4 A Large Steam Turbine
4 A Large Steam Turbine
4 A Large Steam Turbine
December 6, 2005
AUTHORS:
ORLANDO, FLORIDA
Abstract
While new green-field projects are an important part of the long-term expansion of the
growing demand for electricity, they require a large capital outlay and a lengthy approval
process involving numerous government agencies including Siting Councils,
Environmental Agencies (State and Federal), and Utility Commissions. On the other
hand upgrading existing infrastructure with modern technology can occur in a shorter
timeframe, provide improved unit performance, increased reliability and longer operation
between inspections – all with less capital investment.
This paper describes the design and the results of the Steam Turbine Replacement
Components that were supplied by Siemens Power Generation to Dairyland Power
Cooperative.
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Several major maintenance projects, aside from the turbine upgrade, were also
performed at the station during the outage. These projects included significant boiler
maintenance, upgrade of the original plant control system to a modern DCS type,
replacement of the main unit transformer and upgrades of the generator and transformer
protection relays. In addition, a complete generator maintenance inspection was
performed and the stator winding support system was upgraded, to ensure trouble-free
operation with the anticipated higher loads. Considering the many different projects
scheduled for the one outage, it was critical that each program have a detailed schedule
that was closely adhered to in order for the plant to be ready for start-up on time.
Relevant project experience and the structured use of analysis learned from similar
projects prepared project stakeholders for potential contingencies and contributed to
meeting the planned outage duration. Stakeholder teams carried out multiple planning
forums to discuss the modification work needed to install the new turbines and review
installation process improvements learned from similar projects. The outcome was
improved quality and reduced outage duration. The operation and performance of the
retrofitted unit continues to meet or exceed DPC’s defined goals.
1.1 BACKGROUND
In 2003 the originally installed turbines at the Madgett station had been in service for 24
years. The unit was experiencing maintenance issues and performance levels expected
from hardware designed and manufactured in the 1970s. At the same time, DPC was
experiencing an increase in electricity demand.
Market conditions made it necessary for DPC to find a way to increase its generation
capacity, yet still remain competitive from a cost standpoint. New construction was
considered as too expensive and the necessary implementation schedule was too long.
The Madgett station is a major generating facility for DPC and the long-term plan was to
continue operating this plant for at least 30 years. Reducing the maintenance costs by
replacing the turbine components was an attractive solution; however, it would be
necessary to justify this project with additional generation revenue.
This paper will discuss the turbine upgrades to provide insight regarding the magnitude
and extent of this project.
2.1 INTRODUCTION
The BB44FA (Full Arc) turbine retrofit design targets existing Westinghouse Building
Block (BB) 44, sub-critical fleet, operating at inlet conditions up to 2,400 psig and
1,000°F. Currently, these machines are operating between a nominal range of 350 to
over 680 MWs. This design solution offers the highest efficiency and reliability for those
customers who operate their BB44 machines as base loaded units. There is also a
BB44PA (Partial Arc)
design solution that offers
the highest efficiency and
reliability for those
customers who operate
their BB44 machines over a
wide load range.
Siemens PG has all of the existing “as built” records, the original design knowledge and
calculations on all of the original BB44 machines in the Siemens PG fleet. Therefore no
additional field measurements were required at Madgett, prior to the outage. Madgett’s
actual outer casing dimensions were used
to ensure that the inner casing would HP Inlets
All internal stationary components are being removed and replaced with a single, fully
integral casing. This design approach reduces the number of parts and significantly
reduces the installation and outage time. The Madgett BB44FA utilizes the same mating
features as the existing BB44 inner casing. This ensures that the new BB44FA inner
casing will match up to all axial, vertical and transverse anchor points in the outer
casing. The outer casing is re-used with all of the existing outer casing connections.
The BB44FA is truly a “drop-in-place” replacement for the existing BB44.
