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EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
ORDERING INFORMATION
Requests for copies of this report should be directed to EPRI Customer Fulfillment, 1355 Willow Way,
Suite 278, Concord, CA 94520, (800) 313-3774, press 2.
Electric Power Research Institute and EPRI are registered service marks of the Electric Power
Research Institute, Inc. EPRI. ELECTRIFY THE WORLD is a service mark of the Electric Power
Research Institute, Inc.
Copyright 2001 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS
This report was prepared by
European Technology Development Limited
2 Warwick Gardens
Ashtead
Surrey KT21 2HR
UK
Principal Investigator
A. Shibli
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Guideline on the Effects of Cycling Operation on Maintenance Activities, EPRI, Palo Alto, CA:
2001. 1004017.
iii
REPORT SUMMARY
Cyclic operation can result in an increase in forced outage rates, higher operation and
maintenance (O&M) costs, and further wear and tear on components due to additional overhauls
and maintenance. Such operation may also increase unforeseen costs due to additional personnel
training requirements and the use of more sophisticated evaluation and inspection techniques.
These guidelines are intended to help plant operators and engineers assess the impact of cycling
on maintenance activities and take appropriate preventive measures when operating a plant in
cyclic mode. While the guidelines provide important direction on O&M practices when shifting
from baseload to intermittent operation, they do not set out to be a comprehensive listing of
individual plant maintenance activities.
Background
The severity of cyclic operation affects boiler, turbine, electrical, and auxiliary components. The
effect is largely design dependent, and older plants originally designed for baseload usage fall
into the less tolerant category. Such units were designed with heavy section headers and piping
with a poor response to thermal fatigue, which basically results from temperature changes during
startup and shutdown. Cycling tends to exacerbate such problems and will lead to an increased
incidence of stress corrosion and corrosion fatigue of feedwater heaters, economizers, and
turbine units. Clearly, cycling utilities need to understand that events which are tolerable on an
occasional basis during baseload operationin terms of damage to the plant, risk to staff, or
impact on the local environmentwould be quite intolerable if occurring daily. EPRI sponsored
development of these guidelines to provide direction for all cycling plants, but particularly those
shifting from baseload operation to intermittent operation.
Objective
To develop guidelines addressing the effects of cycling operation on maintenance activities.
Approach
Because of the range of technical issues involved, EPRI engaged a multi-disciplinary team to
develop these guidelines. Investigators based the guidelines primarily on United Kingdom
maintenance experience for fossil steam plants with drum boilers, as revealed in a survey of plant
operators and R&D organizations. Information from other countriesincluding Ireland, Italy,
France, Portugal, South Africa, Hong Kong, and the United Stateswas also acquired through
surveys. Included in the survey demographics was a large population of once-through boiler
owners. Finally, in developing the guidelines, investigators also relied on their own knowledge
and understanding of plant issues as well as published literature.
Results
These guidelines focus on a number of key issues connected with O&M activities which are
critical to successful cyclic operation. These issues include
Minimization of plant damage and optimization of operation, with emphasis on turbines and
boilers
Operability enhancements
Also featured in the guidelines are responses to the survey questionnaire along with interviews
concerning routine maintenance practices, condition monitoring, and maintenance scheduling.
The appendices to the guidelines document several new and interesting developments in repair
techniques.
In all, the guidelines emphasize that cycling mode presents challenges in the way utilities view
O&M procedures. Under cyclic operation, nearly every O&M procedure must be analyzed in
detail and almost certainly modified to ensure safety, cost-effectiveness and economy,
reliability/repeatability, and minimization of plant damage.
EPRI Perspective
These guidelines are part of EPRIs development efforts under Target 69, Plant Maintenance
Optimization (PMO). The PMO mission is to lead the industry by developing and demonstrating
products and services that improve the use of power plant maintenance resources and increase
profitability for generation businesses.
Flexible cyclic operation of large coal-fired units has been successfully carried out while
maintaining high plant availability, without excessive additional costs. These guidelines will help
utilities increase plant availability by taking a cost-effective, systematic approach to preventive
maintenance activities when operating units in cyclic mode.
Keywords
Cycling operation
Plant maintenance optimization
Preventive maintenance
vi
ABSTRACT
This overview is mainly based on the UK experience for fossil steam plants with drum boilers.
However, information from other countries including Ireland, Italy, France, Portugal, South
Africa, Hong Kong and the United States has also been utilized with this data including a large
population of once through boilers.
Some new and interesting developments in repair techniques have also been included in the form
of Appendices.
vii
DEFINITIONS
Two-shifting means synchronising and desynchronising from the grid system once per day,
on a regular basis, although it can also imply a week end shutdown.
Intermittent operation can mean anything from a few hours of shut-down from time to time,
to long periods when the plant is cold but available to be called into operation at agreed
notice.
Load following is varying load to match grid requirements and requires ramping up and down
between unit peak capacity and minimum load capability as required. Many plants which are
two shifting will also be required to load follow, rather than running at a constant rate during
the two shift period.
ix
ACKNOWLEDGMENTS
This is to acknowledge the input from a number of European and U.S.A. colleagues in the
preparation of this Report and in the provision of information contained herein. Responses from,
and discussions with, a number of plant operators has provided further insight in to the
maintenance practices carried out in countries outside Europe and North America. This input is
gratefully acknowledged.
xi
CONTENTS
xiii
6 OPERABILITY..................................................................................................................... 6-1
7 OTHER CONSIDERATIONS ............................................................................................... 7-1
Noise ............................................................................................................................. 7-1
Efficiency ....................................................................................................................... 7-1
Maintenance .................................................................................................................. 7-2
Chemistry ...................................................................................................................... 7-2
Water Treatment Plant/Purified Water Provision ............................................................ 7-2
Alarms and Protection.................................................................................................... 7-2
Running Auxiliary Equipment ......................................................................................... 7-3
Operator and Maintainer Training .................................................................................. 7-3
8 PROBLEMS EXPERIENCED UNDER TWO SHIFTING DUTY............................................ 8-1
High Temperature Headers (mainly outlets)................................................................... 8-1
Attemperators ................................................................................................................ 8-1
Tubing ........................................................................................................................... 8-2
Steam Drum .................................................................................................................. 8-2
Economiser Inlet Header ............................................................................................... 8-2
ID Fans.......................................................................................................................... 8-2
Main Steam Pipework.................................................................................................... 8-2
Rotors............................................................................................................................ 8-2
Valves............................................................................................................................ 8-3
Inner Casings ................................................................................................................ 8-3
Feed Heaters................................................................................................................. 8-3
Generator and Stator ..................................................................................................... 8-3
9 ENGINEERING MODIFICATIONS TO FACILITATE FLEXIBLE OPERATION ................... 9-1
10 IMPACT OF CYCLING ON MAINTENANCE PRACTICES RESPONSES TO THE
QUESTIONNAIRE AND INTERVIEWS..................................................................................10-1
Routine Maintenance Practices .........................................................................................10-1
Condition Monitoring and Maintenance Scheduling ...........................................................10-2
Rotating Equipment and associated plant components.................................................10-2
Maintenance Scheduling...............................................................................................10-2
Major Outages .........................................................................................................10-2
Minor Outages .........................................................................................................10-2
xiv
11 INDUSTRY PRACTICES/CODES.....................................................................................11-1
12 NEW DEVELOPMENTS AND RELATED R&D EFFORTS...............................................12-1
13 CONCLUSIONS ...............................................................................................................13-1
14 GENERAL REFERENCES ...............................................................................................14-1
A EXACERBATION OF THERMAL FATIGUE, CORROSION FATIGUE AND STRESS
CORROSION IN WATER AND STEAM SYSTEMS UNDER CYCLING CONDITIONS .......... A-1
Thermal Fatigue of Heavy Section Headers, Steam Chests and Related Components ...... A-1
Corrosion Fatigue of Feedheaters, and Economisers......................................................... A-2
Stress Corrosion in Turbines .............................................................................................. A-2
B ADVANCES IN REPAIR WELDING TECHNIQUES............................................................ B-1
B-1
B-2
B-3
B-4
xv
LIST OF TABLES
Table 10-1 Variation of Valve Maintenance Intervals Detailed by Some Stations ...................10-3
Table 10-2 Variation in National Boiler Inspection Intervals....................................................10-4
xvii
1
INTRODUCTION
Power plant maintenance was originally controlled in the UK by the 1926 Factories Act which
stated that boiler plant should be inspected within a time interval of 26 months. For power plant
this implied a major shut down every two years and the opportunity to link this in with general
maintenance. This changed with the Pressure Systems and Transportable Gas Regulations of
1989, which handed over responsibility for the time interval to the Inspecting Authority. The
impact of this change has been rather less than might be expected, since although in principle the
period between the boiler unit itself has been extended, the need to do maintenance on ancillary
equipment such as valves, turbines, pumps and alternators has tended to shorten this interval.
