PROJECT STATUS UPDATE Hyatt Modernization Program Pump-Turbine Refurbishment, Units 2, 4, and 6...

PROJECT STATUS UPDATEPROJECT STATUS UPDATE Hyatt Modernization ProgramHyatt Modernization Program

Pump-Turbine Refurbishment,Pump-Turbine Refurbishment,Units 2, 4, and 6Units 2, 4, and 6

January 11, 2006January 11, 2006Farshid Falaki, PEFarshid Falaki, PE

Hyatt PowerplantHyatt PowerplantPump/Turbine RefurbishmentPump/Turbine Refurbishment

CV=+$99,012SV=+$801,304

CPI=1.007SPI=1.06CSI=1.07

Earned Value Curve for Hyatt Pump-Turbine Refurbishment Project

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

16,000,000

18,000,000

20,000,000

FY99/00

FY00/01

FY01/02

FY02/03

FY03/04

FY04/05

FY05/06

FY06/07

FY07/08

Time

Ac

cu

mu

late

d V

alu

e (

Do

lla

rs)

Budgeted Cost

Earned Value

Actual Cost

Time Now


FY 99/00 FY 00/01 FY 01/02 FY 02/03 FY 03/04 FY 04/05 FY 05/06 FY 06/07 FY 07/08 Total

Origin

Engr Cost $154,000 $448,000 $192,000 $452,000 $450,000 $493,000 $329,000 $196,000 $0 $2,714,000

Cont Pay $0 $0 $0 $655,000 $3,585,500 $3,585,500 $3,585,500 $3,585,500 $0 $14,997,000

Est. Total $154,000 $448,000 $192,000 $1,107,000 $4,035,500 $4,078,500 $3,914,500 $3,781,500 $0 $17,711,000

Latest

Engr Cost $94,421 $255,855 $258,522 $277,663 $618,067 $1,031,000 $1,168,500 $292,599 $20,000 $4,016,627

Cont Pay $0 $0 $0 $0 $1,540,271 $5,500,000 $5,000,000 $1,425,379 $0 $13,465,650

Est. Total $94,421 $255,855 $258,522 $277,663 $2,158,338 $6,531,000 $6,168,500 $1,717,978 $20,000 $17,482,277

Engr Cost $94,421 $255,855 $258,522 $277,663 $618,067 $1,785,387 $622,153 $0 $0 $3,912,068

Actual Cont Pay $0 $0 $0 $0 $1,540,271 $2,755,427 $5,154,575 $0 $0 $9,450,273

Cost Total $94,421 $255,855 $258,522 $277,663 $2,158,338 $4,540,814 $5,776,728 $0 $0 $13,362,341

Note: Actual costs are shown up to December 22, 2005.

Latest estimate is based on Project Detail, Rev 5 dated 1/12/2005.

Hyatt PowerplantHyatt PowerplantPump-Turbine Refurbishment – Contract schedulePump-Turbine Refurbishment – Contract schedule

Work Work ItemItem

Original Original DateDate

Actual Actual DateDate

Notice To Begin WorkNotice To Begin Work 11/05/200111/05/2001 11/07/200111/07/2001

Complete Model TestingComplete Model Testing 10/23/200210/23/2002 12/12/200312/12/2003

Begin Disassembly of 1st UnitBegin Disassembly of 1st Unit 10/01/200410/01/2004 10/01/200410/01/2004

Complete Installation of 1st UnitComplete Installation of 1st Unit 03/25/200503/25/2005 06/03/200506/03/2005

Begin Disassembly of 2nd UnitBegin Disassembly of 2nd Unit 09/01/2005*09/01/2005* 10/03/200510/03/2005

Complete Installation of 2nd UnitComplete Installation of 2nd Unit 03/15/2006*03/15/2006*

Begin Disassembly of 3th UnitBegin Disassembly of 3th Unit 10/03/2006*10/03/2006*

Complete Installation of 3th UnitComplete Installation of 3th Unit 03/15/2007*03/15/2007*

Close ContractClose Contract 09/15/2007*09/15/2007*

* Revised schedule for 2nd and 3th units.

Hyatt PowerplantHyatt PowerplantPump/Turbine Refurbishment – Unit 2Pump/Turbine Refurbishment – Unit 2

After disassembly, all components were shipped to GE After disassembly, all components were shipped to GE facilities for repair and refurbishment. Work is being facilities for repair and refurbishment. Work is being performed both in the field and in the various performed both in the field and in the various manufacturing shops. manufacturing shops.

After sand blasting the unit, several cracks were After sand blasting the unit, several cracks were discovered on the stay vanes/stay rings and on the discovered on the stay vanes/stay rings and on the casing. casing.

