Sulzer Dowding & Mills

Transcription

1 Sulzer Turbo Services Company overview

2 Sulzer today Sulzer Pumps Market leader in pump technology and solutions Sulzer Metco Market leader in surface technology Sulzer Chemtech Market leader for separation, mixing and service solutions Sulzer Turbo Services Leading independent service provider for rotating equipment Main markets served: Main markets served: Main markets served: Main markets served: Oil and gas Transportation Oil and gas Oil and gas Power Power Power Water Transportation Full year 2012: Sales of CHF 4 billion employees 2013 <Copyright Sulzer> slide 2

3 October 2010, S West A selection of case studies for Sulzer Turbo Services Services for rotating equipment Mechanical Turbines and compressors Electro-mechanical Generators and motors Electro-mechanical Turbine or compressor repair Gas turbine component repair Replacement parts (e.g., blades) Field service Technical supervision Turbine/compressor control retrofits Modifications and upgrades Installation services Long-term service agreements Compressor or motor repair Component repair Replacement parts (e.g., coils) Site service Technical supervision Control retrofits Modifications and upgrades Long-term service agreements

4 POWER GENERATION? How electricity is generated STATOR ARMATURE WINDING TERMINALS 2013 <Copyright Sulzer> slide 4

5 Dunlin Alpha - Generator Rehabilitation Graeme Robertson - April 2013

6 Production Platform Generation Problems 2013 <Copyright Sulzer> slide 6

7 Overview Total generation capacity of 35MW from 5 Generators GT 4 was to be returned to Service after period of inactivity, this was a 15MW, 6.6kv, 4 pole Generator driven by an Avon Engine Provided critical power for Salt Water Injection Pump motors Platform required SWI Motors running to support production Module Roof was not watertight! Generator Anti-Condensation Heaters were defective! 2013 <Copyright Sulzer> slide 7

8 Bringing back to service Pre-commission checks identified very low IR and no PI. 1000v DC Test IR value 0.2MΩ & breaking down after 4 minutes As our engineers were being mobilised to site, platform staff spun the turbine generator for a period of 4 hours unexcited to determine if dampness / condensation was the issue. Retest did not show any difference in the IR or PI levels Complete winding was wet with an earth fault present 2013 <Copyright Sulzer> slide 8

9 Investigating the problem Our Service Engineers then carried out a methodical check: opened alternator for internal inspection of rotor / stator for any evidence of ingress of contamination cables and all connections from the cubicle to the alternator terminal box removed all clamps / post connections disconnected the star point / split phase connections 2013 <Copyright Sulzer> slide 9

10 Investigating the problem internally inspected & tested each phase split low reading phase coils to from 2 halves for inspection & test continue to split until defective coil or coils were located identify the defective area / coil section 2013 <Copyright Sulzer> slide 10

11 The Defective Coil The defective coil was identified by a process of elimination, and located at 4 o'clock position when viewed from DE, fault was specific to one diamond coil. The stator winding had 66 coils connected in 2 parallel circuits The winding had 5 & 6 coil groups We proposed an in-situ repair potentially saving 16 weeks on time scale and circa 700k on rewind costs A primary objective was to minimise outage time to get SWI pumps operating ASAP <Copyright Sulzer> slide 11

12 The Turbo Generator Generator with end covers partially removed to expose Stator Winding 2013 <Copyright Sulzer> slide 12

13 Source of the Problem Generator Stator Coils ready for splitting to locate defective coil 2013 <Copyright Sulzer> slide 13

14 Winding Modification C 1 A 1 Failed Coil 4 pole 3 Phase Generator 66 Slots & 66 Coils 2 Parallel Circuit Star 12 Coil Groups 5 coils & 6 Coils 2 Coil Groups in each parallel path 1 with 5 coils the other with 6 coils Failed coil 2 nd in 6 coil group B 1

15 Winding Modification C 1 A 1 Failed Coil 4 pole 3 Phase Generator 66 Slots & 65 Coils 2 Parallel Circuit Star 12 Coil Groups 5 coils & 6 Coils 2 Coil Groups in each parallel path 1 with 5 coils the other with 6 coils Failed coil 2 nd in 6 coil group B 1 Jumper introduced to take failed coil out of circuit This jumper on its own would leave circulating currents and unbalanced voltages

16 Winding Modification C 1 A 1 Failed Coil 4 pole 3 Phase Generator 66 Slots & 60 Coils 2 Parallel Circuit Star 12 Coil Groups all 5 coils 6 Jumpers introduced to take failed coil & 5 other coils out of circuit B 1

17 Source of the Problem Generator Stator Coils Where jumpers are introduced 2013 <Copyright Sulzer> slide 17

18 Our Solution.. We calculated what would be the effect of cutting out 6 coils, 2 per phase, on the performance of the Generator It was necessary to take 2 coils from each phase, to prevent circulating currents and kept the winding balanced We assessed that a maximum 10 % loss of output Results were relayed to Client who approved the process and methodology of repair <Copyright Sulzer> slide 18

