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  • A10 Steam Turb - CC Plant Webnar (Rev 4-1-16)

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    The document discusses the evolution of GE's A-10 steam turbine model. It describes how earlier models from 1989-1993 had lower inlet steam conditions and performed feedwater heating in the boiler. Later models from 1994-1997 saw increased inlet steam pressures and temperatures up to 1,950 psi and 1,050F. New exhaust casings, generator designs, piping materials, and last stage bucket designs were introduced for improved performance. The document also outlines continued design upgrades through 2001, such as reduced rotor spans and critical speeds, new valve designs, and hydrogen seal clearances.

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    The document discusses the evolution of GE's A-10 steam turbine model. It describes how earlier models from 1989-1993 had lower inlet steam conditions and performed feedwater heating in the boiler. Later models from 1994-1997 saw increased inlet steam pressures and temperatures up to 1,950 psi and 1,050F. New exhaust casings, generator designs, piping materials, and last stage bucket designs were introduced for improved performance. The document also outlines continued design upgrades through 2001, such as reduced rotor spans and critical speeds, new valve designs, and hydrogen seal clearances.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
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    Download as ppt, pdf, or txt
    244 views121 pages

    A10 Steam Turb - CC Plant Webnar (Rev 4-1-16)

    Uploaded by

    Flamingorosado
    The document discusses the evolution of GE's A-10 steam turbine model. It describes how earlier models from 1989-1993 had lower inlet steam conditions and performed feedwater heating in the boiler. Later models from 1994-1997 saw increased inlet steam pressures and temperatures up to 1,950 psi and 1,050F. New exhaust casings, generator designs, piping materials, and last stage bucket designs were introduced for improved performance. The document also outlines continued design upgrades through 2001, such as reduced rotor spans and critical speeds, new valve designs, and hydrogen seal clearances.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as ppt, pdf, or txt
    of 121

    A-10 Steam Turbine

    Presentation Volume 1

    Mark A. Cohen – Steam Turbine Field Engineer


    Index – D-11 Steam Turbine Design
    • (1) Introduction:
    • To Understand The Nature Of The GE A-10 Steam Turbine
    • G
    • G
    • G
    • G

    • (2) Steam Turbine Applications


    • Combined Cycle Steam Turbines
    • Utility Steam Turbines
    • Industrial Steam Turbines
    • G
    • G
    • G
    Index – D-11 Steam Turbine Design
    • (3) A-10 Model Steam Turbine Evolution:
    • S
    • C
    • W
    • W
    • H
    • C
    • (4) Combined Cycle Plant Design Features:
    • Temperature Matching
    • Starting and Loading
    • Plant Bypass Systems
    • Duct Firing Boiler Applications
    • Cyclic Duty Operation
    Index – D-11 Steam Turbine Design
    • Air Cooled Condenser Applications, High Back Pressure D-11 Turbine
    •C
    •W
    • (5) Generators Used With A-10 Steam Turbines:
    • Model 7A6 Generator
    • Model xxx Generator
    • Model xxx Generator
    • C
    Index – D-11 Steam Turbine Design

    • (6) A-10 Steam Turbine Installation: (((( Presentation PART 2)))


    • D-11 Steam Turbine Engineering and Requisition
    • Manufacturing and Shipping
    • Receiving D-11 Steam Turbine and Generator
    • H
    • C
    • C
    • (7) A-10 Steam Turbine Maintenance
    • D-11
    •M
    •R
    Index – D-11 Steam Turbine Design

    • (8) A-10 Steam Turbine Maintenance Issues – Top 10:


    • D
    • M
    • R
    • H
    • C
    • C
    • (9) Turbine Valve Maintenance
    •D
    •M
    •R
    Index – D-11 Steam Turbine Design

    • (10) A-10 Steam Turbine Centerline Maintenance


    • D
    • M
    • R
    • H
    • C
    • C
    • (11) Generator Maintenance
    •D
    •M
    •R
    Index – D-11 Steam Turbine Design

