Engineered Improvements for Feed Pump Turbines FSRUG 2015 Presented by Jim Chalker

Engineered Improvements for Feed Engineered Improvements for Feed Pump TurbinesPump Turbines

FSRUG 2015

Presented by Jim Chalker

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Confidential & ProprietaryConfidential & Proprietary

Safe Harbor DisclosureSafe Harbor Disclosure


DefinitionsDefinitionsRevamps or Re-Rates Change in Power

Change in Rotating Speed

Change in Steam Conditions

Resulting in a change in Nameplate

Upgrades Modernization

Reliability

Efficiency

Operability

Maintenance

Address Technical Concerns


Re-design of hardware for the new conditions of

service.

Manufacture new steam path components using

modern methods

Engineering

Quality Assurance

Manufacturing Technology

“Cookie cutter” vs. custom design

Revamps or Re-RatesRevamps or Re-Rates


Address technical concerns discovered through

operation or maintenance turnarounds.

Technical advisements from OEM or shared

experiences from organizations like FSRUG

UpgradesUpgrades


3 Revamps and 3 New units for an EPU Project3 Revamps and 3 New units for an EPU Project Six GE Model DRV-631’s Reactor feed-pump drives Revamp for greater pump flow Increase in power & speed

Nuclear Power Project ExampleNuclear Power Project Example

Upgrade 3 surplus casings Manufacture 3 new casings 6 New D-R PRV Flow-paths


5-axis CMM with Laser Scanning Head used to gather data5-axis CMM with Laser Scanning Head used to gather data

Nuclear Steam Turbine EngineeringNuclear Steam Turbine Engineering casing and rotors mapped out to ensure interchangeabilitycasing and rotors mapped out to ensure interchangeability


Solid Models Created for design & analysisSolid Models Created for design & analysis


The Solid models were used for design and analysisThe Solid models were used for design and analysis

Unit layout and design “form, fit & function”

Structural & Finite Element Analysis (FEA)

Aerodynamic / Computational Fluid Dynamics (CFD)

Manufacturing CNC codes “Art to part”

Improve the castings

Mechanical design * Rotor dynamic analysis and design * Stress and vibration

engineering * Thermodynamic engineering * Aerodynamic engineering *

Metallurgical laboratory services * Manufacturing engineering

Engineering & AnalysisEngineering & Analysis


Turbine Casing - S.S. Weld InlaysTurbine Casing - S.S. Weld Inlays


Improved Stainless Steel Casings Improved Stainless Steel Casings





Profile Ring and Vane (PRV) Diaphragms Aero Performance improvements

Advanced manufacturing methods

Ability to hold tight tolerances

Less-Heat / Distortion

Steam Product ImprovementsSteam Product Improvements


PRV and Modified PRV DesignPRV and Modified PRV Design


Note the old and new design comparison.

Cylindrical end-walls develop secondary flows in a cylindricalstator end-wall.

Profiled end-walls develop a considerable reduction in secondary flows and pressure gradients in a profiled ring and vane (PRV) construction stator end-wall.

Steam Turbine RevampsSteam Turbine Revamps



Bolted diaphragms



Turbine Casing - Upgraded packing casesTurbine Casing - Upgraded packing cases

Original packing relied on casing fits. New design has an inner-carrier for bolting


Improved bearing casesImproved bearing casesCapability for 2 out of 3 trip system Capability for 2 out of 3 trip system



Original turning gear Original turning gear (field pictures)(field pictures)

Tight space between the exhaust end & containment wall along with the location

of the turning gear made it very difficult to align during turnarounds

Original turning gear

Coupling


Improved clutch type turning gearImproved clutch type turning gearincludes the shaft grounding brushincludes the shaft grounding brush




Upgraded turning gear Upgraded turning gear (test stand pictures)(test stand pictures)

Upgraded from the old linkage to a modern clutch design & moved outboard to

help reduce alignment time in the field


Nuclear Project - EngineeringNuclear Project - Engineering


Nuclear Project - EngineeringNuclear Project - Engineering Engineering designed new components to meet our

current design standards where applicable.

Adaptation Study - Know what needed to be done in the

RCA before we start work and ensure compatibility with

existing systems.

Engineering review meetings with client/user to ensure

that all design and procedure changes receive proper

approval.

Engineering to have ownership of turbine hardware

components that were originally designed by others.


Nuclear Project - EngineeringNuclear Project - Engineering Detailed Engineering and Analysis

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

Thermodynamic Engineering and Design

• Review existing unit performance model

• Develop operational envelope

• Design for new conditions

• Review gland seal system

• Performance curves


Nuclear Project - EngineeringNuclear Project - Engineering Detailed Engineering and Analysis

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

Rotor Dynamic Analysis

• Develop Mass Elastic model

• Perform analysis and summarize

• Review bearing design


Nuclear Project - EngineeringNuclear Project - Engineering

Detailed Engineering and Analysis

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


Project ObjectivesProject Objectives

Re-Rate for EPU conditions

Renew for life extension

Improve or maintain reliability

Improve operability

New controls & instrumentation

Automated turning gear design

Reduce maintenance requirements

Remove from current weld repair schedule

Remove from critical path during future refuel outages

Reduced alignment time

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Engineered Improvements for Feed Pump Turbines FSRUG 2015 Presented by Jim Chalker