All rights reserved. Trademarks mentioned in this document are the property of Siemens AG, its affiliates, or their respective owners. Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract. siemens.com/energy Published by and copyright 2015: Siemens AG Freyeslebenstrasse 1 91058 Erlangen, Germany Field Technology Services Contact Information: 407-736-5809 FTSinfo.Energy@siemens.com Order No. PSPG-B10087-00-76US Printed in USA BU 13589T BR 0915.5 Field Technology Services Performance you can count on Siemens Energy, Inc. 4400 Alafaya Trail Orlando, FL 32826-2399, USA siemens.com/energy
Field Technology Services (FTS) provides a variety of performance enhancement and evaluation services for nuclear, fossil, combustion and industrial turbine-generators. scope People Quality budget Safety Performance Schedule implementation planning Our People make the difference with their extensive knowledge and 24/7 support from a global network of engineers. Safety, it s a mindset. You will see this in action as we utilize industry-leading Human Performance techniques and specially-designed tooling. Quality workmanship is a result of our focus on operational excellence. We strive to provide you peace of mind that the job will be done right. We understand Schedule adherence is important to you. That is why we offer upfront Total Maintenance Service (TMS) planning and a rapid response network of resources, tooling and parts. Our Performance-minded approach provides you scope, budget, planning and implementation support through our local District Service Offices. Our highly trained and experienced FTS field engineers leverage Original Equipment Manufacturer (OEM) fleet knowledge, processes and field procedures to provide quality services in the areas of Diagnostics, Metrology & Alignment, and Controls & Auxiliaries. Dependent upon the scope of work, some services are performed with the unit operating and others during maintenance outages. Benefits that may be realized from these services include: Unit Availability Improvement Unit Reliability Improvement Starting Reliability Improvement Efficiency Optimization Maintenance Cost Reduction Maintenance Ease Component Life Optimization Unit Life Optimization Operational Flexibility Optimization Power Output Optimization Emission Reduction 3
Diagnostics Vibration Surveys and Analysis In an effort to determine vibration root cause, online surveys are conducted under the direction of Siemens Engineering. Vibration and sound data acquisition locations may include rotor, frame, structure and piping. Steam Turbine Unit Condition Evaluation Performed on Nuclear and Fossil turbinegenerators, a unit walk-down is conducted at full load operation approximately 3-6 months prior to a scheduled outage. The objective is to identify potential issues such that those can be incorporated into comprehensive outage planning. During the unit walk-down, operating parameters are documented and vibration and sound data acquired to provide a snapshot of operating characteristics. Additionally, operations and maintenance personnel are interviewed. If advised in advance, some unit specific issues can be investigated during this site visit. Post outage evaluations can also be performed to document the results of work performed during the outage. Rotating Equipment Balancing Vibration levels in excess of OEM recommended operating limits can cause undue stress to rotating and stationary components. These stresses can potentially result in reduced operating life and accelerated integrity deteriorations. Rotating equipment vibration analysis utilizes proprietary software, SE-MEASURE, to acquire transient and steady-state vibration data to determine rotor unbalance conditions. Extensive fleet influence coefficients aid field balancing efficiency which can reduce the number of balance moves. Data collection is performed during unit operation, whereas balance moves are performed during a unit shutdown. Slow Speed Balancing Slow speed balancing can minimize and potentially eliminate the need for field balancing when the unit is returned to service. This process addresses changes in weight distribution of the rotor which can result from blade repair/replacement work. Slow speed balancing is performed during an outage when the rotor is removed from the cylinder or on spare rotors between outages. Balance weight consolidation is performed during the process to maximize the number of balance holes available for field balance needs. Slow speed balance experience list includes: Steam Turbine (ST) and Gas Turbine (GT) turbine rotors, industrial rotors, Forced Draft/Induced Draft fans (FD/ID), Boiler Feed Pump Turbines (BFPT) and motor armatures. Potential diagnoses may include: Oil Instability Steam whirl Rotor thermal shift Cracked shaft detection Sequential valve operation influence High pressure turbine inlet feature distress Foundation degradation Generator frame soft foot Generator core looseness Generator gland seal ring rub Generator rotor thermal instability Balance of plant (BOP) valve leakage SE-MEASURE is available for external software licensing. The program drives a 32 channel data acquisition system that uses off-the-shelf hardware. NOTE: If field balancing has been unsuccessful in reducing elevated operating vibration levels, slow speed balancing may be considered to address changed rotor weight distribution. 5 6
Diagnostics Controls and Auxiliaries Modal Analysis Modal analysis determines the natural frequencies and mode shapes of turbinegenerator static structures across the relevant frequency ranges of operation. Testing ensures that during operation the structure is tuned away from resonant conditions that increases structure fatigue and chance of failure. Modal analysis can be performed in the field or the factory. Gas Turbine Fact Finding Fact Finding is performed on V & W GT frames during unit disassembly including combustion chamber, minor, hot gas path and major inspections. These inspections are used to identify potential issues and support root cause investigations of existing issues. Inspection findings are documented in data sheets from GT Engineering checklists and photographed and associated recommendations can be used for future outage planning. Gas Turbine Post Outage Commissioning Commissioning activities are performed following the completion of maintenance outages or performance enhancements in an effort to maximize the success of the unit startup. Applicable operational and startup service bulletins and internal procedures are also reviewed, for proper unit startup and optimal operational characteristics, per specific site requirements. Toward the end of the outage, a final inspection checklist is performed to confirm that the unit is ready