    • (12) Common Operation and Startup Problems (((Presentation – Part


    3))))
    • D
    • M
    • R
    • H
    • (14) Turbine Vibration
    • D
    • M
    • C
    • C
    Index – D-11 Steam Turbine Design
    • (15) Steam Seal And Vacuum:
    • Steam Seal System
    • Condenser Vacuum
    • (16) Drains And Water Induction:
    • Water Induction – Operation / Piping and Valves
    • Water Induction Damage
    • (17) Control System and Valve Problems:
    • High Temperature Oxide Maintenance
    • Combined Stop And Control Valve Disc
    • (18) Thermal Insulation Issues:
    • Turbine Shell Humping
    • Turbine / Valve Component Heat Damage
    Index – (Cont)
    • (19) Lubrication And Hydraulic Issues:
    • Combined Gas And Steam Turbine Lubricants
    • Lube Oil System
    • Hydraulic Power System
    • (20) Generator H2 Seals, H2 Joints, And Oil Leakage:
    • Hydrogen Systems – Vacuum And Scavenging
    • Hydrogen Seal Designs
    • End Shield Designs
    • Four Way Joints
    • Oil Ingress Into Generators
    • (21) Summary:
    • Successful Turbine Maintenance
    • Technical Direction
    (1) Introduction

    General Electric A-10 Steam Turbine


    • General Electric Model D-11 steam turbines used in combined cycle
    applications are high performance designs, in which many components
    are pushed to the maximum limits, with appropriate engineering
    margin. When technology is advanced, many margins are advanced and
    surpassed with proper justification and development. This is especially
    the case with the D-11 steam turbine designs.
    • This presentation is aimed at providing operation and maintenance
    details for these turbine designs that will be actionable back in the plant.
    A-10 Model Steam Turbine

    307 FA Combined Cycle Plant – D-11 Steam Turbine


    A-10 Steam Turbine – Machine Types

    50 Cycle Models
    207 FA, 209 FA / FB
    Non Centerline Shell

    60 Cycle Models
    207 FA – High Duct Firing
    307 FA
    309 FA / FB
    Centerline Support Shell
    A-10 Steam Turbine
    (2) Steam Turbine Applications

    307 FA Combined Cycle Plant – D-11 Steam Turbine


    High Performance Steam Turbine
    Design Features
    Combined Cycle Designs Traditional Designs
    • 1,050 F Inlet Steam Conditions • 1,000 F Inlet Steam Conditions
    • Rapid Start, Cycling • Higher Inlet Steam Pressures
    • Flexible HP Rotor, Casing Designs • Base Load, Intermediate
    • Single Casing HP Shell • Less Flexible Turbine Casings
    • 12 Chrome, Inconel Materials For • HP Turbine Shell Inner Casings
    High Temp Creep
    • CR-MO-V Materials VS 12
    • Cost Driven Turbine / Plant Designs
    – (Merchant Plants) Chrome
    • Reevaluation of Engineering • Engineering Realities Of Larger
    Design Margins Machines
    Steam Turbine Designs - CC
    • Combined Cycle Steam Turbine Designs
    • 1,050 F Inlet Steam Conditions
    • 12 Chrome Materials - Suitable For 1,050 F High Temp Creep
    • Control Valves – Load Following Design
    • Rapid Start – (For A Price)
    • Combined Cycle Thermal Cycle Heat Balance
    • Turbine Bypass Systems
    • Steam Seal Systems – Temperature Matching Plant Design
    • Air Cooled Condenser Applications
    Steam Turbine Designs – CC

    • GE Combined Cycle Re-Heat


    Steam Turbine
    • Middle East Water Desalination
    Application
    • New Turbine Code
    Steam Turbine Designs – CC

    • GE Combined Cycle Re-Heat


    Steam Turbine
    • Middle East Water Desalination
    Application
    • New Turbine Code
    • Single Inlet Design
    • Turbine Assembly Area BLDG 66
    Schenectady, NY
    • Siemens KN Steam Turbine
    • Competitor to GE D-11 Steam
    Turbine
    • Design Features
    Steam Turbine Designs - Utility
    • Utility Steam Turbine Designs
    • Inlet Steam Conditions – 1,800 psi to 3,500 Psi @ 1,000 F
    • Less Flexible HP Shells – With Inner Casings above 2,000 Psi
    • Full Arc vs Partial Arc Designs
    • Valves Designed For Throttling
    • Larger Machine – (Engineering Realities)
    • Combined Cycle Designs Incorporated Into Utility Steam Turbines
    Steam Turbine Designs - Utility
    Steam Turbine Designs - Utility
    Steam Turbine Designs - Utility