The other factor, which has tended to prevent inspection intervals being increased, is the switch
from base load to cycling or two shifting. To combat this, companies are turning to more refined
approaches to estimating the impact of cycling on the life of high temperature components.
This Report is intended to help plant operators and engineers assess the impact on maintenance
and take appropriate preventive measures when operating a plant in cyclic mode. This is done
with specific reference to European plant operating and maintenance practices. The Report
therefore provides guidance as to what needs to be done when moving from base load to
intermittent operation. However, it does not set out to be a comprehensive guide as to what
should be done on individual plants.
Any station moving from base load operation to intermittent operation will have done cold, hot
and warm starts, and will have procedures for so doing. In moving to more frequent starting and
shutting down, as in the case of cyclic operation, these procedures must be analyzed in detail and
almost certainly modified to ensure:
Safety
Economy
Reliability/repeatability
Environmental acceptability
What is tolerable on an occasional basis, during base load operation, in terms of damage to the
plant, risk to staff or impact on the local environment would be quite intolerable if occurring
daily. Some of these problems can originate from an unprofessional approach to maintenance.
For example, the fact that a safety valve tends to lift during shut down, would be acceptable if it
occurred once or twice a year after a long period of base load operation. It would be another
1-1
Introduction
matter if the safety valve were to blow once a day. This type of issues are addressed in this
Report.
Coal fired units vary immensely in design. Different coals have significantly different
characteristics. Hence it is only possible to offer generalizations here. Whatever the design,
intermittent operation should be possible. In the UK, 660MW coal-fired units have been
regularly two-shifted, and some 500MW coal-fired units have been cycled more than once per
day on a regular basis. The same pertains to oil and gas fired steam units which of course are
spared the problems associated with handling a solid fuel and its waste by-products.
Much of the emphasis, hitherto, on two-shifting, has been with thermal stress and fatigue of large
plant items operating at high temperature. In short, two-shifting has been regarded as another
facet of normal plant operation, where a unit may be cycled just a few times a year. Nevertheless,
two-shifting can bring other problems too. For example, superheaters and reheaters, due to the
need to start up against the clock, can experience temperature excursions significantly above
design.
The UK represents a good example of how attitudes have changed towards the operation of
generating plant and the ability to two-shift it efficiently and quickly. The original specification
for 500 MWe plants, built in the 1960s and 70s, required that units be capable of both
continuous base load and two-shift operation. In terms of two-shifting, after a six-hour overnight
shutdown, when the temperature was expected to be of the order of 480C, units were to be
capable of being brought to full load within 60 minutes. It was also essential that the temperature
of the steam to the turbine, on start up, should not be lower than the turbine metal temperature.
From synchronized no load, the boiler was to be capable of attaining its full rated capacity in
20 minutes, with a steady rise in superheater outlet conditions. In practice these objectives were
never fully achieved. A more typical figure for hot start was 100 to 150 minutes, with loading
rates of 10 MW/min, giving a time to full load of around 50 minutes. That is, 150 to 200 minutes
from request to full load. Improved operation was needed and two-shifting trials were carried out
in the 1970s and 1980s to assess two-shift operability. It was concluded that faster two-shifting
was possible, albeit with a need for some changes to plant equipment and instrumentation.
Since that time, privatization of the electricity supply industry in the UK in 1989, combined with
the competition from new low cost (and hence base load) CCGT plant, has acted as an incentive
for further improvements. Today, a typical 500 MW machine can be brought on line within
about 35 minutes of notice and run up to full load within about 40 minutes. That is about
75 minutes from request to full load. It is probable that some units achieve 60 minutes. This
reduction in time has been achieved by a combination of further modification to units, including
inter-stage drains, improved instrumentation of critical components, improved automated control
and anticipatory sequencing using current computer control software. (Note: Inter-stage drains
are usually located between the various sections of the superheater in the boiler to promote
progressive establishment of flow through the boiler as the boiler is fired. A higher firing rate is
possible allowing condensate to boil out in the inverted sections whilst the flow prevents
overheating of the hotter sections. A bypass drain can usefully be installed around the HP turbine
to the reheater to provide a cooling steam flow to protect the reheater sections which could
otherwise overheat until the turbine stop valves are opened. Critical components will include
1-2
Introduction
most of the later stages of superheater headers, possibly the main steam pipework, boiler stop
valves and HP turbine casing - basically any thick sections susceptible to the generation of
thermal gradients).
Nevertheless in spite of these changes cyclic operation can result in an:
Increase in forced outage rate due to the increased component failure frequency
Increase in wear and tear of components due to additional overhauls and maintenance
Increase in unforeseen costs due to greater personnel training requirements, and more
sophisticated evaluation and inspection techniques.
The severity of cyclic operation affects boiler, turbine, electrical and auxiliary components.
The effect is largely design dependent, and older plant, which was originally designed for base
load usage, is in the less tolerant category. Such units were designed with heavy section headers
and pipe work with a poor response to thermal fatigue which basically results from temperature
changes during start up and shut down. Hence cycling tends to exacerbate such problems.
Cycling will also lead to an increased incidence of stress corrosion and corrosion fatigue of
feedheater, economiser and turbine units which are further explained in Appendix 1.
Advice, information and experience have been sought from a number of plant owners, operators,
researchers and associated organizations in Europe, Asia and South Africa. This Report is thus
based on the reviewers own knowledge and understanding of plant issues, published literature,
and information accessed from plant operators and technical experts.
There are five Appendices with this Report. Appendix 1 describes some practical aspects of
thermal stress, corrosion fatigue and stress corrosion as applied to critical plant items.
Appendix 2 describes a few innovative repair processes which the user of this Report may find
helpful. Appendix 3 describes a few Alternator related issues and Appendix 4 reproduces the
Questionnaire sent out to some of the plant operators. Appendix 5 is perhaps the most significant
appendix in that it gives an overview of the maintenance related issues concerning various
components of cycling plant and the significance of these problems.
1-3
2
OBJECTIVES OF THE STUDY
This was to assist EPRI in the above study by supplying information on maintenance practices
and activities necessitated by the cyclic operation of fossil steam plants in Europe with the
emphasis on coal fired plant.
2-1
3
METHODOLOGY USED TO CONDUCT THE STUDY
Because of the range of technical issues involved, a multi-disciplinary team was engaged in
carrying out this study. The team has conducted surveys of plant operators and R&D
organizations. The surveys were conducted through the questionnaire shown in Appendix 3 and
through interviews and discussions/meetings with plant operators and experts. The countries
involved in the survey were the UK, Italy, Ireland, Hong Kong, Portugal and South Africa. Input
to the report also includes UK experience in maintenance through ETD staff/consultants own
experience.