An FEA solid model of the base and cover was used with all operating conditions
applied for the analysis. Figure 6 shows the steady state temperature distribution of the
BB44FA inner casing. Axial and radial clearances were calculated specifically for
Madgett’s steam conditions and blade path configuration. This was done to ensure that
once the inner and outer casings reach steady state operating condition, the optimal
clearances are achieved at all locations within the
machine (inner casing to rotor) and the inner to outer
casing (including all connection points).
The BB44FA HP/IP rotor consists of a monoblock, fully integral no-bore forging, which
allows for quicker start-up times and long fatigue life. Coupling flanges are integral to
the rotor body and all rotating blades utilize either single or double tee-roots. The
BB44FA rotor weight is comparable to the original BB44 rotor, which allows the existing
bearings to be re-used. The BB44FA rotor overhang geometry was machined to
exacting standards, to greatly reduce the potential for field modifications. The journal
diameters and the coupling bolt holes are machined to match up with existing
equipment, again reducing cost, field scope and installation time.
An axisymmetric FEA was performed on this rotor geometry with all of the Madgett
specific operating conditions. Low Cycle Fatigue (LCF), fracture mechanics, torsional
and lateral vibration calculations were also performed on this rotor geometry. Figure 8
shows the final machined and assembled BB44FA rotor.
The HP and IP blade paths were designed specifically for Madgett to provide improved
efficient performance for the available space. Many recent improvements in blade path
design have been incorporated into the BB44FA design:
The drum-type HP/IP blade construction features an integrally shrouded blade design
concept (figure 9). The integral shrouds provide two basic functions: First, they form a
circumferential steam path boundary allowing efficient seal designs to be utilized; and
second, they provide individual blade tip support between neighboring blades in each blade
row. Siemens PG has more than 40 years of successful experience with integrally
shrouded blade designs [4, 5, 6, 7].
The first stage of the HP and IP blade paths may utilize a low reaction design with a
diagonal arrangement (figure 10) to reduce rotor inlet temperatures while providing
favorable flow conditions where the radial steam flow enters the reaction blading axially.
This first stationary row is supported in the casing at the base and tip of the airfoil to
minimize leakage. Due to Madgett’s operating conditions a diagonal stage was required for
the HP blade path, but not for the IP blade path.
The blade paths for both the HP section of the turbine and the IP section are composed
entirely of 3D airfoil construction. The benefits of this technology allow the airfoil shape
to be enhanced to the varying steam conditions between the
base and tip of the blade. This design is a considerable
advantage over the previous generation of the typical parallel-
sided airfoil.
The HP blade path uses spring back seals for both the rotating and stationary blade
rows. The IP blade path uses spring back seals over the rotating rows and staked-in
seals under the stationary rows. Staked-in seals can be machined closer together thus
allowing for more seal fins in the same axial length, increasing the sealing efficiency.
2.6 PERFORMANCE
DPC’s BB44FA upgrade was successfully installed at the Madgett plant in the fall of 2004.
This upgrade has improved HP element efficiency by 8-10% and IP element efficiency by
2-4%, with a 15-20 MW output increase. Two other B44FA upgrades were installed in the
fall of 2004 with similar results. Degradation testing has been performed on Madgett’s
BB44FA and results show that this design is still performing with minimal degradation.
Figure 12 shows the complete BB44FA inner casing and rotor assembled at the
manufacturing facility.
3.1 INTRODUCTION
The following list is a brief summary of the strategy that was implemented to achieve
higher performance and world class reliability:
• Eliminate riveted shrouds on front-end blading
• Eliminate riveted shrouds and lashing wires on large LP blading
• Single inner casing with moisture removal features
• Increase resistance to stress corrosion cracking
• Increase resistance to high cycle fatigue
• 8.7 inches of HgA exhaust pressure limit at high loads
• 10-year inspection interval
• Torsional compatibility with existing generator rotor
The design features included in the LP upgrade are many. It has a monoblock rotor
forging without thru-bore. The front-end stages are reaction type with integral shrouds.