    • 40 MW Non Reheat GE Steam


    Turbine
    • Cast Iron Exhaust
    • 40” Center Line Design
    • Westinghouse 150 MW Reheat
    Steam Turbine
    • Combined Cycle Repowering
    Using 501 F Westinghouse Gas
    Turbine Technology
    Steam Turbine Designs - Utility

    • 40 MW Non Reheat GE Steam


    Turbine
    • Original Asphalt Generator
    Winding
    Steam Turbine Designs - Utility

    • 750 MW G3 GE Reheat Steam


    Turbine
    • Six Rotors
    Steam Turbine Designs - Utility

    • 625 MW G3 GE Reheat Steam


    Turbine
    • 1970s Peeking Unit Used in
    Conjunction with Nuclear Power
    Plant
    • Low Steam Conditions 1800 PSI
    950 F - Large Axial Clearances
    Steam Turbine Designs - Utility

    • 625 MW G3 GE Reheat Steam


    Turbine
    • Dome Cooler Generator Design
    Steam Turbine Designs - Nuclear

    • 1100 GE MW Nuclear Steam


    Turbine
    • Rotor Speed – 1800 RPM
    • First 52” LSB
    Steam Turbine Designs - Utility

    • 1125 GE MW Super Critical Cross


    Compound Steam Turbine
    • High Pressure – 3600 RPM
    • Low Pressure – 1800 RPM
    • First 52” LSB
    Steam Turbine Designs - Utility

    • 1125 GE MW Super Critical Cross


    Compound Steam Turbine
    • High Pressure Turbine Section
    Steam Turbine Designs - Utility

    • 1125 GE MW Super Critical Cross


    Compound Steam Turbine
    • High Pressure Turbine Section
    Steam Turbine Designs - Utility

    • 850 GE MW Super Critical Cross


    Compound Steam Turbine
    Steam Turbine Designs -
    Geothermal

    • Fuji 50 MW Geothermal Steam


    Turbine
    Steam Turbine Designs -
    Geothermal

    • Ansaldo 50MW Geothermal


    Steam Turbine
    • GE Type Steam Path Technology
    Steam Turbine Designs - Industrial
    Paper Mill Application • 23 MW GE DAXC Industrial
    HP Extraction 156.5 PSI Steam Turbine
    LP Extraction 42.7 PSI
    Steam Turbine Designs - Industrial
    (3) A-10 Steam Turbine
    Evolution

    110 - 130 MW
    107 FA Combined Cycle
    High Back Pressure
    Applications – 90 MW

    130 - 150 MW
    209 FA / FB Combined
    Cycle
    A-10 Steam Turbine
    A-10 Steam Turbine
    A-10 Steam Turbine Evolution
    • 1989 - 1993
    • Feed Water Heating Done In Boiler, Turbine LP Admissions
    • Inlet Steam Conditions 1,450 Psi @1,000 F
    • Turbine Bypass Systems
    • 1994 - 1997
    • Inlet Steam Conditions 1,950 Psi @ 1,050 F – (7” Inconel Studs -INCO 718)
    • New Exhaust Casings – Modernized, Flexible, And Design To 750 F Inlet
    • Titanium LSB Introduced – (42” 50 Cycle)
    • New Generator Designs – Model 324 (Uprated) and Model 380 (New)
    • P91 9 Chrome Piping Introduced
    • New High Back Pressure Last Stage Buckets (LSB) For Air Cooled Condenser
    Applications
    • D-10 Steam Turbine Introduced For Single Shaft Steam And Gas Turbine Applications
    A-10 Steam Turbine
    A-10 Steam Turbine
    A-10 Steam Turbine
    A-10 Steam Turbine – Reaction
    Design
    A-10 Steam Turbine
    A-10 Steam Turbine
    A-10 Steam Turbine - Design
    Evolution
    • 1998 - 2001
    • Structured D-11 Beta Designs
    • High Duct Fired D-11 Designs Up To 30-40 % Of MW Rating
    • Reduced Rotor Spans
    • Increased Use Of Short Elliptical Bearings
    • Rotor Critical Speed Design Reduced From 2,000 to 1,500 Rpm
    • Valve Design Changes – Direct Acting CRV, Rexroth Actuators
    • Hydrogen Seal Ring Clearance Changes
    • Generator Key Bar Clearances
    • Enron / Combined Cycle Boom Crash
    A-10 Steam Turbine - Design
    Evolution
    • 2001 – 2010
    • New Last Stage Bucket (LSB) Designs
    • Elliptical Packing Rings Introduced D-11 and A-10 Steam Turbines
    • Hydrogen Seal Clearance Changes
    • New D-11 N-2 Packing Casing Design
    • Combined Cycle / Desalination Steam Turbine / Plant Designs For
    Middle East
    • Reaction Steam Turbine Designs
    • 2010 - Present
    • Reduced Steam Turbine Shipments
    Design Evolution – D-11 HP Turbine
    Shell
    Single Shell Design – (1,975 Psi 1,050 F) Super Alloy (INCO 718) Bolting