to start. Gas Turbine Tuning Combustion tuning is performed on Gas Turbines with Ultra Low NOx (ULN)/ Dry Low NOx (DLN) premix or standard combustion systems operating with natural gas or oil. Unit control settings are optimized in order to help minimize NOx and CO emissions and combustion dynamics. During the tuning process, the gas turbine is loaded to various load points (typically break points on the control curves) within the unit s normal operating range. In special situations, tuning is also performed at lower loads to improve turndown or startup emissions. Combustion tuning is typically performed when a unit is exiting an outage, but may also be done when an emissions or combustion dynamics issue exists. Seasonal tuning may also be performed, typically at the onset of cold weather and then again when warm weather returns. Modal analysis applications include: Generator end windings Generator pedestals Generator frame Generator lead box Operational deflection shape (ODS) Blade frequency testing Turbine structural shaker test Rotor modal analysis Baffle plates W GT Frame Compressor Hook Fit Measurements Hook fit measurements are recommended during major outages on the compressor rows 1-6 casing diaphragm grooves on some frames. Measurements are made at select locations in order to evaluate condition, track each row s performance, and assess future operation. The as found measurements are submitted to Siemens Engineering and based upon indicated wear, specific weld and grind repair recommendations are provided. These repairs are performed by Siemens Turbine Services personnel under the guidance of the measurement engineer. Upon completion of weld and grind repair activity, final as left hook fit measurements are documented. Checklist inspections include: Control system settings Inlet and Inlet Guide Vane (IGV) system Fuel and combustion system Exhaust system Auxiliary skids Upgrade verification 7 8
Controls and Auxiliaries Mechanical Hydraulic Controls (Vintage Steam Turbine) Systems supported include: Westinghouse 150# Westinghouse 300# Allis Chalmers Westinghouse BFPT Westinghouse extraction Westinghouse EH (electro-hydraulic) The mechanical hydraulic controls service can be used to resolve control system issues or optimize control system performance related to component integrity, fluid contamination, debris build-up, or improper valve sequencing. Some control system related issues can be resolved or optimized during operation and others may require a maintenance outage to reestablish design control settings and system performance. Related control system issues addressed include: Latching Valve operation Protective trip functions Lube oil system Control devices (Gov, Aux Gov, Load Limit) Speed / load instability Trip Block Analyzer The Trip Block Analyzer is a self contained system (independent of the turbine lube oil and vacuum systems) that allows for the simulation and adjustment of trip point settings on most 300#, Analog Electro- Hydraulic (AEH) and Digital Electro-Hydraulic (DEH) control system protective trip blocks. Performed at a maintenance outage with the trip block removed, the low bearing oil, low vacuum, and thrust trip set points are tested and returned to the design settings. Electro-Hydraulic System Analyzer (EHSA) The EHSA is used to locate sources of EH valve actuator internal leakage. EH actuator steam control valve assemblies can be completely tested for leakage in place. EH emergency trip block and servo valves can also be tested. Performing this service at the very beginning of a maintenance outage can allow for lead time to replace or repair leaking components. Generator Auxiliaries (Seal Oil, Stator Water) Generator performance can be adversely affected by auxiliary system issues. Seal oil system performance can negatively affect hydrogen purity, hydrogen leakage, and may induce seal rubs resulting in elevated generator or exciter vibration levels. Stator water system performance can negatively affect cooling of the generator, corrosion buildup within cooling passages and hydrogen leakage. Some issues related to the seal oil and stator water systems can be resolved or optimized during operation and others may require a maintenance outage to reestablish design settings and system performance. Flow Measurement Non-intrusive flow measurements can be performed in support of troubleshooting various control system and auxiliary system issues related to: Seal oil systems Lube oil systems Balance of plant systems Generator hydrogen coolers Generator stator cooling water systems Hydrogen Leakage Detection Excessive generator hydrogen leakage presents a safety hazard and impacts unit efficiency. A comprehensive procedure aids in locating and identifying hydrogen leakage paths on the stator frame, piping and auxiliary systems. Leakage detection walk downs are performed on or off-line, as long as generator hydrogen pressure is maintained. The service can also be performed during a generator air test by adding helium or CO 2 as a trace gas. NOTE: Siemens Engineering can review on a unit specific basis the utilization of CO 2 (in lieu of SF 6 ) as a trace gas for on-line leak detection. 9 10
Metrology and Alignment 3D Optical Coordinate Measuring System Laser Scanner (Long and Short Range) Laser Tracker Applications include: This form of stationary component alignment is used to help optimally align the internal components. This service simplifies and optimizes the internal alignment through the use of photogrammetry principles. Unlike a tight wire or laser, there are no wires to trip on or beams to reset, which can result in improved outage time savings. Applications include: GT cylinder alignment GT stationary component alignment ST stationary component alignment Generator air gap baffle alignment Laser scanning allows the operator to scan small and large components and structures; then convert those scanned images (point clouds) to working CAD models. Applications include: Site surveys Pre-outage layout / lay down area surveys Piping surveys 3-Dimensional scanning Cylinder surface mapping Legacy parts mapping Interference checks Inspections Laser tracker portable coordinate measurement machines (PCMM) are used to provide the highest accuracy of any other PCMM method (outside of a laboratory environment). Laser trackers are used to perform a wide range of metrology functions. Horizontal joint / surface mapping ST stationary component alignment Adaptation studies GT blade ring mapping Generator core mapping and aligning Generator gland seal bracket perpendicularity Generator air gap baffles ST catenary curve measurement Whole train pedestal alignment (thermal growth analysis) Turbine cylinder mapping Component replacement Adaptation studies 11 12