STEAM PATH AUDIT

February 19, 2009 New Delhi, India

Arun Kumar SarnaSteam path AuditorHead-BD/ EVONIK Energy Services India Paul F. RoedigerSteam path AuditorPresident/ Encotech Inc. USA`

3rd Thermal Power India 2009

Overview

•  Brief about Evonik & its activities in India

•  What is a Steam Path Audit?

•  Benefits of SPA

•  Specific Areas of Concern

•  Steam Path Audit Experience

Seite 3

A new company

A new brand

Seite 4

Model of foundation

Evonik Industries AG

Chemicals Energy Real Estate

100 % 100 %

Evonik Industries AG

Seite 5

A global group

Evonik has production and distribution sites in 52 countries across the globe and operates in more than 100 countries.

Production and distribution sites

Seite 6

Immobilien 3%

Business Area Energy

Solid foundation for mastering the challenges of the future

Power District Heating

Power Minerals

Energy Services

Trading Renewable Energies

Seite 7

Business Line Power Power Plant Sites

Based on decades of experience…

… trading new paths in the energy business..

Köln-Godorf

211 MW

2004

Termopaipa

165 MW

1999

Infracor

600 MW Iskenderun

1,320 MW

2003

Mindanao

232 MW.

2006

Walsum

750 MW COD 2010

Walsum

600 MW Weiher

724 MW Fenne

502 MW Lünen

500 MW Voerde

2,234 MW Bergkamen

747 MW Herne

950 MW Bexbach

773 MW

Leuna

158 MW

1996

COD = projected commercial operation date

Seite 8

Energy Technologies Nuclear Technologies Plant Services System Technologies

Design, construction, decommissioning and disposal of nuclear plants

Design, site supervision and commissioning of power plants

Operation & Maintenance Measurement & Analysis

Energy Management Systems Operation Management Systems Communication Technologies Site IT

Evonik Energy Services Business Lines

Evonik Energy Services

• Sales 65,6 Mio. EUR *

• Employees 498* *data 2007

SUMMARY SHEET:

Renovation & Modernization studies: 16 Units of 110 to 210 MW fleet

Energy Audit studies: Various Units upto size 210 MW

Steam Path Audit studies: Various Units upto size 500 MW

Performance Testing: 3 Coal Fired Units upto size 210 MW 156 MW Gas fired CC Station

Energy Efficiency Solutions by Evonik in India

Ener

gy E

ffici

ency

Act

iviti

es

What is a Steam Path Audit?

•  A detailed inspection of the stationary and rotating steam path components

•  An accounting of performance losses on a stage-by-stage basis

•  A presentation of losses in power and heat rate

Benefits of a SPA

•  Provides detailed inspection of steam path

•  Repair/replacement decisions, early in outage

•  Aid decisions for future repair

•  Provides excellent record/history of equipment condition for future reference

The Outage Time-Line

Disassembly Reassembly

The specific areas of concern addressed by the audit are:

1) Leakages: - past stationary stage blading - past rotating stage blading - past shaft end packings where rotors emerge from casings - across poorly fitting joints - other miscellaneous leakages

3) Flow blockages from: - deposits - foreign objects - mechanical damage

2) Surface finish degradation: - deposits - corrosion - solid particle erosion - mechanical damage

4) Flow path modification from: - solid particle erosion - water droplet erosion - mechanical damage

Results

•  Quantification of losses measured in pre-outage test

•  Quality check on maintenance performed during the outage

•  Performance improvement resulting from individual maintenance actions

•  Expected return-to-service performance

Opening Audit Power Loss

Closing Power Loss

Results by Category

Encotech STPE - Fossil 5.2....05/11/2000..................Turbine Audit Summary

County Unit 1 Turbine Totals

Open audit 05/08/2000

Change In Heat Rate

Power Loss Heat Rate Loss

Audit Section (KW) (BTU/KWH) (%)

--------------------------- ---------- --------- ---------

Interstage Packings 152.9 118.20 1.10

End Packings 282.4 220.37 2.05

Tip Spill Strips 329.3 257.87 2.40

Miscellaneous Leakages 8.7 6.62 0.06

Flow Path Damage Results 109.5 20.42 0.19

Surface Roughness 122.7 94.70 0.88

Cover Deposits 0.0 0.00 0.00

Trailing Edge Thickness 0.0 0.00 0.00

Hand Calculations 0.0 0.00 0.00

--------------------------- ---------- --------- ---------

Totals 1005 759.8 7.07

See Casing Totals For Flow Change Impact

Results by Stage

Interstage Packing Root Spill Strip

<---Clearance----> <--Clearance---> Change In

Location Design Measured Design Measured Power Loss Heat Rate

Descr. (IN.) (IN.) (IN.) (IN.) (KW) (BTU/KWH)

-------- ------ -------- ------ -------- ----------- ---------

Stage 2 0.010 0.075 0.000 0.000 56.7 43.52

Stage 3 0.010 0.024 0.000 0.000 14.9 11.42

Stage 4 0.010 0.019 0.000 0.000 16.6 12.71

Stage 5 0.010 0.014 0.000 0.000 8.8 6.76

Stage 6 0.010 0.021 0.000 0.000 17.4 13.29

Stage 7 0.010 0.010 0.000 0.000 3.4 2.57

Stage 8 0.010 0.014 0.000 0.000 8.4 6.43

Total Power Loss (KW)........................ 153

Total Change In Heat Rate (BTU/KWH).......... 118.2

Total Heat Rate Loss (%)..................... 1.1

Chronology of

Steam Path Audit

Computer Model

Create turbine model at Evonik’s office using the Thermal Kit

•  Design heat balance (VWO)

