REFINERY INITIATIVE 2001

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REFINERY INITIATIVE 2001
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STEAM TURBINES
Jim Feltz Manager, Engineered Solutions and
Revamps Product Services Wellsville, NY Phone
[phone] Fax [phone]
EMAIL james_l_feltz_at_dresser-rand.com
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Customer Needs

• Reduced operating and maintenance costs
• Extended component life
• Increased efficiency and power output
• Increased reliability

Dresser-Rand can provide complete solutions
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Why upgrade your equipmentwith Dresser-Rand?

• All originally built information available
• All engineering disciplines available
• History of equipment
• Experience (New equipment, upgrades, feedback
  from site)
• Dresser-Rand OEM guarantee
• Field service repair center support
• ALL PARTS SERVICES OUT OF ONE HAND

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Revamps UpgradesDresser-Rand Terminology

• REVAMPS
• Changes to components in steam flow path, such
  as nozzle rings, diaphragms, blading, and
  valves/cams to achieve
• New operating characteristics
• -Increased power and speed
• -New steam condition
• -Increased efficiencies

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Revamps UpgradesDresser-Rand Terminology

• UPGRADES
• Modifications to turbine and/or system components
  to achieve
• Better availability
• Reduced maintenance
• Increased efficiency
• Example -Governor conversion,
• -Bearing conversion
• -Mechanical seals, retractable seals

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STEAM TURBINE REVAMPS
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Profiled Ring and Vane Nozzle Rings Diaphragms
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PRV Nozzle Rings
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PRV Diaphragms
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PRV Center Supports
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CFD Results for Stator Suction Surface
With Profiled Stator Endwalls
With Cylindrical Stator Endwalls
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Results of Recent Performance Tests
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DRESSER-RAND PRV DESIGN

U.S. PATENT NUMBER 544 7413
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PERFORMANCE IMPROVEMENTS SUMMARY
SOLUTIONS GAINS Stator blades 0.5-0.75 Pr
ofiled end wall 1.0-1.5 Rotating
blades 0.5-0.75 Steam path surface
finish 0.5-3.0 Labys 0.5-1.0 Throttling
losses 1.0-2.0 Axial spacing 0.25-1.0 TOT
AL 4.25-10.0
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Example
Turbine Generator set, Straight Condensing

Power 30 mW (14 stage machine) Steam 600
psig-750 F- 4 inHgA Steam flow340,000
lb/hr Efficiency improvements ( 6 ) New
blades 1.0 mil New Diaphragms 1.1
mil Total 2.1 mil
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Example Continued
Turbine Generator set, Straight Condensing

Steam flow reduced 6 or 20,400 lb/hr
saved. Cost Assume 6.00/ 1000
lb/h 6.00/1000 lb/hr x 20.4 x 24 hrs x 365
days 1,072,224./ yr
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Example Continued
Turbine Generator set, Straight Condensing

Additional power produced 6 or 1,800 kW
generated. Cost Assume 0.10 / kW-hr
0.10/kW-hr x 1800kW x 24 hrs x 365 days
1,576,800./ yr ( 47)
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Double Flow Conversion
Features Removal of double flow section for
improved efficiency

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Blading

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Blading

• Purpose To review the possible use of different
  airfoil design and/or the use of coatings.
• Engineering investigation to match the airfoil
  design to the required conditions of service.
  Due to changes in either technology or
  operational parameters, the current airfoil may
  not be an efficient match to the required
  conditions of service.
• Due to changes in operation, the conditions may
  be more severe than originally designed for. A
  coatings investigation may be warranted.

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Safe Diagram

• Purpose Design and reliability tool for turbine
  blading
• Allows better definition of resonant condition in
  a given stage of blading
• Is an extension of standard Campbell diagram.
  Does not invalidate Campbell
• Plots frequency versus nodal diameters on
  vertical and horizontal axes while Campbell plots
  frequency versus speed
• Nodal diameters define shape of steam force
  excitation frequency and bladed disc natural
  frequencies. Gives better indication where true
  resonance will occur.

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Advanced interference diagram
incorporates shape of excitation for
identification of true resonance condition
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Classical interference diagram - Campbell
Diagram for stage vibratory response
evaluation
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Reliability
Evaluation based on stress results and
appropriate material properties
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Life Extension Calculation
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STEAM TURBINE UPGRADES
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Retractable Interstage Seals

• BENEFITS
• To reduce leakage associated with start-up seal
  wear.
• Demand in market for a seal to combat start-up
  wear Due to close design clearances, start-up
  vibration due to critical speeds and shaft
  bows often lead to seal rubs causing excess
  steam leakage resulting in lower
  efficiency. Seal is pulled away from shaft
  until sufficient steam pressure is achieved
  allowing the seal to be positioned in the
  normal operating mode.