A survey of available literature was carried out with reference to sources which included:
Ex-CEGB
UK
UK
Worldwide
EU-funded projects
EC
EC
3-1
4
RELIABILITY/REPEATABILITY OF CYCLIC
OPERATION
The first consideration for the operator and maintainer must be the commercial conditions within
which the plant operates. For many IPPs (Independent Power Producers) there are narrow
timeslots for synchronization and penalties for not meeting them, or even the risk of losing the
generation opportunity. These commercial penalties are a key input into the cost/benefit analysis
of any expenditure to improve reliability for intermittent operation. Commercial opportunities
may present themselves from the ability to deliver at short notice times and fast loading and
these must be weighed against the increased risk of failing to meet the targets and possible
increased plant damage.
The first condition of avoiding commercial penalties is reliability; can the start procedures be
gone through regularly with an acceptably low percentage of failures? The second condition is
repeatability: can the procedures deliver synchronization and load-up within the target times
despite changing conditions (e.g. with wet coal and dry coal, with the plants best coal and its
worst, with the best shift team and the worst) or can simple variations be devised which will
cater for known different conditions?
To achieve repeatability, the procedures must allow for varying conditions and therefore the
standard procedure to be adopted for each type of start will be neither the quickest nor most
economical achievable. It is usually easier to delay the late stages of a start-up that is going well
so as to avoid being too early, than to try to accelerate a too ambitious start procedure. However,
some designs of steam turbine run into differential expansion problems if run-up or load-up is
delayed.
The reliability of a unit depends on the product of the reliabilities of the individual critical-path
items. Given the large number of critical-path items (e.g. switches, actuators, motors, valves) on
a big unit, each critical path item needs a very high reliability for the overall reliability to be
satisfactory RCM (Reliability Centered Maintenance) practices can be applied to focus
predictive and preventive measures on critical components to better meet a units mission at
minimum cost and highest availability (footnote reference to appropriate EPRI report #).
4-1
5
MINIMIZATION OF PLANT DAMAGE AND
OPTIMIZATION OF OPERATION
Reliable instrumentation in the right place with output made available in the control room is the
major requirement to minimize damage. Very often the original instrumentation package
provided by the plant manufacturer is not adequate for intermittent operation. Deducing plant
conditions (e.g. turbine differential expansion) from an envelope of input conditions and time
can be very risky when abnormal conditions arise. However, instrumentation is expensive and it
may be economically necessary to install extensive instrumentation on only one of a type of unit
so that the other units may be instrumented only in areas found to be critical.
Turbine
As a sweeping generalization, steam turbines can usually be cycled without significant damage
if attention is paid to temperature matching and drainage. For a running regime involving
shut-downs of up to 8-10 hours (often the definition of hot start for turbine starting), the best
procedure is usually to deload the turbine quickly, thus preventing significant cooling. During
start up steam temperatures should be matched on the positive side with the temperature of the
turbine. That is the steam before inlet valves should be towards the upper limit for matching, as
set by the manufacturer. This temperature should take into account the throttling loss through the
valve (i.e. typically about 50oC above the turbine metal temperature). This will permit the turbine
to be run up and loaded up.
Drainage is critical, as water in the wrong place can do severe damage. Reliance should not
be placed on steam traps or opening drains for a specific period of time. The ideal drainage
arrangement on important steam lines is for two drain valves (one for isolation, one for
controlling the drainage) in series together with a reliable thermocouple. Drains should not be
closed until a temperature margin above saturation has been achieved, and then may need to be
blown through again as a precaution at a later stage of the run-up/load-up. The length of drain
line between the item being drained and the first drain valve should be minimized to prevent
blow-back of collected water onto hot components in the event of a trip or sudden deload.
Drain locations will vary from plant to plant and will be provided by the Original Equipment
Manufacturer. All that is being suggested here is two drain valves in series on each drain line,
one to be used for isolation and the other for throttling the drainage (the latter one clearly subject
to throttling wear, hence the need for an isolating valve to minimize on-load losses).
The thermocouple should be placed where it will give a reading representative of the steam
temperature in the drain line. A bypass line controlled by an automatic drain valve may be
desirable in some locations. Some manufacturers have been known to rely on automatic drain
5-1
valves only for e.g. turbine casing drains, but this is not recommended by the authors of this
report.
Thermocouples should be provided to allow differentials to be read between the inside and
outside of thick metal components such as the main steam valve chests and strict limits observed.
The limits were traditionally (pre ~1980) set based on manufacturers experience 100oC
(180oF) was a typical figure. These were aimed at achieving a certain design life (e.g. a particular
number of hot, cold or warm starts). Where the manufacturer does not provide a limit or the
operator desires to change from the manufacturers design criteria (e.g. by changing the speed or
frequency of starts), an independent engineering study will be needed. These days of course, it is
possible to come up with a scientific value by the use of finite element analysis when it should be
possible to optimize the through wall limit. This technique can also be used to optimize the
geometry of the component to improve its tolerance to temperature differentials.
Top to bottom temperatures for turbine HP and IP cylinders may be desirable. Bearing
temperatures and vibrations are essential, and differential rotor/casing expansions highly
recommended. A reading of the critical metal temperature for steam matching must be available,
together with a fall-back temperature measurement that can reliably be used to deduce the critical
temperature should that thermocouple fail.
The failure mechanism is thermal fatigue and creep fatigue. A common failure mechanism would
be the overheating of the inner surface of a thick metal section relative to the outer section. The
outer section constrains the expansion of the inner section, causing the inner section to go into
plastic deformation (yield) in compression. When the section temperature is re-equalised (on
reaching steady state temperature or during or after cool-down), the inner surface will be in
tension. If the tension is sufficient, the inner surface may then crack under the tension. Once
cracks are formed, further temperature cycling (even within the normal limits) may propagate the
cracks leading to eventual failure by loss of cross-section. Many cracks will not propagate, but
this must be established by monitoring and/or engineering analysis.
Turning gear to prevent bowing of the shaft during cooling down and jacking oil pumps to lift
the rotor shafts off the bearings will spend much more time in service and have many more
starts. Attention should be given to provision of spares and to eliminating poor reliability or
excessive manual input requirement. An alternative means of turning the shaft in emergencies is
desirable. There should be a standard procedure dealing with failure to go on turning, including a
time limit beyond which attempts to re-establish barring will not be continued.
Boiler
Boilers vary considerably in design and, together with the fuel/combustion system, are most
critical and vulnerable for intermittent operation; they go through big heating/cooling and
expansion/contraction cycles. Initial water wall flow distribution can be poor. Superheaters
will accumulate water. Mills will go through the coal/air explosive range on each start-up and
shut-down.
5-2
The following are checkpoints, but there is no substitute for a thorough engineering study,
including additional thermocouples and a test program by an experienced engineering team;
many such are available commercially.
Stressing of Thick Section Components
Careful consideration needs to be given to each header to ensure the inner to outer temperature
limits are not exceeded. The economizer inlet header tends to be vulnerable as it will stay hot
during a short shut-down, but may be chilled during the start-up until the feed heaters come into
service. On drum boilers, the drum is generally not a limiting factor for hot starts unless
excessive feeding is required such that only cool water is available.
Drainage
Water will accumulate in the tubes of pendent and platen superheaters. It is possible to monitor
this by thermocoupling in the dead spaces which is much cheaper than trying to thermocouple
on the tubes in the furnace. (Note: Dead spaces are the regions of the boiler within the casing,
but outside the gas flow region where there is no heat transfer into the steam/water flow.
For example, the Top Dead Space is the region above the furnace roof where headers and
interconnecting tubes are located; a small dead space usually exists at the throat of the furnace).