•  Turbine cross section

•  Clearance and steam seal system diagram

•  First stage shell pressure curve

Coordinate Activities

Coordinate activities with owner

• Review safety procedures

• Sign contract

• Plan around grit blasting schedule

Coordinate Activities

Coordinate with outage crew

•  Place upper half of casing w/ horizontal joint up or lay on ground with trailing edges up

•  Leave all packing (interstage & shaft end) in place until measured. This speeds SPA process significantly

•  All stages must be inspected prior to grit blasting

Sequence of Events (Casing Lifted)

•  Inspect casing horizontal joint for leakage paths

•  Measure blade geometry

•  Measure packing teeth, interstage, tip, root, and & shaft end

•  Create a photographic record of the steam path

Before Lifting Rotor

Chart rotor for actual radial clearances

•  Interstage packings

•  Shaft end packings

•  Root spill strip clearances

•  Tip spill strip clearances

After Lifting Rotor

Measure lower half tooth heights

•  Interstage packing and shaft end packing

•  Root and tip spill strips

Inspect lower half diaphragms

•  Surface roughness

•  Solid particle erosion

•  Mechanical damage

Rotor

Inspect rotating blades

•  Surface finish

•  Solid particle erosion

•  Mechanical damage

•  Cover deposits

Geometric Data

Geometric data for the steam path must be obtained to properly model turbine

•  Blade heights and widths

•  Blade root diameters

•  Balance holes

Photographic Record

Photographs of the steam path document condition

•  All packing teeth

•  Trailing edges of stationary and rotating blading

•  Specific damage associated with the steam path

Completion

•  Enter audit data into eSTPE™ computer model

•  Review results

•  Present preliminary report to owner at site

SPA - Flow Path Damage

Solid Particle Erosion

Blade Deposits

Foreign Object Damage

Tip Spill Strip

Tip Spill Strip Measurements

Clearance Calculation Method

Martin’s Formula

Root & Tip ToothTypes

Interstage Tooth types

Casing Spring

Elliptical Flow Area

Balance Hole Measurements

Blade Geometry

Root Diameter Measurement

Impulse Blading

Stationary Blading Root Dia

Rotating Blade Axial Width

Cover Deposits

Deposit & Throat Opening

Foreign Object Damage

Erosion Measurements

Surface Roughness Measurement

Steam Path Audit Experience

Turbine Manufacturers Modeled with eSTPE software

AEG/ Siemens Allis-Chalmers Alstom Ansaldo Asea Brown Boveri DeLaval Doosan Dresser-Rand Elliott Escher Wyss GE/Doosan

GEC Alsthom Co. General Electric Hitachi LMZ Mitsubishi Parsons Siemens Siemens/Kraftwerk Siemens/Westinghouse Skoda Toshiba Westinghouse

Models by Size and Manufacturer

Under 51 MW 101 MW 251 MW 501 MW Above 50 MW 100 MW 250 MW 500 MW 750 MW 750 MW

AEG/ Siemens 1 Allis-Chalmers 1 1 2 Alstom 1 Ansaldo 1 Asea Brown Boveri (ABB) 1 1 4 1 DeLaval 2 1 Doosan 1 Dresser-Rand 3 Elliott 1 Escher Wyss 1 GE/Doosan 1 GEC Alsthom Co. 1 2 General Electric 12 16 30 13 20 5 Hitachi 1 LMZ 3 Mitsubishi 4 Parsons 3 1 Siemens 2 Siemens/Kraftwerk 4 Siemens/Westinghouse 2 Skoda 1 Toshiba 2 Westinghouse 1 7 13 11 8 4

Steam Path Audit experience in India (Joint experience of Evonik & Encotech Inc.)

Location Unit Manufacturer Generator Output (kW)  Jhanor St 1 ABB 243,380

 Kahalagaon 1 LMZ 210,000

 Kawas St 1C Alsthom 122,600

 Mettur 1 LMZ (Baughman Stage) 210,000

 Ramagundam 3 Ansaldo 206,260

 Ramagundam 5 Siemens Kraftwerk 500,000

 Rihand 1 GEC Alsthom 534,000

 Singrauli 6 Siemens Kraftwerk 532,072

 Talcher 5 Skoda 110,000

 Vindhyachal 2 LMZ 210,000

 Vindhyachal 4 LMZ 210,000

 Vindhyachal 7 Siemens Kraftwerk 500,000

 Ropar 1 Siemens Kraftwerk 210,000

 Ropar 2 Siemens Kraftwerk 210,000

 Korba (West) 2 Siemens Kraftwerk 210,000

 Kahalgaon 2 LMZ 210,000

 RGCCPP, Kayamkulum BHEL 129,000

 Ramagundam 2 Ansaldo 206,260

Steam Path Audit Experience

- A Case Study

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