    Special Elongation – 60, 000 Psi 1.9 Mils / Inch


    Design Evolution – LP Exhaust
    Casings
    Flexible Exhaust Casing – (750 F Inlet) Rigid Exhaust Casing – (Old Design)
    Design Evolution – Rotor Spans,
    Critical Speed
    Rotor Span - 1995 Rotor Span 1995 – Coupling Extension
    Turbine Rotor Designs
    (4) Combined Cycle Plant Design
    Features
    Air Cooled Condensers – High
    Backpressure Designs
    Air Cooled Condenser – High
    307 FA Combined Cycle Plant Backpressure LP LSB’s
    Combined Cycle Plant Design
    Features

    • Low Cost Power Plant Design


    • No Crane
    • Outside Unit
    • Remote Control Room
    Combined Cycle Plant Design
    Features

    • 307 FA Combined Cycle Plant


    • Air Cooled Condensers
    • Water Restriction Application
    Combined Cycle Plant Design
    Features

    • D-11 Steam Turbine Combined


    Cycle Plant
    Combined Cycle Plant Design
    Features

    • 7E Gas Turbine Technology


    • HRSG with Bypass Stack
    Dampers
    • 207 E Combined Cycle Plant
    • Plant Constructed with Used
    Turbine Equipment
    GE Combined Cycle Steam Turbine
    Models
    • F Class Technology Combined
    Cycle Plant
    • Westinghouse 501 F Gas Turbine
    Technology
    • HRSG Stack Bypass Dampers
    • 3 Pressure Level HRSG -3 Steam
    Drums
    (5) Generators Used With The A-10
    Steam Turbine
    A-10 Steam Turbine Generators

    110 - 130 MW
    107 FA Combined Cycle
    High Back Pressure
    Applications – 90 MW

    130 - 150 MW
    209 FA / FB Combined
    Cycle
    • Model 324 Generator Shipment
    • Rotor Coupling Lock
    • Installation Contractor
    Responsible for Removal of
    Shipping Ties
    • Model 324 Generator Shipment
    • Preparing Generator Lifting
    Trunnions
    • Lifting Model 324 Generator
    • Transporting to Turbine
    Pedestal
    D-11Steam Path Alignment –
    Engineering Factors
    Turbine Shell Arm Support - Correction Turbine Shell Deflection – Corrections
    Engineering Alignment Factors -
    Turbine Shell Support
    Non Centerline Support Shell Design Centerline Support Shell Design
    D-11 LP Casings
    D-11 Steam Path Installation Alignment D-11 Turbine LP Casing - 33.5 “ LSB
    D-11 N-2 Packing Casing
    Original N-2 Design
    New N-2 Design
    (6) A-10 Steam Turbine

    110 - 130 MW
    107 FA Combined Cycle
    High Back Pressure
    Applications – 90 MW