Direct drainage is not possible, therefore the rate of firing must be controlled until all the water
has boiled off and a cooling steam flow is available to all tubes. Lower headers on other
superheater banks will require a routine of blowing down.
Drum Level Control
Testing will be necessary to determine the optimum program of drum level control, starting
with the level to be achieved when the boiler is boxed up on the previous shut-down; this must
maximize the amount of hot water available for the restart but avoid the need for expensive
blowing down to control the level as the water swells under the start-up firing. The need to run
a feed pump to top up during the shut-down should be avoided if possible. All steam and water
valves on the boiler must be maintained such that leakage and loss of pressure and water is
minimized. Operators must make proper use of master/slave valve arrangements.
Furnace Wall Tubes
In a natural circulation boiler, there may be difficulties in getting even flow distribution
established and this will be exacerbated by uneven slag formations. Uneven flow distribution
can lead to differential expansion problems between tubes, overheating of tubes, stressing of
membrane walls (where applicable), overstressing of tube attachment clips and stress on tube to
header stubs; these must be contained by limiting the rate of initial firing. Steam division walls
and furnace wall superheaters and reheaters are particularly vulnerable to overheating and
failure.
5-3
boiler/turbine unit to be stabilised at a low load, supplying its own auxiliaries. Thus the bypasses
served two functions.
A major consideration in plant start-ups and shut-downs is to avoid overheating or chilling thick
metal components. Hence, for a hot start, the steam temperature at the boiler final superheater
outlet must be raised close to the temperature of the main steam legs to the turbine before steam
is admitted to the legs. Then steam will have to be passed down the steam legs into drains until
the steam temperature at the turbine end of the legs matches the metal temperature (depending on
the exact layout of the plant) between the throttle valves and the stop valves in the steam chest.
Again depending on the plant design, the next metal temperature to match will be a
representative temperature (probably the inlet belt metal) in the hottest section of the turbine,
allowance being made for the temperature loss caused by throttling through the turbine
admission valves.
The pressure/temperature raising characteristics will depend greatly on the balance between
radiant and convection superheaters in the boiler (for each fuel type). Experimentation will be
needed to determine the target boiler pressure to be achieved at shut-down to optimize the startup, though this will need to be modified to allow for passing valves and dampers. A water/steamtight boiler will retain its pressure better and will not need to be topped up with cold feed water .
Similarly if the dampers pass, there will be a cooling draft through the boiler to conduct the heat
away.
In general, less stress is caused to a hot steam turbine by running it up and loading it quickly
rather than slowly. The problem, particularly with coal-fired boilers, is to achieve a fast, but
steady increase in firing and to ensure that the firing is matched to the steam flow (to avoid steam
and boiler metal temperature excursions). The steam boundary layer effect in the superheaters
means that maximising the steam flow through the boiler is necessary to achieve the desired
steam temperatures.
To ensure that the desired run-up and load-up rate of the steam turbine can be achieved, it is
useful to have stored energy in the boiler (in the form of high pressure) so that delays in
increasing the firing rate (perhaps because of problems starting a mill) do not immediately
require reduction in the turbine loading rate.
There are three factors which limit the desirable boiler pressure during start-up:
one is that if the firing rate increases faster than targeted, the boiler safety valves will be
lifted causing a number of undesirable effects.
The second is that the higher the boiler pressure, the more throttling is necessary to control
the turbine run-up and load up rates. The increased throttling increases the temperature drop
in the steam. Since most boilers have difficulty in achieving high steam temperatures at low
throughputs, increased throttling will exacerbate the problems of steam to metal temperature
matching.
The third is that the specific heat of the steam is increased at higher pressure, making it
harder to achieve the desired steam temperatures.
5-5
There is therefore an ideal boiler pressure to be achieved at the start of the steam to legs, steam to
turbine process. To achieve this ideal pressure at the end of the initial boiler fire-up process most
economically, a target boiler pressure should be established to be achieved when the boiler is
boxed up at the end of the previous shut-down. The relationship between the ideal start-up
pressure and the shut-down pressure is determined by the shut-down time, the cooling and
leakage rates of the boiler during shut-down and the pressure/temperature raising characteristics
of the boiler during start-up.
It will generally be found that different mills have a markedly different effect on the rate at
which furnace and steam temperatures can be raised. Because of the different heat emission
characteristics of oil and coal flames, it will probably be necessary to fire a mill as soon as it is
safe to do so. However to prevent the risk explosions, pulverized coal should not be admitted to a
boiler until oil or gas start-up fuel has reached safe temperature limits.
Light-up Burners
These must be maintained for high reliability, particularly those that ignite the start-up mill
burners otherwise excessive delays and/or extensive use of back-up staff will be incurred. The
problems will depend on the manufacturer and type. Light up burners generally work better
when used frequently. Other than the fact that they are used more and therefore require more
maintenance, they may well be more reliable!
Some of the precautions to be taken and points to be considered are listed below:
During shut-down, the lighting-up oil will typically be on recirculation at a low rate.
During start-up, the pumping and heating will need to increase quickly and reliably to allow
the firing of a lot of burners in quick succession.
For a hot start, a high percentage of the boilers light-up burners will be needed, so they need
to be reliable.
Usually, not all the mills are useable for initial light-up and temperature raising. For safety
reasons, the early mills probably need all of the relevant oil burners to be in service; this
requires a very high reliability of these particular burners.
Older designs of light-up oil burner involved the ignition and oil lances to be pushed forward
into position by rams as part of the starting process. Boiler casing distortion and ram failures
caused reliability problems with such burners.
Recirculating tip oil burners avoid the need for oil lance purge sequences. Where other types
of burner are used, steam or air purging has to be effective or the burner tip may get
carbonised deposits during the shut-down and therefore fail to ignite when called for.
Many big, coal-fired units with low NOx burners are successfully two-shifted. It should be
stated here that there is nothing unique with low Nox burners and the light up burners are
generally the same for all types of burner.
5-6
Dust Plant
If the fly ash dust is sold, it may be necessary to dispose of the dust created during start-up
separately because the initial boiler combustion will be poor, leading to carbon in dust levels
which may not be acceptable to the purchaser.
Feedwater Regulating Valves
Sustained low feed flow rates will need to be achieved during start-up. This requires careful
maintenance of the main valves or the provision of a start-up valve bypassing the main valves.
The usual failure mechanism is cutting of the seat through sustained, heavy throttling with the
valve nearly closed. Vibration can be a problem. The important issue is to have a valve that is
specifically designed for this sort of application, but maintenance is important and problems can
be alleviated sometimes by e.g. hardening of the seats. A small, start-up feed regulator valve is
recommended.
Condenser Air Extraction System
This must be able to raise vacuum reliably and repeatably despite the strong possibility of greater
than normal air in-leakage arising from the more frequent expansion and contraction of the
relevant joints. Vacuum raising should be fast enough not to be on the critical path for the startup.
5-8
6
OPERABILITY
Unless labor is cheap and can be deployed plentifully, all valves and dampers must be power
operated and with control and indication on the operators panel, likewise electric motors.
All key instrumentation must also be readable at the operators panel.
The next major step is to make it possible for the operator to be able to take an overview and
monitor the key elements of the process and not be overwhelmed with the volume of information
presented and number of individual actions he has to perform. However many staff are deployed
to operate the unit, one person must have the overview and be able to spot the variations that
could lead to commercial loss or plant damage. Here, modern control systems and VDU
(Visual Display Unit) displays can make an immense difference compared with old control
systems and chart recorders. To give some examples:
All the turbine bearing vibrations and shaft eccentricities can be displayed on a single,
histogram VDU display where the color of each block changes to yellow then red when its
value approaches the warning or danger level.
