confidential & Proprietary Information
Nuclear Project - Engineering Confidential & Proprietary Information
Nuclear Project - Engineering u Engineering designed new components to meet our current design standards where applicable. u Adaptation Study - Know what needed to be done in the RCA before we start work and ensure compatibility with existing systems. u Engineering review meetings with client/user to ensure that all design and procedure changes receive proper approval. u Engineering to have ownership of turbine hardware components that were originally designed by others. Confidential & Proprietary Information
Nuclear Project - Engineering u Detailed Engineering and Analysis l Geometric Engineering • Develop blade/bucket root models • Develop casing diaphragm geometry • Develop rotor model • Layout existing steam path • Multi-unit dimensional comparison of critical dimensions l Thermodynamic Engineering and Design • Review existing unit performance model • Develop operational envelope • Design for new conditions • Review gland seal system • Performance curves Confidential & Proprietary Information
Nuclear Project - Engineering u Detailed Engineering and Analysis l Analytical Engineering • Review bucket and root selection for stress in operating range • Review for frequency interference • Campbell & Goodman Diagrams (blade & bucket stress) • Review shaft end stress at new conditions l Rotor Dynamic Analysis • Develop Mass Elastic model • Perform analysis and summarize • Review bearing design Confidential & Proprietary Information
Nuclear Project - Engineering u Detailed Engineering and Analysis l Design Engineering • Develop blade moisture protection plan • Review casing erosion issue and create repair or prevention plan • Create manufacturing drawings and specifications • DARS (Design Assessment Reports) • Control and protection valves • Bearing systems • Lubrication system Confidential & Proprietary Information
Project Objectives u Re-Rate for EPU conditions u Renew for life extension u Improve or maintain reliability u Improve operability l l u New controls & instrumentation Automated turning gear design Reduce maintenance requirements l u Remove from current weld repair schedule Remove from critical path during future refuel outages l Reduced alignment time Confidential & Proprietary Information
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