Transcript Yards Creek Rotor Poles

Asia Pacific Partnership
United States of America
Power Generation Task Force
August 13 – 17, 2007
Yards Creek Rotor Poles
J.J. Geuther
Project Details
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Replacement of all amortisseur bars—poles must be
removed and clamping heads removed.
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Refurbishment of pole windings—asbestos turn
insulation removal; new groundwall insulation.
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Modification of pole clamping heads for reduction of
stresses at step in amortisseur bars.
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New pole keys.
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Specialized tooling for pole rework.
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
2
Project Details
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All 30 poles were removed and refurbished.
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National Electric Coil (NEC) handled the insulation
removal and pole refurbishment.
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Millwrights under FE supervision removed, prepared
for transport and re-installed the poles
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Project was completed in 49 days working
two hour shifts, 7 days/week.
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All poles had to be removed via the
gantry crane—up through the
powerhouse roof.
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
3
Project Details
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Additional challenges included key removal and
rigging of poles.
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Two poles were worked on simultaneously from
opposite sides of the rotor. Only one could be
removed at a time due to crane constraints.
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The remote control of the gantry crane was
critical for the close tolerance work.
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
4
Project Details
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Early delivery of poles to the repair shop was critical.
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It was decided to perform work without removal of the
rotor to expedite pole removal.
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Other work items were identified.
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Microsoft Project was used for project planning.
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
5
Concurrent Work
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Unit No. 1:
– Inspection of M-G and P-T
– Governor Unloader Modification
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Unit No. 3:
– Inspection of M-G and P-T
– Governor Oil Pump Unloader Modification
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Unit No. 2:
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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
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
6
Concurrent Work
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Common Plant Items:
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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
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
7
Removal of Rotor Poles
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Removal of Rotor Pole
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Rotor in Place
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Outdoor Gantry Crane
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Close Tolerances
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
8
Pole Removal
Rotor Rim With Poles
Removed
Damage Pole Iron—2 Broken
Amortisseur Bars
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
9
Damage Pole Iron
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Damaged Pole #20 (2002)
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2 Broken Amortisseur Bars
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Damper Bars Unsupported in Clamping Heads
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
10
Cracked Damper Bar
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Removal of Rotor Pole
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Rotor in Place
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
11
Winding at Removal
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
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Amortisseur Bars
Amortisseur Bars Following
Removal
Crack in High Stress Area of
Amortisseur Bar
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
13
Stator Corona System
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Corona Paint Restored
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
14
What Can Be Done Better
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Amortisseur series connection hardware difficult to install.
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Handling and laydown of rotor poles.
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Access through powerhouse roof.
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Safety and access to stator improved by new decking.
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Early delivery of replacement keys, amortisseur bars,
shorting rings, etc.
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Incentive for Contractor performance on critical path.
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
15
What Can Be Done Better
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Item #28 Hardware Modification
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Expedite Installation
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Improved Quality Control
Asia Pacific Partnership • Aug 13 - 17, 2007
FirstEnergy Corp. & Duke Energy Corporation
Yards Creek Rotor Poles
16