A target critical path line can be displayed on a screen for start-up, run-up and load up, with
the actual achievement also displayed live during the process. In this way, the operator
quickly becomes aware of variations and can make timely corrections.
Elements of the task can be combined into single-button-start subroutines, e.g. firing mills,
commissioning feed-water heaters, steam to turbine/generator set and run-up.
Alarms can be graded according to their relevance at any point in the process. Early
computerized systems often churned out huge amounts of irrelevant alarm state information.
Complete replacement of existing control and information systems can be very expensive, but
there are now available commercial systems that will extract and process information from the
existing system and provide high level information and control facilities.
The demands for tight combustion control to meet environmental standards are likely to
necessitate a modern, automatic system.
6-1
7
OTHER CONSIDERATIONS
Noise
Starting up steam plant usually creates high noise levels over a sustained period. Depending on
the situation of the plant, noise measurements and modifications may be necessary. Neighbors
may need to be informed of the changed operating regime and its implications.
Efficiency
Once at steady load, the unit will usually need a period of optimization before the usual
efficiency is achieved; this needs attention to minimize cost increases. Pressure may need to be
applied to operators, whose major task has been to get the unit started and to the required load on
time, to continue the effort until the efficiency has been maximized.
Variable or sliding pressure control is a possible option to reduce heat rates during ramp up and
ramp down. Here the inlet pressure and flow rate to the turbine is controlled by altering the
pressure on the feed pump to the boiler. This enables governor valves to be set fully open
avoiding throttling loss. There will also be some reduction in feed pump power.
This option is more feasible on once through systems, which can respond quickly to changes in
output. With drum type systems, if the feed pump pressure is reduced too quickly, there is a risk
of the boiler priming. Furthermore the drop in pressure can lead to a temporary cessation of flow
in the boiler. In such situations hybrid operation may be feasible. Here the unit is operated with
variable pressure from about 60-85% of rated output. Above this rating the system is run under
constant pressure or throttle control.
Availability of the unit will probably suffer during the early period of flexible operation and
boiler tube leaks will need systematic analysis. However, many large flexing units achieve high
availabilities. This is interpreted as a shake down effect - when you push a machine to its
limits in new ways there will be an increase in certain types of problem - in this case thermal
fatigue of attachments is typical. Once the problem is identified it is possible to do something
about it by modifying the operation, improving the design or simply setting higher standards of
maintenance. Most of the UK units encountered increased rates of attachment weld failures when
they started two shifting - this was overcome by modification of attachments and application of
rigorous quality control in welding detail. Attachment failures are now at acceptable levels.
7-1
Other Considerations
Maintenance
The shut-down periods create opportunities for doing optional or forced maintenance on more of
the plant than is available when on load. Plans for taking advantage of the opportunities need to
be made. Procedures for fast depressurization to allow pressure parts repairs should be made
available. Opportunities should be taken to inspect suspect areas of the plant. The statutory
pressure parts inspection regime may need to be changed, at least until more experience of
flexible operation is gained. This may be in conflict with the return to service lay-up procedures
aimed at minimizing start-up time and wear and tear on components so a balance has to be
reached. A Reliability Centred Maintenance (RCM) program enhanced by inspection data and
operating history that incorporates risk based inspection methods can help to prioritize
maintenance activities to match a selected operational regime. RCM is a technique for ensuring
that maintenance expenditure is focussed on achieving the desired plant performance.
Chemistry
Periods of shut-down allow aeration of some of the condensate and contamination from transient
or small condenser leaks. Improper shutdown and layup can lead to serious plant damage such as
pitting, oxidation and corrosion, which during operation can be the indicators of the major failure
mechanisms affecting plant availability. Damage due to cycling includes boiler tube failures,
condenser leaks, and low pressure turbine blade problems. The boiler and feed dosing regimes
will need reconsideration, and condensate dumping may need to be carried out before it can be
returned to the feed system. Silica and conductivity limits prescribed by the turbine
manufacturers for the steam may take too long to achieve on a regular basis; polishing plant
and/or temporary relaxation of the limits may be necessary. Poor shutdown and layup exacerbate
the problems of higher levels of corrosion products flowing from the feedwater system and
within the boiler.
Water Treatment Plant/Purified Water Provision
8-10 hour shut-downs are likely to increase the demand for purified water for additional
blowing-down and drainage. Additional storage and/or production or purchasing capability may
be necessary. The choice of chemistry for a unit is important, not only when the unit is operating,
but also during the transient conditions of shutdown and startup according to the above
referenced EPRI Guidelines. For instance: the choice of oxygenated treatment (OT) over all
volatile treatment (OVT) for drum and once-through units reduced markedly the level of
corrosion products during startup; the choice of EPT (equilibrium phosphate treatment) over
CPT (congruent phosphate treatment) should remove the possibility of hideout and hideout
return during startup and shutdown respectively.
Alarms and Protection
Regular starts and stops exercise protection equipment such as water level detectors and help
prevent inoperability from non-use. However, this regime also puts the plant into risky
conditions more often where the protection may be required. Therefore a regular schedule of
7-2
Other Considerations
protection testing is required. To some extent this can be combined with the operating regime,
by noting alarms as they routinely come up and by shutting down the plant on a routine basis
using the different trip functions.
Running Auxiliary Equipment
As much auxiliary equipment as possible should be shut down when the unit is off load to save
works power. The procedures and maintenance should try to avoid the need for occasional
running of a feed pump during shut-down. Some of the larger systems, such as fuel oil or
Circulating Water (CW) will probably require too much effort and create too much additional
start-up risk to be worth shutting down for short unit shutdowns, but the number of pumps and
heaters in service should be minimized. It may be possible to maintain the CW system prime
with a special small pump rather than keeping a main CW pump running. Consideration should
be given to whether it is more economical to supply the auxiliaries of a shutdown unit from a
running unit, if available, rather than from an external grid source.
Operator and Maintainer Training
Systematic training and regular re-familiarization of operators is necessary; a simulator can be
very helpful, but they tend to be expensive. Good practice is to give the maintenance staff
operations training or at least get them together with operators round the simulator or during
two-shifts, so that the maintainers can recognize the aspects of maintenance that are important to
the start-up and shut-down process.
7-3
8
PROBLEMS EXPERIENCED UNDER TWO SHIFTING
DUTY
When flexible load operation is practised, the nature of plant failures can change. Long term
creep damage can become less of a concern, and fatigue type problems become more evident.
In high temperature components, the interaction between creep and fatigue can result and
exacerbate damage accumulation. Thus it becomes imperative to monitor major components
such as headers and other thick sectioned components.
Mechanical problems arise due to thermal gradients and to restricted expansion etc. Problems
ranging from boiler tube attachment failures to more complex problems affecting banks of tubes
can ensue. Similarly, turbine rotor expansion becomes more critical with gland sealing and rotor
blade clearances a concern.
It is impossible to identify the precise effects of cycling on plant due to the extensive variations
in the design of components and operating conditions. However, typical examples of actual
experience are summarised below. A few examples of unusual failures are also included to
highlight how design specific the impact of cycling can be. It should be noted that some of the
examples are from units with broad differences in cycling characteristics, from load cycling to
two shifting.
High Temperature Headers (Mainly Outlets)
Ligament cracking
Tube stub cracking (frequently affecting stubs at ends of headers and also free standing bottle
headers)
A report of spring mountings being used in Russia to negate fatigue stub cracking
unconfirmed.
Attemperators
Liner cracking
8-1
Tubing
Typical cycling related failures e.g. at tube to tube attachments, at windbox welds, openings
etc., corners, (with and without corrosion influence).