19 The Completion.. Work was completed in 14 Days utilising 24 hr working :- The generator was part dismantled, rotor remained in position An environmental habitat was erected around the stator Stator winding configuration was changed and reconnected, the defective coil and 5 other coils removed from circuit. Stoving heaters were applied to dry the rest of winding The stator winding was cleaned, dried, and spray varnished The machine was fully built and prepared for test 2013 <Copyright Sulzer> slide 19

20 Testing & Hand Over Insulation Resistance Test gave PI values of >4 with IR levels commencing at 4GΩ on 5kV Megger Phase Resistance was tested and found to be within 5% range Generator returned to service with slow increase of load from 2 MW to 7MW over a shift and then up to 13.8MW Machine was handed back to client after successful commissioning test, with some alterations to protection relays and AVR settings <Copyright Sulzer> slide 20

21 Conclusion Drilling Program was at risk due to lack of generation capacity Failure to complete the well work-over in time put the complete well at risk, including future oil revenues Failure to provide power for the SWI Motors would result in loss of oil production Generator Repair saved 16 Weeks of down time and circa 700k in repair costs but no estimate of production loss cost?? M/day Work competed to Timeline & Budget, the future revenues from an oil well secured! 2013 <Copyright Sulzer> slide 21

22 Planta Centro, Venezuela 400 MW Kraftwerk Union Steam Turbine Train Rotor Rewind Siemens Westinghouse Turbo Rotor 2012

23 Removing End Bell 2013 <Copyright Sulzer> slide 23

24 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 24

25 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 25

26 Stripping of Rotor 2013 <Copyright Sulzer> slide 26

27 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 27

28 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 28

29 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 29

30 Transport to Machine Workshop 2013 <Copyright Sulzer> slide 30

31 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 31

32 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 32

33 Siemens Westinghouse 400MW Turbo Rotor 2013 <Copyright Sulzer> slide 33

34 Cross Section Layout 1 Modified Retaining Ring Attachment OriginalRetaining Ring Attachment 2013 <Copyright Sulzer> slide 34

35 New Landing Area 2013 <Copyright Sulzer> slide 35

36 New Landing Area 2013 <Copyright Sulzer> slide 36

37 New Landing Area 2013 <Copyright Sulzer> slide 37

38 New Landing Area 2013 <Copyright Sulzer> slide 38

39 Machining New Landing Area s 2013 <Copyright Sulzer> slide 39

40 Grinding Land Area 2013 <Copyright Sulzer> slide 40

41 New Landing Area 2013 <Copyright Sulzer> slide 41

42 Clean Room 2013 <Copyright Sulzer> slide 42

43 QA of New Materials 2013 <Copyright Sulzer> slide 43

44 New J Lead 2013 <Copyright Sulzer> slide 44

45 Cleaning Coils 2013 <Copyright Sulzer> slide 45

46 Rewinding 2013 <Copyright Sulzer> slide 46

47 Rewinding 2013 <Copyright Sulzer> slide 47

48 Rewinding 2013 <Copyright Sulzer> slide 48

49 Rewinding 2013 <Copyright Sulzer> slide 49

50 Blocking 2013 <Copyright Sulzer> slide 50

51 Wedging 2013 <Copyright Sulzer> slide 51

52 Blocking 2013 <Copyright Sulzer> slide 52

53 Curing 2013 <Copyright Sulzer> slide 53

54 Curing 2013 <Copyright Sulzer> slide 54

55 Curing Ends 2013 <Copyright Sulzer> slide 55

56 Curing 2013 <Copyright Sulzer> slide 56

57 Oven 2013 <Copyright Sulzer> slide 57

58 Curing 2013 <Copyright Sulzer> slide 58

59 Wedging 2013 <Copyright Sulzer> slide 59

60 Wedges 2013 <Copyright Sulzer> slide 60

61 Wedging 2013 <Copyright Sulzer> slide 61

62 Wedges 2013 <Copyright Sulzer> slide 62

63 Wedges 2013 <Copyright Sulzer> slide 63

64 Wedges 2013 <Copyright Sulzer> slide 64

65 Insulating End Windings 2013 <Copyright Sulzer> slide 65

66 Insulating End Windings 2013 <Copyright Sulzer> slide 66

67 Overspeed and Balancing 2013 <Copyright Sulzer> slide 67

68 Overspeed and Balancing 2013 <Copyright Sulzer> slide 68

69 Complete Rewind ready for Transport Return 2013 <Copyright Sulzer> slide 69

70 Transport back to site 2013 <Copyright Sulzer> slide 70

71 Benefits for Insurers Quick response Outage duration minimisation Service approach with customers Listen, analyse & provide solution Independent advise on repair or replace Wide range of repair capabilities & expertise Knowledge of all manufacturers product Experts in reverse engineering & re-manufacture Machine performance as original machine performance as a minimum Competitive pricing 2013 <Copyright Sulzer> slide 71