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Stepped Interstage Labyrinth

• BENEFITS
• Reduced steam leakage
• Improved efficiency

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Mechanical Seals

• BENEFITS
• Reduces end gland leakage down to a small trace.
• Can be used for various steam conditions -
  saturated or superheated
• Steam leakage is virtually zero
• Bearing oil contamination is eliminated
• Costly repairs and maintenance are eliminated
• Designs for both single and multi-stage turbines

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Type 28ST (Steam) SealTypical Arrangement
Pressure Up To 400 PSIG Exhaust Temp Up To
750F Speed Up To 590 Ft/Sec. Gases Steam
SERVICE Single and Multi Stage Steam Turbines
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Valve Coatings

• BENEFITS To minimize corrosion and increase
  wear resistance.
• Use of High Velocity Oxy-Fuel (HVOF) spray
  coating
• Use of CoMoCrSi thermal spray coating for
  stainless steel valve stems
• Use of overlay coating to extend service life of
  governor control valves Benefits are
  Improved erosion and corrosion resistance
  2-3 times the service life
  Reduced downtime and maintenance costs
  Direct replacement for existing valves
• Use of stellite to double seated valve plugs

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Electronic Governor

• Features
• Speed control
• Load control
• Inlet and exhaust pressure control
• Hand valve control
• Remote auto-start

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Electronic Governor
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MULTI-VALVE MECHANICAL GOVERNOR WITH MECHANICAL
FEEDBACK
End view of multi-valve steam turbine. The blue
areas are removed when converting to electronic
governor.
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MULTI-VALVE TURBINE WITH ELECTRONIC GOVERNOR
ALARM RELAY
SHUTDOWN RELAY
OVERSPEED RELAY
COMPUTER/PERIPHERAL INTERFACE

PROGRAMMABLE RELAYS (5 AVAILABLE)
4-20mA PROGRAMMABLE ANALOG OUT (4 AVAILABLE)
RAISE/LOWER
FUNCTIONS
LOAD SIGNAL
SWITCH INPUTS
IN THIS APPLICATION YOU MAY CONTROL ANY ONE OF
THE FOLLOWING FUNCTIONS
ACTUATOR
INLET PRESSURE
T/T
EXHAUST PRESSURE
GENERATOR LOAD CONTROL
LOAD
INLET PRESSURE
PUMP COMPRESSOR GENERATOR ETC.
SPEED
POWER SOURCE 24VDC, 115VAC, OR 125VDC
EXHAUST PRESSURE
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RESTORED CLASSIC PROGRAM
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Example U-22266 originally located at Riegel
Textile Mill in Ware Shoals, SC since 1981
abandoned. FSO removed train (turbine, gear,
and generator) and shipped to DR/Horsham, PA.
Here the unit was over- hauled and rebuilt.
DR/Wellsville supplied engineering support and
parts. Unit is currently being commissioned for
the City of Baltimore waste recovery plant.
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INITIATIVES Restored Classics
BEFORE
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AFTER
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Applied Technology Engineering
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Applied Technology Engineering

• Tools and methods required for Applied Technology
  Engineering have been in use in the form of part
  inspecting, part geometry verification and
  Non-OEM manufacturing.
• With increased activity in Non-Name Plate
  manu-facturing we found a need to consolidate and
  formalize our Applied Technology Engineering
  activities.
• Procedure for Applied Technology Engineering has
  been completed and QA procedures formalized.

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History of Wellsville Operations

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Why Dresser-Rand?

• Our clients are looking for this service.
• Dresser-Rand has a reputation as a firm with
  superior engineering and technical capabilities.
• Dresser-Rand has state of the art machining and
  manufacturing capabilities, second to none.
• Core competencies, machinery, programs, etc.
  required to enter and compete in this market
  already exist at Dresser-Rand.
• The potential market is very large and represents
  an area of strong growth potential for
  Dresser-Rand.

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Our Strengths

• Over 90 Years of Experience
• 700 employees, with less than 2 annual turnover
  rate
• Over 80,000 steam turbines manufactured
• Installations in over 90 countries
• Offer the most comprehensive range of steam
  turbines in the industry

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Product Services

• Engineered Solutions
• Efficiency Upgrade for Existing Equipment
• Upgrades and Retrofits of Existing Equipment
• Reapplication
• Replacement Parts Repair under 6 Nameplates
• Non-D-R steam turbines Applied Technology
• Re-Manufacturing Restored Classics
• Training
• Rapid response to Clients needs

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QUESTIONS? COMMENTS? OPPORTUNITIES?

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