One unusual failure type involved localised hot spots at reheater bends (12CrMOV material)
due to oxide spalling of 1Cr0.5Mo lodging at bends temperatures were particularly high at
start-up and cycling promoted oxide spalling which located at tube bend.
Several instances of pendant superheater and reheater tubing replacement due to excessive
temperatures during start up. Usually solved by upgrade replacement.
Although not common one respondent cited corrosion fatigue failures (explosive) at neutral
axis of horizontal superheater drain bends (condensate gathered and caused pitting).
Steam Drum
Cracking at penetrations e.g. risers, thermocouples etc., section changes at doors, attachment
welds etc. Chamfering of openings used to reduce stresses. Grinding and monitoring usually
adopted.
ID Fans
Recent experience in UK plant of internal thermal fatigue cracking in main steam pipes
particularly at welds. Cracks initiate relatively early but appear to grow more slowly with
increasing depth. Normal weld ultrasonic inspection procedure required to be modified to
enable detection. European Commission supported project developed fatigue life monitoring
software programme for HT piping (Mitsui Babcock Energy Ltd., UK).
Some evidence that increased incidence of Type IV cracking with the amount of cycling.
Rotors
Cracking at gland steam heat relief grooves of some designs removed via reprofiling
grooves.
8-2
LP blade root hole cracking on some designs (finger and slot in Alstom designs not certain
to be cycling related as similar cracking reported on baseload plant).
Valves
Internal Cracking at section changes, webs, thermocouple holes etc. Usually leave and
monitor or grind out and improve profile if possible. Craze cracking usually not considered a
problem.
Inner Casings
Cracking at section changes, bolt holes, openings etc. general policy is to grind out if minor
and improve profile and monitor. Some weld repairs reported.
Feed Heaters
Cracking at hemiheads and at baffle plates and a few instances of small (fatigue?) cracks at
openings in shell resulting in brittle fracture of shell (UK) generally fairly long time to
materialise. Problems with some designs resulting in erosion and fatigue related leaks.
Insulation breakdown.
8-3
9
ENGINEERING MODIFICATIONS TO FACILITATE
FLEXIBLE OPERATION
Older base load plant was not designed with the expectation of flexible operation. The majority
of UK plant is sub critical type with forced and natural circulation evaporative sections. Turbines
were designed with throttle control suitable for high load operation.
In order to meet the requirements of flexible operation, various modifications have been
implemented. The most notable modifications include:
1. Improved instrumentation and integrated system control to give better indication of plant
periods.
5. Improved light up burner reliability and operability. This is especially the case for coal fired
units where smaller gas/oil burners are used for coal burner ignition and flame stabilisation.
6. Boiler Off Load and Economiser Recirculation to maintain an even temperature distribution
one which is off load and reduce the thermal shock to economiser inlet etc.
8. HP Turbine Bypass to provide a flow path for steam through the cold reheat steam legs and
9-1
A general indication of plant problems associated with flexible plant operation was given in the
ETD previous report on Damage to Power Plant Due to Cycling in Appendix P, a copy of
which is attached here as Appendix 3. A general vulnerability index of the various components
to damage and need for maintenance has been added to this Appendix.
9-2
10
IMPACT OF CYCLING ON MAINTENANCE PRACTICES
RESPONSES TO THE QUESTIONNAIRE AND
INTERVIEWS
A questionnaire (see Appendix 4) was sent to a number of utilities and the analysis of the
responses received is described below.
Drains with associated steam traps, blowdown tanks etc. and valves, especially wedge type,
required more frequent maintenance/inspection/replacement.
Some problems with pumps (mainly wear and tear but a few instances of cracking) and
associated motors were reported (some circulating water boilers moved to continuous
operation of pumps as the avoided wear and tear costs were more than saving in house load).
Change to variable speed drives to reduce house loads and reduce maintenance.
Some vibration related problems with Electo Hydraulic Control Piping some changed to
constant pressure operation to minimise.
Main valve overhaul intervals generally reduced by one year when moved to cyclic duty.
Boiler related intervals dictated by statutory requirements but inspection scope usually
increases.
10-1
10-2
Station
Valve Type
Inspection
Interval
Operating Mode
Operation
Testing
Frequency
Ref. 1
MSSV
25000 hours
Load Following
Daily
MSSVBV
25000 hours
MSCV
20000 hours
Daily
CRV
20000 hours
Daily
MSSV
5 years
MSSVBV
5 years
MSCV
5 years
Daily
CRV
5 years
Weekly
MSSV
3 years
MSSVBV
3 years
MSCV
3 years
2 weeks
CRV
3 years
2 weeks
MSSV
2 years
MSSVBV
2 years
MSCV
3 years
Weekly
CRV
2 years
Weekly
MSSV
2 years
MSSVBV
2 years
MSCV
2 years
Weekly
CRV
2 years
Daily
Ref. 2
Ref. 3
Ref. 4
Ref. 5
Load Following
Partial cycling
Load Following
Load Following
Daily
2 weeks
Weekly
Daily
MSSV = Main Steam Stop Valve, MSSVBV = Main Steam Stop Valve Bypass Valve, MSCV = Main Steam
Control Valve, CRV = Combined Reheat Valves
Three of the above reduced the interval by one year when moving to cycling duty. One reduced it
by two years, the other did not change the interval.
Boiler maintenance is largely time-based. This arises primarily as a result of the prescriptive
nature of most of the National pressure vessel inspection regulations, refer Table 10-2. A unified
European approach to pressure vessel manufacture comes into effect in 2002 and there is
10-3
Periodicity
Type
Hydrotest
AUSTRIA
3 years
VT, UT, MT
6 years
BELGIUM
2 years
VT and (1)
After major
repair
DENMARK
3 years
VT and (1)
6 years
40 months
VT and (1)
10 years
3 years
VT and NDE
9 years
FRANCE
GERMANY
Remarks
Extension possible to 30 months
on advice of inspector
Usually VT
ITALY
2 years
and/or
After major
repair
UT and (1)
NETHERLANDS
2 years
VT
2 years
VT
(endoscopy)
SWEDEN
2 years
PT, RT
After repair
Eddy Current
IRELAND
26 months
up to 30
years old,
16months
thereafter
NORWAY
2 years
VT and (1)
After repair
8 years
No prescriptive intervals.
UK
NDE = Non Destructive Examination, VT = Visual Testing, UT = Ultrasonic Testing MT = Magnetic Testing,
PT = Penetrant Testing, RT = Radiographic Testing (1) as required by inspector (MT, PT, UT, RT)
10-4
It appears that in most instances boiler inspection findings will influence intervals but usually are
focused to specific problem areas. Responses to the most effective fixes were inconsistent and
ranged from detailed life assessment strategy to increased instrumentation and introduction of
more automated valves. This variability in response possibly stems from the background of the
individual completing the questionnaire i.e. whether on the operational side, maintenance or
engineering. Similarly varied responses were obtained regarding problem areas - turbine flexible
joints, LP disc serration related cracking, LP blade erosion were typical of the turbine problems
cited. A few indicated water chemistry related problems, in particular phosphate hideout. Air inleakage problem at low loads was also mentioned, but the most common was tube failures.
Further details of problems are presented in Section 8.
Most respondents indicated some increase in O&M costs but they were not more definitive in
terms of percentages or details of high cost areas other than valve replacements and automation
aspects.
10-5
11
INDUSTRY PRACTICES/CODES
At present there are no maintenance codes in Europe. As a result most of the European plant
operators use either manufacturers guidelines or in-house guidelines. In the UK where the
practice is more developed and advanced in-house guidelines are used, for example, by Innogy
and Powergen. However, other countries, such as EDP/PROET in Portugal for example, use
mainly codes such as ASME (adapted for repair work). For component replacement
PROET/EDP reported that they may use the applied Code of Manufacture, which is generally
ASME (for Forster-Wheeler steam boilers, which are the vast majority). For steam turbines,
where applicable, generally ABB internal standards are used by this company.
