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Siemens AG
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91058 Erlangen, Germany
Siemens Energy, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399,
USA
siemens.com/energy
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
Field Technology Services (FTS) provides a variety of performance
enhancement and evaluation services for nuclear, fossil, combustion
and industrial turbine-generators.
Our People make the difference with their
extensive knowledge and 24/7 support from a
global network of engineers.
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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
Component Life Optimization
Unit Reliability Improvement
Unit Life Optimization
Starting Reliability Improvement
Operational Flexibility Optimization
Efficiency Optimization
Power Output Optimization
Maintenance Cost Reduction
Emission Reduction
Maintenance Ease
3
Diagnostics
Vibration Surveys and Analysis
Steam Turbine Unit Condition Evaluation
Rotating Equipment Balancing
Slow Speed Balancing
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.
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.
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 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
5
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.
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Diagnostics
Modal Analysis
Gas Turbine Fact Finding
Gas Turbine Post Outage Commissioning
Gas Turbine Tuning
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.
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.
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.
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
7
Controls and Auxiliaries
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
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
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 ElectroHydraulic (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)
Seal oil systems
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.
Balance of plant systems
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
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 CO2 as
a trace gas.
Non-intrusive flow measurements can be
performed in support of troubleshooting
various control system and auxiliary system
issues related to:
NOTE: Siemens Engineering can review on
a unit specific basis the utilization of CO2
(in lieu of SF6) as a trace gas for on-line leak
detection.
Lube oil systems
Generator hydrogen coolers
Generator stator cooling water systems
Hydrogen Leakage Detection
Valve operation
Protective trip functions
Lube oil system
Control devices (Gov, Aux Gov, Load Limit)
Speed / load instability
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.
Laser scanning allows the operator to scan
small and large components and structures;
then convert those scanned images (point
clouds) to working CAD models.
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
Applications include:
GT cylinder alignment
GT stationary component alignment
ST stationary component alignment
Generator air gap baffle alignment
Applications include:
Site surveys
ST stationary component alignment
Adaptation studies
GT blade ring mapping
Generator core mapping and aligning
Pre-outage layout / lay down area surveys
Generator gland seal bracket
perpendicularity
Piping surveys
Generator air gap baffles
3-Dimensional scanning
ST catenary curve measurement
Cylinder surface mapping
Legacy parts mapping
Whole train pedestal alignment
(thermal growth analysis)
Interference checks
Turbine cylinder mapping
Inspections
Component replacement
Adaptation studies
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