seneca overview & generator rewind ron kovach/tom groff asia pacific partnership united states...

Seneca Overview & Generator Rewind

Ron Kovach/Tom Groff

Asia Pacific PartnershipUnited States of AmericaPower Generation Task ForceAugust 13 – 17, 2007

Asia Pacific Partnership • Aug 13 - 17, 2007FirstEnergy Corp. & Duke Energy Corporation

Seneca: Generator Rewind

Seneca OverviewSeneca Overview

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Seneca – View of Upper Reservoir

1/2 mi. dia.60 ft deep

800 ft above plant

asphalt lined

1/2 mi. dia.60 ft deep

800 ft above plant

asphalt lined

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Seneca – View of Plant & Lower Reservoir

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Seneca Plant

Pumped Storage Facility

3 Units – Unit 1 218MW; Unit 2 195 MW; Unit 3 30 MW

Role of Plant– Provide generation, regulation and spinning reserve during

on-peak hours– Provide an energy sink off-peak (11 P.M. – 7 A.M.) to allow

Fossil and Nuclear plants to remain more fully loaded (Base-Load Strategy)

– Black Start capability

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Priorities

Safety

Environmental and Regulatory Compliance– Federal Energy Regulatory Commission (FERC)– Pennsylvania Department of Environmental Protection

(PADEP)

Reliability

Cost effective operations

6Seneca: Generator Rewind


Staffing

On-site staffing– 6 Operators / 3 Maintenance– 1 Administrative– 2 Management

Corporate Support– Engineering– Environmental– Administrative– IT– Legal

Other– Contract labor services




View of Motor/Generator

1. Exciter

2. Upper Guide Bearing

3. Motor/Generator Rotor

4. Motor/Generator Stator

5. Thrust and Guide Bearing

6. Main Shaft

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View of Pump/Turbine

7. Wicket Gate Servomotor

8. Wicket Gate Operating Ring

9. Lower Guide Bearing

10. Turbine Head Cover

11. Stay Ring12. Wicket Gate

13. Runner

14. Spiral Case15. Draft Tube Cone

16. Draft Tube Man Door

17. Spherical Valve

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Typical Spherical Valve(also called High Head Guard Valve)

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Equipment Suppliers

Newport News Pump-turbines – Voith Runners

L & S Governors

Westinghouse motor – generators / National Electric coil rewinds

Westinghouse voltage regulators

BLH spherical valves

ABB 230kv GCB’s

Allis Chalmers 220MVA Step-up transformers

Pascor Atlantic 230kv Phase reversal switches

400kva Emergency generator



Significant Projects

Pump-Turbine Upgrades– Unit No. 1 – 1992– Unit No. 2 – 1991

Motor-generator rewinds– Unit No. 1 – 1971, 1985, 2006– Unit No. 2 – 1977, 1981, 2007– Unit No. 3 – original

Upper Reservoir side slope paving – 2000




Generating Operation

#1 generates to LowerReservoir only

#1 generates to LowerReservoir only

#3 generates to Allegheny River only

#3 generates to Allegheny River only

#2 can generateto Lower Res orriver

#2 can generateto Lower Res orriver

#1 218 MW

#2 195 MW

#3 30 MW

21' diameter pipe, 3200' long

Upper Reservoir

Upper Reservoir

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321Motor/Generator

Pump/Turbine

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Penstock Rendering

Unit No. 1 – 218MW Unit No. 2 – 195MW Unit No. 3 – 30MW




Pumping Operation

Units 1 & 2 draw water from the Lower Reservoir

Units 1 & 2 draw water from the Lower Reservoir

#1 220 MW

#2 220 MW

#3 Does not pump - used for starting #1 & #21 2 3

Upper Reservoir

Upper Reservoir

2 31

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Operation

Upgraded Pump-Turbines – Efficiency Gain– 3% Pumping– 5 % Generating

700,000 + MWH Annual Generation

Equivalent Forced Outage Rate (EFOR) < 2%

High starting reliability– 8 minute generate starts– 30 minute pump starts




Seneca Plant Available Generation& Upper Reservoir Elevation

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

19:53- 01 -

21:53- 01 -

23:53- 01 -

01:53- 02 -

03:53- 02 -

05:53- 02 -

07:53- 02 -

09:53- 02 -

11:53- 02 -

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19:53- 02 -

21:53- 02 -

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01:53- 03 -

03:53- 03 -

05:53- 03 -

07:53- 03 -

MWH

2010

2020

2030

2040

2050

2060

2070

2080

ELEV. FT.

Total Available MW Hrs Net Available MW Hrs

MINIMUM RESERVE 600 MWH

MAXIMUM UPPER RES. CAP. 4500 MWH

(Black Start Reserve)

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Seneca Pumping Effect on Total Load

2000

3000

4000

5000

6000

7000

8000

9000

10000

19:53- 01 -

21:53- 01 -

23:53- 01 -

01:53- 02 -

03:53- 02 -

05:53- 02 -

07:53- 02 -

09:53- 02 -

11:53- 02 -

13:53- 02 -

15:53- 02 -

17:53- 02 -

19:53- 02 -

21:53- 02 -

23:53- 02 -

01:53- 03 -

03:53- 03 -

05:53- 03 -

07:53- 03 -

System Load

Less Seneca Pumping

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Generator RewindGenerator Rewind

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Decision to Rewind

Last rewind occurred 20 years ago

Tax Credit– Upgrade (8MW)– Extra copper – 7%

Coil replacement– End-of-life– Proactive– Partial Discharge (PD) / Corona

Rotor Pole refurbishment– Asbestos removal

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Generator Rewind

Unit #1 – Core Iron Continuous Restack

Unit #2 – Core Repairs– Loop test criteria max– 10°C Hot Spots– Repair techniques– Thin mica sheets, between laminations– Grind and electro-mechanical etching

New Air Coolers - #1 & #2

Crane– Engineered lift

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Stator Lifting Beams

Bolted to Stator

Pinned to(2) crane hooks

Stator weighs232 tons

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Stator Lift over Unit #3


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W Nameplate Info

336 Coils


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Loop Test Cables

16x3 Turns

2400 Volts

300/Loop Amps

Stator Iron in3 Sections

IR Camera tolook for hot spots

10°C or lessacceptancecriteria


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Coil Wedges

Top view of slot wedges with ripple springs behind

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Brazing

Brazing done using anInduction Machine

264 Series Joints

50 Jumper Joints

50 Phase Joints


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Pole Keys

2 per Pole

225 RPM

32 Poles


(( ))225 Revolutions

1 Minute

225 Revolutions

1 Minute (( ))1 Minute

60 Seconds

1 Minute

60 Seconds (( ))32 Poles

1 Revolution

32 Poles

1 Revolution (( ))1 Cycle

2 Poles

1 Cycle

2 Poles == 60hz60hz(Cycles/second)(Cycles/second)

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Pole ShipmentFixture


Bottom fixture rounded to allow horizontal placement

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Thrust Bearing Shoes

Thrust Bearing Shoes in place

Oil supply hoses installed

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Wear Pattern on Thrust Bearing Shoes

Removed from Unit #1

Units No. 1 and No. 2– 12 shoes each

Unit No. 3– 8 shoes

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seneca overview & generator rewind ron kovach/tom groff asia pacific partnership united states...

Documents

duke energy corporation

generator rewind slide

legal n

storage facility n

mw n role of plant

kv gcbs n allis chalmers

kv phase reversal switches

kva emergency generator