Generally it can be stated that most maintenance regimes are set up by the OEM (Original
Equipment Manufacturer). The only exception to this is where there is a statutory requirement
e.g. in the UK as set out under the Pressure Systems regulations. Similar Statutory requirements
exist in all countries and require certain components to be examined at periods as set out by law.
Most maintenance is based on custom and practice and can vary even within one company.
Organisations with a high level of commercial awareness will carry out value for money type
assessments and optimize maintenance practices to suite. As an example, a few years ago the JIT
(Just In Time) approach was widely used whereby you aimed to replace or repair components
just before they failed - they often missed!
European standards which take in to account cycling are not known to exist at present but five of
the general maintenance standards are being developed which cover different aspects of
industrial maintenance. All are being developed under the auspices of CEN Standards
Committee TC319. The CEN TC 319 was divided into five working groups:
WG1: classification of maintenance services,
WG2: maintenance documentation,
WG3: guidelines for maintenance contracts,
WG3: concepts and terminology of maintenance activities,
WG5: quality assurance of the industrial maintenance.
Further information on these can be accessed from the CEN site http://www.cenorm.be or
http://www.ini.hr/efnms.
11-1
12
NEW DEVELOPMENTS AND RELATED R&D EFFORTS
A number of new European projects, some funded by the European Commission, have been or
being undertaken in the field of maintenance. Although, as far is known none of these deal
directly with maintenance of cycling plant, many of these activities can help a plant operator to
benefit in terms of damage monitoring and engaging in predictive maintenance. Thus
developments have been made in terms of remote temperature and strain monitoring using fiber
optics, as in the case of the European Commission funded project Forms. Concepts of total
maintenance have also been developed which integrate corrective and preventive modes of
maintenance and introduce concepts of benchmarking. Similarly models which can offer
adaptive and dynamic frameworks have been developed. However, none of these is at the stage
of commercial application at present and therefore perhaps not suitable for further discussion in
this Report.
12-1
13
CONCLUSIONS
Cyclic operation is merely the more frequent application of existing procedures. This, however,
multiplies the plant and commercial risks and costs so all aspects operations, maintenance,
chemistry and engineering - must be tackled systematically to produce a commercially optimal
result. Very flexible operation of large coal-fired units has been successfully carried out while
maintaining high plant availability and without excessive additional costs.
13-1
14
GENERAL REFERENCES
1. M P Shipley and R J Browne Cost- Effective Maintenance for the New Millennium
Power Station Maintenance 2000, I.Mech E 2000, London, UK.
2. W H Stroman Cyclic Corrosion Concerns for HRSG Users Int. Seminar on Cyclic
Operation of Power Plant - Technical, Operation and Cost Issues, London June 2001, ETD
Publication.
3. M G Dyson Start Up Issues with Boiler Water Treatment and Their Solution ibid.
4. EPRI TR-107754 (August 1998) Cycling, Startup, Shutdown, and Layup Fossil Plant Cycle
Chemistry Guidelines for Operators and Chemists.
5. ETD Report No. 1002-iip-1001, Damage to Power Plants Due to Cycling, Issued December
2000.
6. EPRI TR-105382 Proceedings:1994, EPRI Fossil Plant Cycling Conference.
7. EPRI GS-7219, Project 1184, September 1993, Cycling of Fossil-Fueled Power Plants
Volume 6: Evaluation and Strategy.
8. EPRI GS-7219 Volume 2 Project 1184-20, May 1991, Cycling Operation of Fossil Plant,
Volume 2: Converting PG&Es Moss Landing 6 & 7 to Cycling Duty.
14-1
A
EXACERBATION OF THERMAL FATIGUE, CORROSION
FATIGUE AND STRESS CORROSION IN WATER AND
STEAM SYSTEMS UNDER CYCLING CONDITIONS
Exacerbation of Thermal Fatigue, Corrosion Fatigue and Stress Corrosion in Water and Steam Systems Under
Cycling Conditions
A-2
B
ADVANCES IN REPAIR WELDING TECHNIQUES
B-1
Repair welding of defects, without subsequent stress relief was originally developed by CEGB
Marchwood (UK) for Cr-Mo-V thick section pipe work and is now being extended to other
materials and structures by the TWI and associated organizations [1].
The technique should only be used where either the defect or crack is of sufficient magnitude to
preclude it being lived with or ground out. If a crack is present or needed to be cut away,
(i.e. ground or burnt out to prevent the crack growing or to enable the weld repair to proceed),
this procedure should be started at the ends of the crack. This will prevent the crack tending to
run on.
Despite avoidance of post weld heat treatment, which implies taking structural components up to
high temperature, a procedures need to be thought through. It is advisable to carry out trial weld
operations on test pieces that will oblige the welder to simulate the actual conditions. During the
work, the job should be supervised to ensure that procedures are adhered to.
Preheat will still be necessary, so that in confined conditions, it is necessary to take due
precautions to ensure that the welder can carry out his job properly. Heating elements, for
preheating, should be placed on the opposite face to that being welded, and temperatures
monitored with thermocouples.
The weld faces need to be buttered, using a two-layer technique, and close control of weld heat
in put levels is required. This avoids dilution and ensures that the requisite grain structure is
obtained. A low heat input stringer technique is recommended for the first layer, and this may
require some training.
B-2
Mitsui Babcock in the UK, in conjunction with other organizations, have developed weld repair
procedures, where there have been concerns about the risk of over-pressurizing a system or
causing brittle fracture to the component. The problems with this type of work increase with
older structures where there is a risk of hydrogen cracking, laminations in material and a risk of
poor toughness in HAZ regions, particularly if there is no PWHT [3].
B-1
Toughness is in fact a major limitation and it may be necessary to carry out fracture toughness
tests on trial specimens containing HAZ. The properties of the sub-critical HAZ are, of course,
the ruling factor.
The work was initially done on a cracked boiler. Backing and wing plates were used to retain the
weldment. Finite element analysis was used to estimate the residual stress field, but a short
period was allowed between each weld sequence, to allow some stress relaxation to occur. In
contrast to the procedures described above and developed by ex-CEGB Marchwood (UK), it was
agreed to use standard welding practices, since this avoided welder induced defects, due to lack
of familiarity.
B-3
Hopkinsons Ltd have developed a machine for re-welding, grinding and lapping of valve seats in
main steam line isolation valves. Because these valves are of the gate type, it implies renewing
an annular valve seat that is concentric with the pipe diameter. All welding, cutting and grinding
actions have to be done in a plane that is at right angles to center line of the pipe [4].
The need for this comes from plants operating on two shift duty, which leads more wear of the
sealing surfaces, due to opening and closing, and more cracking of the seat due to thermal
fatigue. There is also the prospect in some designs of creep of the valve body which result in the
valve seat breaking away.
One issue, which is highly pertinent, is that although it is possible to relap valve seats several
times, eventually the lapping reaches a zone of the valve seat in which dilution of the seat
material occurs. This will then result in very high rates of wear and scoring during the next
period of service. During repair, Stelliting is practical.
B-4
References
B-2
C
ALTERNATORS
There have been a number of changes to generator design and materials of construction, among
which has been the switch to end rings of the Fe-18Mn-18Cr type which has reduced stress
corrosion as an issue. ENEL, however, did detect stress corrosion of Fe-18Mn-18Cr (for
consistency) end rings, which was associated with copper deposits. It is therefore advisable to
keep the alternator enclosure dry at all times.
