High Performance Steam Turbine Maintenance

Workshops Thumbnail_High Performance Steam Turbine Maintenance.jpg
Workshops Thumbnail_High Performance Steam Turbine Maintenance.jpg

High Performance Steam Turbine Maintenance

500.00

IN PREPARATION

DATE September 2016

TIME 8 AM EDT

DURATION 4 Hours

PRESENTER Mark A. Cohen, Steam Turbine Field Engineer

OVERVIEW  This workshop is designed to provide a review of the evolution of significant engineering, hardware, and plant design features and how these relate to operation and maintenance of combined cycle steam turbines. Operational issues and how to avoid and diagnose symptoms will be the main focus of this course.

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PRESENTER

Mark Cohen

Mark A Cohen, Steam Turbine Field Engineer, Consulting With Krishnan & Associates Inc.

Originally from Boston and having spent his career with the General Electric Company in the Steam Turbine business, Mark Cohen started with General Electric on the Field Engineering Program with international field service in the installation and service of steam turbines. He then worked in Turbine Engineering in both the GE Lynn and Schenectady turbine manufacturing facilities, and in turbine manufacturing and turbine assembly factory operations. Mr. Cohen is fully knowledgeable and an expert in the design evolution, and service intricacies of the various steam turbines built by the three traditional steam turbine product departments of General Electric (LSTG, MSTG, MDT) from 1950’s to present.  He is also an expert with the various Mechanical Hydraulic Control (MHC) systems and presently consults and freelances as a Turbine Field Engineer with various customers in the USA and throughout the world, and speaks several  languages fluently.

Mr. Cohen is an expert regarding the many versions of D-11 Steam Turbine design, having worked in Turbine Engineering, Factory Turbine Assembly area and serving as a factory expert on the shop manufacturing floor, and performing field work on the D-11 machines and other models as the design was evolving. He was also involved in design reviews and development of field service and installation  methodology during this design evolution and technology boom of  combined cycle products since introduced around 1990 and worked with many turbine equipment purchasers, plant designers and equipment owners regarding the manufacturing, installation and service of GE steam turbine requisitions.

Information  presented will be valuable for  those involved with planning, installation, and service and operation aspects of the D-11 Steam Turbine such as equipment purchasers, plant designers, installation and maintenance  personnel, and plant owners. Mr. Cohen especially enjoys working with customers to diagnose and fix turbine operational and maintenance problems, as well as installation issues, and welcomes all inquiries.  

 

Mark Cohen, D-11, Steam Turbine

EVENT DETAILS

  • Duration: 4 Hours
  • Instructor: Mark A. Cohen,  Turbine Field Engineer
  • Education level:  Open
  • Who Should Attend: Individuals or groups involved in procurement, engineering, installation, service, and operation of combined cycle plants containing the General Electric Model D-11 Steam Turbine who would like to intimately understand this type of machine, and how it interfaces with the combined cycle plant . This includes Architect Engineering Firms, Turbine Service Companies, and plant / equipment owners.

 

OVERVIEW

The General Electric D-11 Steam Turbine Model is a high performance combined cycle machine that is used in combination with the many models of Frame 7 and 9 “F” Class gas turbines. These versions come in both 50 and 60 cycle versions in which thousands are in operation all over the world. The D-11 is an extremely common steam turbine model, however there are many hardware versions since introduction around 1990. It is a big misconception that the D-11 is a standard model, and that installation and maintenance is standard or similar to previous utility steam turbine designs, or across the existing fleet of machines. This is a very high performance machine, requiring specialized maintenance methodology, and maintenance rules that address the engineering design, and design margins, as well as specific fleet experiences of this unit. As such, it is necessary to know and understand  these issues and specialized hardware on this machine, and how it differs in order to avoid costly maintenance problems, especially regarding alignment, valve issues, different generator designs, and to address the 1,050 F operating temperature of these units. Complicated plant design and extreme cyclic operation that these machines are now exposed to require careful attention in certain areas of operation and maintenance as well.

The course is designed to provide hard to find expertise information regarding the hardware variations of the D-11 Steam Turbine as it relates to the numerous fleet issues that arise when installation and maintenance techniques do not address the high performance engineering realities of these machines.  

 

D-11 STEAM TURBINE DESIGN FEATURES

Participants will learn about the following General Electric Steam Turbine design features:

  • STEAM TURBINE APPLICATIONS
    • Combined Cycle Steam Turbines
    • Utility Steam Turbines
    • Industrial Steam Turbines

 

  • D-11 MODEL STEAM TURBINE DESIGN EVOLUTION

The design evolution of hardware, manufacturing, and issues associated with many of these changes and designs will be demonstrated for the general classes of D-11 Steam Turbines and hardware, as well as market drivers and plant operational changes that these designs were made to address. 

