NEX Submarine Neu
NEX Submarine Neu
NEX Submarine Neu
Introduction
Aging steam turbines require your attention
An increasing number of industrial steam turbines are Depending on live steam parameters, mode of operation,
operated beyond their design lifetime. Operating a turbine service conditions etc. certain damage mechanisms can
for extended periods beyond the end of its normal design take effect, leading to deterioration of various components.
lifetime may result in increasing failure risk and un-
This can result in uncertainty about what measures should
planned outages.
be taken to meet your requirements for reliability and
Each turbine is unique! Most of them are designed for availability, and when such measures should be carried
over 100,000 operating hours but their real life time out from an economic point of view.
depends on
Siemens program for Life Time Assessment (LTA) and Life
■■ Operation profile of the turbine Time Extension (LTE) is the structured way to secure oper-
ation beyond designed lifetime!
■■ Performed scope and intervals of maintenance
■■ Possible calculation margins.
Failure risk
Without LTA/LTE
With LTA/LTE
2
Continuing profitable operation for decades
Reliable turbine operation is often of great importance. After careful investigation by our experienced engineers,
The high investment cost and long delivery time of new it could be possible to extend the operating life of the
equipment make it worth considering the alternative of turbine plant by tens of years at a limited investment cost.
LTE. The comprehensive LTA/LTE program available from In some cases the cost could be restricted to the inspection
Siemens can help to secure future reliable operation of a cost only. In other cases, additional benefits can be gained
turbine approaching the end of its design lifetime. It is in performance or efficiency when replacing old parts
recommended to perform Siemens LTA/LTE program latest with modern equipment. This depends on the assessment
at 100 000 equivalent operating hours (EOH). of our engineers in each individual case.
Rotation Fatigue
Stress
Flow
Moisture content
Depositions
Failure mechanisms
3
LTA/LTE program
Siemens has developed a program for the Life Time The program consists of three main parts:
Assessment (LTA) and Life Time Extension (LTE) of LTA Desktop study, LTA and LTE.
industrial steam turbines.
General information
Result
Step 1
Setting the goals
Step 2
Identification of critical components
4
LTA
Step 3 Step 4
Theoretical status and Life Time Assessment Experimental status and Life Time Assessment
Components identified in step 2 will be further analyzed Inspection and non-destructive testing (NDT) of critical
in step 3. Complementary theoretical analyses are per- components will be performed based on the LTA Desktop
formed based on today’s design criteria and Siemens’ study. Common activities are:
experience from similar units and components. To make
■■ Inspections
the inspections more focused, they might be preceded by
detailed temperature and stress analyses using ■■ Dimension checks
■■ Magnetic particle test, liquid penetrant test,
ultrasonic examination, eddy current inspection,
phased arrays inspection, etc.
■■ Hardness tests
■■ Replica extraction
■■ Surface sampling
In most cases the specified activities are enough for
a LTA, but in some cases more specific or even extended
NDT-activities are needed. In-depth analysis, like FE-based
calculations with modified material data or updated
performance calculations, might be necessary for evalua-
tion of the results. Investigations continue only as far as
necessary to ensure the accuracy required.
Class 2:
■■ Operation time have exceeded the design
life time
■■ Long term actions
Class 3:
■■ No special action needed
■■ Normal inspection/maintenance
The output of this step is a conservative theoretical
Life Time Assessment and a specification of further
recommended LTA work.
Ultrasonic testing of bearings in the workshop
5
LTE
Step 5 Step 6
Recommendations for Life Time Extension Life Time Extension
All information collected during the LTA work form A life time extension plan is established by executing the
the basis of Siemens’ recommendation for LTE. recommended measures found in the LTA study. This means,
For each component, a unique recommendation for example, that parts will be replaced, repaired or re-
is specified: inspected. The recommended LTE work will be updated
continuously and adapted to present customer needs.
■■ Return to service with no additional limitation
■■ Modify operating conditions
■■ Repair specific components
■■ Replace exhausted components
■■ Re-inspect at suitable time intervals
6
Case study
Turbine in a district heating plant As part of the lifetime extension work, step 6, one year
later the ESV and CV casings were tested with a magnetic
■■ In operation since: 1983
particle test complemented by structure examination and
■■ Operating hours: 154,000 h hardness measurements. At this time, the serious creep
damages had returned. The updated LTE recommendation
■■ Number of starts: 310
was now to plan for a replacement and to evaluate the
■■ Steam temperature: 540 °C/1000 °F optimum operation manner to secure a low risk level until
a new valve casing was manufactured. Based on a fracture
■■ Steam pressure: 114 bar/1650 PSI
mechanical calculation Siemens recommended turbine
The goal was set in step 1, the client wanted to secure operation with a decreased inlet temperature to minimize
continued operation for at least 85,000 operating hours. further creep damages until the new casing were available.
The customer focused on high availability and the intention After the old ESV and CV casing was replaced, the unit
was continuous operation as long as possible, with the had no limitation for further operation over the requested
turbine originally designed for 100,000 operating hours. period.
The results of the evaluation in steps 2-4, inspections and
complementary non-destructive testing, were that most
parts of the turbine were in good condition and the exper- Potential benefits of LTA/LTE are:
imental status and LTA agreed with the theoretical. Fur-
■■ High availability and Reliability of a turbine
ther operation for 85,000 hours was considered possible
at the end of its design life
for most components. Serious creep damages were, how-
ever, found in the inlet emergency stop valve (ESV) and ■■ Extension of the operating life of the turbine
the control valve (CV) casing. All cracks were grinded until at limited investment cost
no indications were visible and further investigations and
■■ Performance and efficiency increase
inspections for LTE were recommended for the casing
within one year, step 5.
7
Published by and copyright @ 2015:
All rights reserved.
Siemens AG For more information, contact our Subject to change without prior notice.
Power Generation Services Division Customer Support Center.
Freyeslebenstrasse 1 Trademarks mentioned in this document
Phone: +49 180/5 24 70 00 are the property of Siemens AG, its affiliates,
91058 Erlangen, Germany
Fax: +49 180/5 24 24 71 or their respective owners.
Siemens Energy, Inc. (Charges depending on provider) The information in this document contains
4400 Alafaya Trail general description of the technical options
E-mail: [email protected]
Orlando, FL 32826-2399, USA available, which may not apply in all cases.
The required technical options should there-
fore be specified in the contract.
Power Generation Services Division
Order No. E50001-E510-A247-X-7600
Dispo 34803
siemens.com