Yards Creek Rotor Poles J.J. Geuther Asia Pacific Partnership United States of America Power...
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Transcript of Yards Creek Rotor Poles J.J. Geuther Asia Pacific Partnership United States of America Power...
Yards Creek Rotor Poles
J.J. Geuther
Asia Pacific PartnershipUnited States of AmericaPower Generation Task ForceAugust 13 – 17, 2007
Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Project Details
Replacement of all amortisseur bars—poles must be removed and clamping heads removed.
Refurbishment of pole windings—asbestos turn insulation removal; new groundwall insulation.
Modification of pole clamping heads for reduction of stresses at step in amortisseur bars.
New pole keys.
Specialized tooling for pole rework.
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Project Details
All 30 poles were removed and refurbished.
National Electric Coil (NEC) handled the insulation removal and pole refurbishment.
Millwrights under FE supervision removed, prepared for transport and re-installed the poles
Project was completed in 49 days workingtwo hour shifts, 7 days/week.
All poles had to be removed via thegantry crane—up through thepowerhouse roof.
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Project Details
Additional challenges included key removal and rigging of poles.
Two poles were worked on simultaneously from opposite sides of the rotor. Only one could be removed at a time due to crane constraints.
The remote control of the gantry crane wascritical for the close tolerance work.
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Project Details
Early delivery of poles to the repair shop was critical.
It was decided to perform work without removal of the rotor to expedite pole removal.
Other work items were identified.
Microsoft Project was used for project planning.
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Concurrent Work Unit No. 1:
– Inspection of M-G and P-T– Governor Unloader Modification
Unit No. 3:– Inspection of M-G and P-T– Governor Oil Pump Unloader Modification
Unit No. 2: – Inspection of P-T– Replacement of Wicket Gate Stem Packing– Thrust Bearing Oil Cooler Replacement.– 230kv GCB Control Wiring Replacement– Lower Guide Bearing Oil Cooler Inspection– Equalizing Line Inspection– Installation of Air Gap Instrumentation– Stator Cleaning and Corona Repair
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Concurrent Work
Common Plant Items:• Dewatered Inspection of Penstock and Tunnel• Upper Reservoir Intake Inspection• Replacement of Spherical Valve Bypass Line Guard Valves• Replacement of 6” Nozzles on Penstock Upstream of
Spherical Valve• Modification of Tailrace Trashracks• Penstock Rocker Repair• Penstock Expansion Joint Repairs• 230kv Phase Reversal Switch Maintenance
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Removal of Rotor Poles
Removal of Rotor Pole
Rotor in Place
Outdoor Gantry Crane
Close Tolerances
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Pole Removal
Rotor Rim With Poles Removed
Damage Pole Iron—2 Broken Amortisseur Bars
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Damage Pole Iron
Damaged Pole #20 (2002)
2 Broken Amortisseur Bars
Damper Bars Unsupported in Clamping Heads
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Cracked Damper Bar
Removal of Rotor Pole
Rotor in Place
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Winding at Removal
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Amortisseur Bars
Amortisseur Bars Following Removal
Crack in High Stress Area of Amortisseur Bar
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
Stator Corona System
Corona Paint Restored
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Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation
What Can Be Done Better
Amortisseur series connection hardware difficult to install.
Handling and laydown of rotor poles.
Access through powerhouse roof.
Safety and access to stator improved by new decking.
Early delivery of replacement keys, amortisseur bars, shorting rings, etc.
Incentive for Contractor performance on critical path.
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