  • 1990 Model Introduction (1,450 Psi 1,000 F)
  • 1994  Models (1,950 Psi 1,050 F), New Generator Designs
  • 1998 D-11 Beta Models, Combined Cycle Boom
  • 225 MW to 280 MW Class Designs
  • 280 MW to 340 MW Class Designs
  • D-11 Steam Turbines Designed For High Duct Firing Operation
  • Toshiba Manufactured D-11 Steam Turbines
  • 2001 - 2010
  • 2010 to Present

 

  • SPECIALIZED COMBINED CYCLE PLANT DESIGN FEATURES
    • Temperature Matching Issues
    • Starting and Loading
    • Plant Bypass Systems
    • Duct Fired Boilers Applications
    • Cyclic Duty Operation
    • Air Cooled Condenser Applications, High Backpressure D-11 Designs

 

  • GENERATORS USED WITH D-11 STEAM TURBINE MODELS
    • Model 324 Generator
    • Model 7FH2 Generator
    • Model 390 Generator
    • Hydrogen Cooling Systems – Scavenging vs Vacuum Systems

 

D-11 STEAM TURBINE INSTALLATION AND MAINTENANCE

Participants will learn about the following D-11 Steam Turbine installation and maintenance, and maintenance issues:

  • D-11 STEAM TURBINE INSTALLATION
    • D-11 Steam Turbine Engineering / Requisition
    • Manufacturing and Shipping
    • Receiving a D-11 Steam Turbine Shipment
    • Technical Direction and Installation Contractors
    • D-11 Steam Turbine Centerline Installation
    • Steam Turbine Valves, Piping, and Systems
    • Installation Startup Activities

 

  • UNDERSTANDING D-11 STEAM TURBINE MAINTENANCE
    • Technical Direction, Labor, capabilities
    • Developing Maintenance Outage Work Scope
    • Steampath Inspection and Maintenance
    • 1,050 F High Temperature Maintenance Issues
    • HP Turbine Single Shell Construction – Flexibility Issues
    • Reduced Rotor Spans, Lower Critical Speeds, Special Bearing Designs
    • Alignment Issues - Steam Path
    • Different Component Designs Within the D-11 Model
    • Valves – High Temperature Oxide Maintenance
    • Operation Issues Affecting Maintenance and Vice Versa
    • Maintaining Engineering Design Margins
    • Generator Maintenance W
    • Technical Information Letter (TIL) and Warrantee System

 

  • TOP 10 D-11 OPERATION AND MAINTENANCE ISSUES
    • Rotor Vibration
    • Steampath Alignment
    • Coupling / Rotor Alignment
    • Valve Failures – Valve Stem Sticking, High Temperature Oxide Maintenance
    • N-2 Packing Casing Cracks, Leakage, Alignment / Vibration
    • Rotor Position, Using Correct Maintenance References and Methodology
    • Turning Gear Issues
    • Thermal Insulation
    • Generator Excess Hydrogen Consumption, Oil Ingress / Leakage
    • Parts / “Parts Changing” and Technical Direction

    

  • D-11 STEAM TURBINE MAINTENANCE
    • Turbine Centerline Maintenance
    • Valve Maintenance
    • Turning Gear Maintenance
    • Lubrication and Hydraulic Systems
    • Control System Maintenance
    • Auxiliary System Maintenance

 

  • D-11 GENERATOR MAINTENANCE
    • Traditional vs Present Generator Designs Used in Combined Cycle Applications
    • Maintenance Issues By Generator Model
    • Maintenance of Hydrogen Sealing System
    • Hydrogen Seals and End Shield Issues
    • Collector and Brush Maintenance
    • Shaft Grounding Brushes
    • Generator Specialist Work

 

 D-11 STEAM TURBINE OPERATION

 Participants will learn about the following D-11 Steam Turbine and plant operation and startup issues:

  •  OPERATION AND STARTUP ISSUES
    • Common Startup Problems
    • Rotor Vibration – Diagnosis, Trips, Restarts
    • Cold Starts – Thermal Stress, Rotor Stress Management
    • Hot Restarts – Parts Thermal Stress / Quenching
    • Installation Related Issues
    • Maintenance Related Issues
    • Plant Design Related Issues
    • Steam Piping Related Issues

          

  • COMMON STARTUP PROBLEMS
    • Turning Gear Operation and Roll Off Issues
    • Pulling Vacuum
    • Steam Seal Operation
    • Starting and Loading
    • Drains and Water Induction
    • Starting and Loading
    • Thermal Stress Management