The last-stage rotating blades are freestanding design. The inner casing is a fabricated
single inner cylinder design with an
improved exhaust diffuser. The blade
path sealing includes tip to tip inter-
stage and shaft seals. Figure 14 shows
the BB73-8.7m2 longitudinal section.
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The inner cylinder design is a fabricated single casing construction with a separate
upper and lower half and a bolted flange at the horizontal joint. In each flow direction
the casing supports and aligns three separate blade path stationary components: 1)
guide blade carrier for front-end drum stages, 2) segmental assembly for L-1C row, and
3) L-0C segmental and exhaust diffuser.
Tip to tip seals have been adopted for the inter-stage sealing of
this upgrade design. This type of seal arrangement allows large
relative axial displacements without rubs, thus improving the
cycling ability and sustained efficiency of the unit. As can be
seen in figure 16, there is a large range of relative axial
movement possible while still maintaining 100% of the sealing
effectiveness. In addition, Siemens PG uses different seal strip
spacing for the mating seals, so that in case there is a rub (tip to
tip), only one or two seal strips will be affected while the
remaining strips are untouched.
Figure 16 - BB73-8.7m2
Double-Strip Seals
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The BB73-8.7m2 rotor consists of a monoblock, fully integral, no thru-bore forging. Both
coupling flanges are integral to the rotor body and all rotating blades utilize either a tee
root or side entry root. The Madgett BB73-8.7m2 rotor is approximately 20% heavier
than the original rotor. The decision for constructing modern turbine rotors with no thru-
bore was based on many design advantages. Obviously, without a rotor bore, it is no
longer a long-term maintenance requirement to perform bore inspections. The operating
stresses of a no-bore rotor are lower compared to a similar design with an axial thru-
bore.
The BB73-8.7m2 rotor overhang geometry is a duplicate of the existing rotor overhangs,
which enables the new rotor to be installed without any modifications to the existing
equipment. The journal diameters and the coupling bolt holes are machined to match up
with existing equipment, again reducing cost,
field scope and installation time.
Fracture mechanics, torsional and lateral calculations were performed to evaluate and
analyze the complete rotor train for Madgett specific static and dynamic loadings. Rotor
dynamic calculations were performed with both the existing and replacement turbine
rotors. Torsional integrity of the upgraded rotor train was evaluated to address single-
and double-line frequency responses, and it was confirmed that the existing torsional
characteristics of the turbine-generator system has not been impacted. Lateral dynamic
analysis confirmed that rotor stability and high-cycle fatigue requirements are met.
Stress corrosion cracking prevention was addressed through the use of selecting
favorable material properties, applying residual compressive stresses and by reducing
stress concentrations in the blade attachment areas.
The machined BB73-8.7m2 rotor in the cylinder base during the final assembly checks of
the Madgett LP in the manufacturing facility is shown in figure 18.
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The existing bearings are re-used with some field alterations to accommodate the
installation of bearing oil lift for use during turning gear operation. The independent oil
lift systems are mounted directly to the LP bearing pedestals to prevent the requirement
for high pressure piping runs in the power plant. The oil lift system was implemented to
prevent stick-slip of the rotor during turning gear, which would potentially damage the
bearing babbitt material.
The Madgett BB73-8.7m2 LP blade path has been designed with seven stages per flow
utilizing Siemens PG’s standard 37.7-inch free-standing L-0R row, interlocked L-1R row
and integrally shrouded L-2R row. The four front-end stages (drum stages) are of
Siemens PG integrally shrouded tee-root blade design with customized 3D blade profiles
that match the existing cross-over and extraction pressures. The entire blade path is
made from 12% Cr and 13% Cr stainless steel with the exception of the last rotating
blade, which is made from 16% Cr (16-4 PH).