Despite this there has been a move towards utilizing air cooled designs, particularly for CCGT
plant where there is a strong drive to reduce manpower and ancillary equipment. However,
similar pressures have led to the design of air cooled alternators being pushed to the limit and
problems are beginning to emerge. Design stresses and temperatures are higher, which will
impact on maintenance and reliability. Some of the issues were covered in a recent paper and are
summarized below [1]. These problems can appear within a short time of the machine being run,
and it is recommended that the first inspection be carried out after 12 months operation.
The problems encountered so far are:
Due to changes to the support of the coils in the stators, it is easier for the coils to move
under the effects of 100 or 120 Hz magnetic forces. This causes the semi-conductive layer
and then the epoxy insulation to wear away. The process is accelerated if oil is present.
Somewhat similar problems are found in VPI (Vacuum Pressure Impregnated) machines
where the coils are held in place by a combination of an interference fit and the adhesive
effect of the epoxy. Here again the magnetic forces will lead to stresses on the windings.
These magnetic induced stresses in conjunction with differential expansion between the slot
components will lead to the development of porosity.
End winding problems have also increased due in part to the tendency of some manufacturers
to place the windings with a smaller volume. The air gap is then too small and there is a risk
of partial discharge, eventually boring a hole through the insulation. Symptoms of this are a
white powder that is produced. Some amelioration can be obtained by filling the void spaces
with silicone rubber or Nomax (Dupont tm) sheets.
Every effort should be made to identify whether such problems are occurring, by electrical
testing, otherwise repair may become impossible.
References
1. S. Tucker, J. Milsom, G. Griffith and G. Stone Problems with Modern Air- Cooled
Generator Windings Power Station Maintenance 2000 I.Mech E 2000.
C-1
D
THE QUESTIONNAIRE
Survey Form
Survey of Plant Cycling Effects on Maintenance Practices
Introduction: Many generating plants require greater operating flexibility to be commercially
competitive in the evolving deregulated industry. As a result, plants are changing to cycling
operation, expanding ranges of automated operation and spending greater time at minimum
loads, extending time between overhauls, and purchasing fuels having broad characteristics,
which causes greater wear and tear on equipment and potentially impacts failure rates and
reliability. In some cases, plants have transitioned from cyclic operation to base loaded
operation to supply power when market prices are high. In either case, plants need to adjust their
maintenance basis and adjust condition diagnostics to optimize maintenance costs and reliability.
Survey Objective: This survey is aimed at describing the impact of changing operation modes
on equipment and describe the change in maintenance activities when a plant transitions from
base-loaded to load-cycling operation.
To cover only the Coal Fired Steam Plant
Plant Name and Location (Optional)
this information is confidential and will
not be stated in the analysis Report.
Type of Plant /Output in MW.
When was it commissioned.
Approx Run hours/starts.
Usual Fuel.
Steam Temperatures and Pressures.
Plant operating mode (base load,
cyclic, load following etc.).
How long in this mode?
D-1
The Questionnaire
D-2
Technique e.g.
NDE, vibration
monitoring
,thermography etc.
Frequency e.g.
minor + major
overhauls, monthly
checks, annual etc.
The Questionnaire
HT piping
Motors
Pumps
What are your most serious
maintenance problems, especially
when plant cycling ?
What do you think have been the most
cost effective fixes that you have made
to improve equipment reliability when
plant cycling?
What maintenance/plant areas do you
feel have needed/will need extra
maintenance and attention when plant
cycling.
Any Other Comments
D-3
E
CYCLING EFFECTS ON MAINTENANCE ACTIVITIES IN
THE UK SUMMARY OF TYPICAL CYCLING
PROBLEMS AND THEIR POTENTIAL IMPACT
The following categories have been given as an indication of each activity to suggest the
likelihood of the problem occurring, its possible impact on availability and the type of
expenditure involved. It should be noted that locations are likely to operate with differing
commercial constraints, which could change the way in which any of the problems are managed.
These categories are intended for preliminary guidance only. The list is not necessarily
complete. Not all problems will be experienced and some utilities will experience other
problems. The engineering strategy/solution is given as the basis for further development to suit
the specific objectives of a utility.
Column: Probability of problem occurring (this gives some idea of how likely it is that the
problem will occur).
N Near certainty
R Reduced load
E-1
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential
Impact
Column: Type of Action required (gives an indication of the nature of the solution to the
problem).
E-2
Feed Pumps
HP Feed System
Deaerator
DC Heaters
LP Feed Heaters
Condenser
extraction
LP Feed System
Plant Area
R
R
Consequence
of Problem
Probability
of Problem
Occurring
E-3
MOD
OP
MOD
REN
OP
MOD
OP
OH
OP
OH
Type of
Action
Required
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
E-4
Headers
Economiser
Feed Regulating
Valves
Feed Pipework
HP Feed Heaters
B
0
L
OP
MOD
M dif b il
d t t i kl f
REN
OH
OH
OH
REN
OH
MOD
OH
OP
OH
REN
OH
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
Evaporative
Section
Tubing
E-5
MOD
MOD
OP
MOD
OH
MOD
OH
MOD
OH
MOD
OH
MOD
MOD
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
E-6
Internals
Drum Shell
Drum
Circulating Pumps
Boiler structure
L
H
N
M
OH
OH
OH
OH
MOD
OH
MOD
OH
MOD
OH
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
Headers
Secondary
Superheater
Attemperator Sprays
Desuperheaters
Tubing
Headers
Primary
Superheater
S
B
M
OH
E-7
OP
OH
MOD
MOD
REN
MOD
OH
REN
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
Tubing
E-8
Headers
Reheater
Structure
Tubing
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
OH
OH
MOD
OP
MOD
MOD
OH
MOD
REN
Vent Silencers
Vent valves
Drain valves
Safety valves
Stop valves
Boiler Valves
Structure
0
0
L
OH
E-9
MOD
MOD
MOD
OP
OH
MOD
OH
OH
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
E-10
Stop/Throttle valves
Turbine Steam
Chest
Supports
Welds
R
0
0
0
M
M
M
Pipework
Main Steam
Pipework
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
OH
OH
OH
MOD
OH
OH
OH
OP
OP
OP
Casing
Rotor
Inlet nozzles
HP & IP Turbine
Chest Body
E-11
MOD
MOD
MOD
OP
MOD
MOD
MOD
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
E-12
Condenser Tubes
Vacuum raising
Condenser
Casing
Rotor
LP Turbine
Seals
Bearings
Monitor situation.
OP
REN
REN
OH
OH
MOD
OP
OH
OP
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
Stator
Rotor
Generators
Chemical dosing
Make up water
Water Treatment
Plant
OP
E-13
OP
MOD
REN
MOD
OH
MOD
OP
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
E-14
Controllability
Control Systems
Motors
Electric Motors
Transformers
Switchgear
Switchgear
MOD
REN
MOD
OP
OH
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
Pumps
Storage tanks
Coal Bunkers
Conveyors
Coal stocks
Coal Plant
E-15
OP
MOD
MOD
OP
MOD
OP
MOD
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
E-16
PF distribution
Classifiers
PA Fans
Mills
Feeders
Milling Plant
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
OP
MOD
OP
MOD
OP
OP
Oil Burners
Ash Slagging
Low NOx
Coal Burners
Gas Ignition
Combustion
OP
E-17
MOD
OP
MOD
OP
REN
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
Ductwork
E-18
Refractory brickwork
Air Heaters
Gas Pass
ID & FD Fans
Fans
Monitor corrosion.
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
MOD
REN
MOD
OH
REN
REN
OP
MOD
OP
Bag Filters
Precipitators
Dust Extraction
E-19
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
OP
OP
OP
E-20
Cycling Effects on Maintenance Activities in the UK Summary of Typical Cycling Problems and their Potential Impact
OP
Target:
Maintenance Task Selection Guidelines and
Technologies
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