GT 26 Users Conference 2011

RDK 4, 365 MW CCGT Plant

2. C-Inspection in 2011

KWG TR
Frank-Peter Kirschning
16. Juni 2011
Energie
braucht Impulse
Agenda

›Power plant RDK 4 – introduction

›Scope of work executed

›Assessment / Findings

›Challenges

›Conclusions
RDK 4 Power plant
RDK 4 Projekt Data

Rheinhafen Dampfk
ampfkraftwerk:

› Karlsruhe, Germany
› Small o&m contract - end with the C-inspection performed
› Plant scope covered by EnBW

› Power Station in the harbour of Karlsruhe

› GT26AB
› PAC end 1998
› ...
RDK 4 Projekt Data - location

RDK 4,
Karlsruhe

Zürich
CH
RDK 4 – 2nd C-inspection

This C-inspection:
inspection:

› 2 x 10h shift , 6 days a week

› 42 days outage duration equal to 35 days (2 x shift/ 7 days)

› Partially execution (combustors) at Alstom Mannheim factory

› Manpower from EnBW directly envolved (8.500 h)
› EnBW scope e.g. GT transmitter calibration, electrician work,
P14 I&C work, ...
› Close co-operation between Alstom team and EnBW
› two EHS audits performed
Overview of work during Outage RDK 4

Scope:
Scope:

› Gasturbine C-Inspektion

› Generator small B-Inspection

› Steam Turbine IP ST Outage

(mainly rotor rework due to lifetime)
Gas Turbine

2nd C-inspection of GT26AB (SN G02604)

Outage start: 26th April 2011
ODC: total / since last C-insp.
OH = 21.417 / 8.437
EOH = 62.708 / 20.717
S= 1.426 / 509
Main works carried out
› Visual inspection
› Hot Gas Path parts exchange (RECO and new parts)
› Hot spot repair at GT Exhaust duct
Other scheduled work
› OTC steam outlet pipe improvement
Dismantling Rotor 125 t Weight
SEV Combustor before Dismantling
Agenda

›Power plant RDK 4 – introduction

›Scope of work executed

›Assessment / Findings

›Challenges

›Conclusions
Gas Turbine scope – scheduled exchange of HGPP
LP Turbine:
- Blade 1, Blade 2, Blade 3
- Vane 1, Vane 2, Vane 3
- SHS A, SHS B, SHS C
SEV Combustor:
- SEV Inner Liner segments
- SEV Outer Liner segments
- SEV Burners
- SEV Diffusors (OGV)
- SEV Lances
HP Turbine: EV Combustor:
- HPT Blades - EV Inner Liner segments
- HPT Vanes - EV Outer Liner segments
- EV Front Segments
- HPT SHS
- EV Rear Hood Wall with burners
Structural parts & Rotor:
- MBH40 Internal Cooling Air Pipes
(one chip design)
 Agenda

Power plant RDK 4 – introduction

›Scope of work executed

›Assessment / Findings

›Challenges

›Conclusions
Low Pressure Compressor - blades

Small dent at
airfoil
Cleaning done thoroughly
Small dents were blended and polished
Low Pressure Compressor - vanes

Misaligned vanes found in row 3, 10, 13 & 16

Vanes found shifted. Re-alignment of rows done.

High Pressure Compressor – blades and RHS

Minor dents at airfoil and bended corners seen

High Pressure Compressor - vanes

Increased clearance at row 21 found

Damaged fixation pins on row 21 were exchanged

Mini OGV’s in good condition

Compressor Vane Carrier 2 (MBH40 piping)
piping)

Wear

Wear marks inside CHIP and piston end

Pipes and pistons were replaced.
EV Combustor

EV burners were replaced within EV RHW

Sieves were good for reuse after cleaning

Rear Hood Wall

Front segments
Sieve
EV Combustor

EV inner liner replaced – TBC

still in good condition

EV outer liner replaced

SEV Combustor

SEV inner and outer liner

replaced – TBC still in good
condition

Cracks found at SEV burner

Oxidation on the front face and
vortex generator
SEV burners were replaced
during outage
High Pressure Turbine

HPT blades, vanes and heat

shield were exchanged
Three lobe design of HPT blade
installed now

HPT blades showed

coating spallation on
leading edge

Blade crown was

oxidised
Low Pressure Turbine

HPT vanes were seen

with coating depletion
at pressure side

HPT heat shields

Low Pressure Turbine

LPT turbine - overview

LPT Blade 1
Low Pressure Turbine

LPT Blade 2

LPT Vane 2
Low Pressure Turbine

LPT Blade 3

LPT Vane 3

Honeycombs found brittle

Low Pressure Turbine

LPT Blade 4

Blade and vane row 4 found in good condition and therefore re-used

LPT Vane 4
Low Pressure Turbine

RHS A

RHS A assessed – good for re-use

rubbing from honeycombs seen

RHS B
RHS B assessed – good for re-use
Minor rubbing from honeycombs seen

RHS C
RHS A assessed – good for re-use
Gas Turbine Rotor

Overall good condition of rotor

Some minor rubbing spots on surface seen
HPT fir tree without cracks

LPT fir trees

HPT fir trees
Rotor has been cleaned

A few
deformed
seals seen
Rotor re-conditioned
Agenda

›Power plant RDK 4 – introduction

›Scope of work executed

›Assessment / Findings

›Challenges

›Conclusions
Scope split between site and factory Mannheim

EV and SEV combustor went to Mannheim (80 km distance)

TVC also modified in factory Mannheim
Disassembly of old parts and assembly of new parts in factory done
Reason: Limited space during outage at RDK4 site

Combustors
Cold side

New parts installed

Hot spot repair at exhaust duct

Hot spots and high temperature in bearing tunnel

Extensive repair carried out

bearing tunnel

as found repaired
Hot spot repair at exhaust duct

“MBH-
MBH-tunnel”
tunnel” special cooler not any more required !
☺

bearing tunnel
fan
Hot spot repair at exhaust duct

Hot spot repair …

Diffusor outer
insulation
as found repaired
Once Through Cooler (OTC)

RDK has different arrangement than GT26 fleet

Steam Outlet Pipe replaced (improved mixed weld)
Pre-manufactured pipe piece delivered to site
Before outage

New connection and sensing

lines with valves
Agenda

›Power plant RDK 4 – introduction

›Scope of work executed

›Assessment / Findings

›Challenges

›Conclusions
Conclusions

›All Over performance ?

›Outage duration ?
›H&S ?
›To be improved for future ?
›Co-operation between Alstom and EnBW ?
›Others ?

two EHS audits performed – both passed successfully

RDK 8

Supercritical Hard Coal-Fired

Power Plant under construction/
progress

912 MW

KWG TR
Frank-Peter Kirschning
June 15th, 2011 Energie
braucht Impulse
Site-
Site-View
Boiler-
Boiler-House
Electrical Precipitator
400 kV-
kV-Portal FGD-
FGD-Plant
Discharge Cooling Tower
Mechanical Draft Circular cooling/
cooling/ 28 Fans
Discharge Cooling Tower
 Thank You
for your attention !