Using Siemens proprietary design tools, the drum stage blade path has been designed
for Madgett specific steam conditions to optimize the thermal performance of the turbine
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The effects of moisture erosion on the LP turbine at Madgett were a concern regarding
long-term operation. Addressing this concern was one of DPC’s requirements.
There are different methods for protecting against erosion, depending on the moisture
content of the steam in the blade path. The standard BB73-8.7m2 design uses laser
hardening on the last rotating blade leading edge. For higher levels of moisture, suction
slots can be machined into the last-stage stationary airfoils, and the moisture is removed
from the blade path and drained to the condenser. In applications with very high levels
of moisture, Siemens PG employs a ‘steam heating’ system which is unique to our
turbine designs. For the Madgett station, it was decided to implement the steam heating
system as an extra precaution against moisture erosion of the last-stage rotating blades.
Steam Heating
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The improved performance of the new BB73-8.7m2 comes from improved front end
(drum stages) blade design, the 25% increased annulus area and the more efficient last
three LP stages. Additionally, exhaust losses are reduced with the use of an improved
exhaust flow guide.
The boiler supplied steam conditions at the Madgett station were not changed as part of
the turbine upgrade program. For units of similar size to Madgett, it would be expected
to gain approximately 7 to 8 MWs by upgrading the original LP turbine to modern
technology.
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Siemens PG has successfully designed, manufactured and installed three BB44FA style
machines in the US market, including Dairyland Power Cooperative, J. P. Madgett
Station. All three of these machines have met or exceeded contractual requirements.
The advanced technology and techniques described in this paper are being
implemented into all of Siemens PG’s modernization products. Following is a summary
of the features and benefits of the BB44FA turbine upgrade.
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Siemens PG has successfully designed, manufactured and installed five turbines with
BB73-8.7m2 upgrades in the US market, including Dairyland Power Cooperative, J. P.
Madgett Station. These machines have incorporated Siemens PG’s advanced
technology LP blades for improved reliability and increased power generation. The
design features as described in this paper are being implemented into all of Siemens
PG’s LP upgrade products to address all fleet issues such as SCC, moisture erosion
and long-term performance. Following is a summary of the features and benefits of the
BB73-8.7m2 turbine upgrade.
There are inherent cost advantages to upgrading both turbine elements at the same
time. While the hardware cost for each turbine component is not affected; there are cost
savings associated with project support, transportation, mobilization, installation and
program management. DPC and Siemens PG spent considerable efforts coordinating
the tasks to ensure issues were addressed and redundancies were eliminated.
The new turbine hardware for both the HP/IP and LP elements has recommended
intervals between major inspections of 10 years. By upgrading both turbines at the
same time, the number of turbine maintenance outages is significantly reduced, and the
turbine outages can be coordinated more easily.
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As with most major purchase decisions, the key issues are product features, price, and
performance. Siemens PG’s advanced design LP and HP turbines provide the reliability
and performance improvement that DPC required, with features that addressed their
long-term maintenance concerns.
A turbine retrofit project is a major undertaking for both the plant owner and the turbine
vendor. The Madgett Turbine Retrofit/Generation Upgrade project began as a project
evaluation program and transformed into a strategic planning initiative for DPC. Long-
term maintenance issues were considered as well as current and future electric power
market conditions. Turbine retrofit decisions had to consider the long-term operation,
including potential uprate plans, for the life of the station.
From a project evaluation standpoint, DPC took a global perspective to ensure that all
alternatives were properly assessed and considered and all bidders were evaluated
fairly.
From a long-term reliability standpoint, the Madgett station project goal is to address on-
going maintenance issues and provide significant performance improvements using the
latest design turbine technology. Through a team approach and flexibility, the project is
poised to provide excellent value to all the project stakeholders. The increased asset
value of the project has not gone unnoticed by the member-owners of DPC as well.
IN MEMORIAM
David is survived by his wife, Fran and two adult sons, Brian Rybarik (Madison, Wis.)
and Scott Rybarik (Denver, Co.).
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