    130 - 150 MW
    209 FA / FB Combined
    Cycle
    A-10 Steam Turbine
    A-10 Steam Turbine
    Understanding The A-10 Steam
    Turbine - Operation and
    Maintenance Issues
    Maintenance Operation
    • 1,050 F High Temperature • 1,050 F Inlet Steam Conditions
    Maintenance
    • Valve Stem Sticking Issues
    • Valves – High Temp Oxide
    Maintenance • Vibration – Caused By Alignment
    • Rotor Position, Steam Path • Starting And Loading – Thermal,
    Clearance, Differential Expansion High Temp Materials Issues
    • Three Bearing Turbine Rotor • Steam Seal Temperature Matching
    Maintenance
    • Alignment Issues – Steam Path • Rotor Differential Expansion, Axial
    Rubs
    • Engineering Maintenance
    Conventions & Design Margins • Mid Standard
    • Engineering Margins, Realities
    A-10 Steam Turbine - Top 10
    Maintenance Issues
    Turbine / Generator Problems Turbine / Generator Problems
    • (1) Rotor Vibration • (7) Thermal Insulation
    • (2) Steampath Alignment • (8) Thrust Bearing / Mid
    • (3) Coupling / Rotor Alignment Standard
    • (4) Valve Failures, Sticking – High • (9) Axial Exhaust Casing Loading,
    Temp Oxide Maintenance Foundation
    • (5) Rotor Position - Maintenance • (10) Parts / “Parts Changing”
    • (6) Steampath Clearances, N-3
    Packing Casing Axial Rubs
    A-10 Bearing Alignment – (Rotor
    Cold)
    A-10 Rotor Bearing Loading
    A-10 Rotor Form – (Cold Alignment)
    • Engineering
    • Rotor Dynamics – Cold To Hot
    • Vacuum Deflection – LP Bearing Cone
    • Traditional Bearing Loading – (200 Psi
    to 450 Psi)
    • Bearing Loading Design Margin –
    Through Operating Range
    • Symptoms - Vibration
    • Bearing Unloading - (½ Per Rev), Step
    Change
    • Coupling Misalignment - (Rim 1 Per
    Rev)
    • Coupling Misalignment – (Face 2 Per
    Rev Generator Rotor)
    A-10 Rotor Vibration – Rotor
    Alignment Issues
    3 Bearing Non- Maintenance Coupling
    A-10 Rotor 3 Bearing Turbine Issues

    • Rotor Sling Check – (Rotor


    Straightness)
    • Rotor Run Out During Coupling
    Assembly
    • Coupling Bolt Elongation
    • Coupling Face Condition
    • Bearing Elevations Per Bearing
    Alignment Diagram – (Bearing
    Loading)
    A-10 Rotor Vibration – Rotor
    Alignment Issues
    A-10 Rotor 3 Bearing Turbine 3 Bearing Non-Maintenance Coupling
    A-10 Steam Path Clearances, N-3
    Packing, Rotor Position
    Major Issues – Operation And GE Turbine Engineering – (Conventions)
    Maintenance
    • Turbine Engineering
    • Failure To Follow
    Conventions
    Engineering Conventions
    • Wrong Steam Path Clearances • Turbine Generator Set Reference
    – Looking From “Driver To Driven”
    • N-3 Packing Axial Rubs
    • Turbine Generator Set Reference
    • Thrust Failure Device Alarms / – Bearing Numbers And L / R
    Trips
    • Steam Path Clearances And Rotor
    • Startup Differential Expansion Position – (Rotor Pushed Toward
    Issues – (Rot Pos & Operation) Front Standard)
    • Rotor Long - Starting Techniques, • Steam Path Reference
    LP Cooling Flow And Hold Point
    N-3 Packing / Steam Path
    Clearances - Axial
    Rotor Position – Axial Clearances – (Incorrect) Rotor Position – (Correct)
    A-10 Mid Standard / Thrust Issues
    A-10 Mid Standard – Between HP And A-10 Mid Standard Issues
    Reheat Sections (1,050 F)

    • Thermal Insulation Critical In


    This Area
    • Oil Cooled Oil Deflectors – (Since
    2000)
    • Thrust High Temperatures –
    Insulation Work
    • Incorrect References And
    Conventions During
    Maintenance – Clearances,
    Rotor Position, Etc
    A-10 Axial Condenser Loading –
    Casing And Foundation Issues
    A-10 Axial Condenser Loading Casing / Foundation Issues

    • Very High Axial Casing • Axial Flow Casing


    Loads • LP Casing Belt Deflection –
    • Plant Designs Differential Expansion
    • Foundation Interfaces • Casing Deflection Movement
    • Key Maintenance
    • Foundation
    • Casing Anchor System
    • Foundation Cracking At Anchors

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