Cracks on the stay vane/stay rings: On November 4, Cracks on the stay vane/stay rings: On November 4, 2005, the Department discovered several cracks that 2005, the Department discovered several cracks that were mostly shallow except for a few that seemed to were mostly shallow except for a few that seemed to havehave propagated through the entire thickness of the stay propagated through the entire thickness of the stay ring. Based on our investigations, the cause of these ring. Based on our investigations, the cause of these cracks were shrinkage porosity thatcracks were shrinkage porosity that probably occurred probably occurred during the original casting. during the original casting.

These cracks were excavated to the depth of 2 inches These cracks were excavated to the depth of 2 inches and repairs were completed on 11/19/2005. and repairs were completed on 11/19/2005.


Cracks on the casing: On November 21, 2005, GE Hydro Cracks on the casing: On November 21, 2005, GE Hydro began to replace the drum head due to discovery of began to replace the drum head due to discovery of cracks on the weld. However, numerous cracks were cracks on the weld. However, numerous cracks were found behind the drum head on the spiral case. This found behind the drum head on the spiral case. This was the first unit with these types of defects on the was the first unit with these types of defects on the casing. casing.

Due to the specialized nature of welding T-1 steel, the Due to the specialized nature of welding T-1 steel, the Department requested that the same GE subsidiary Department requested that the same GE subsidiary repair these cracks as had repaired previous cracks repair these cracks as had repaired previous cracks found around spiral case access doors. This was found around spiral case access doors. This was mutually agreed up on since GE indicated that they do mutually agreed up on since GE indicated that they do not have the expertise in-house to repair these type of not have the expertise in-house to repair these type of cracks. cracks.

WSI completed the repair of the cracks on December 14, WSI completed the repair of the cracks on December 14, 2005.2005.


Drum Head Third Party Repair

Casing Crack Heat Treatment


Drum Head Stiffeners

Drum Head Grouting


On November 7, 2007, GE completed the as On November 7, 2007, GE completed the as found measurement of the unit.found measurement of the unit.

On November 11, 2005, GE Hydro started in-On November 11, 2005, GE Hydro started in-place machining of the spiral case and place machining of the spiral case and completed the machining on November 22, 2005 completed the machining on November 22, 2005 and removed the machining equipment. and removed the machining equipment.

On December 5, 2005, GE Hydro informed the On December 5, 2005, GE Hydro informed the Department that the lower wicket gate mounting Department that the lower wicket gate mounting flange is out of level by 0.035 inches. It seems flange is out of level by 0.035 inches. It seems that GE inadvertently used an out of caliber that GE inadvertently used an out of caliber measuring instrument causing error in many of measuring instrument causing error in many of their readings. their readings.


On December 16, 2005, GE Hydro re-installed the On December 16, 2005, GE Hydro re-installed the machining equipment (after all repair welding on the machining equipment (after all repair welding on the casing was completed) and re-machined the spiral case casing was completed) and re-machined the spiral case machined surfaces. machined surfaces.

This issue is impacting the schedule since GE was not This issue is impacting the schedule since GE was not able to provide the stack height to Lachine able to provide the stack height to Lachine manufacturing facility for refurbishment of turbine manufacturing facility for refurbishment of turbine components in Canada until all field machining was components in Canada until all field machining was completed and verified. completed and verified.

This has delayed the delivery of the turbine components This has delayed the delivery of the turbine components from mid December 2005 to mid January 2006. from mid December 2005 to mid January 2006.

Based on GE’s latest schedule, the Unit completion date Based on GE’s latest schedule, the Unit completion date has been changed from 3/15/06 to 4/7/06. has been changed from 3/15/06 to 4/7/06.


Machining Weld Seal In Draft Tube

Machining O-RingSurface


After disassembly, GE Hydro provided the shaft After disassembly, GE Hydro provided the shaft run-out, shaft coupling bore, and chord run-out, shaft coupling bore, and chord measurements. Due to excess run-outs, measurements. Due to excess run-outs, Department directed GE to correct shaft Department directed GE to correct shaft coupling bore misalignment and chord coupling bore misalignment and chord misalignment. All shafts (except for generator misalignment. All shafts (except for generator shaft) were shipped to Hitachi Canadian Industry shaft) were shipped to Hitachi Canadian Industry in Saskatoon for shaft string correction work.in Saskatoon for shaft string correction work.

After detailed measurement of each shaft in the After detailed measurement of each shaft in the shop, it was determined that majority of the shop, it was determined that majority of the dimensions were within IEEE 810 standards. dimensions were within IEEE 810 standards.

It is believed that the excess TIR problems on It is believed that the excess TIR problems on the shaft are associated with poor design of the the shaft are associated with poor design of the thrust collar installation on the shaft. thrust collar installation on the shaft.


Polishing IntermediateShaft, 12/14/05


The runner for unit 2 was mostly manufactured in The runner for unit 2 was mostly manufactured in Norway and shipped to Lachine, Montreal to be Norway and shipped to Lachine, Montreal to be completed.completed.

In Norway, GE had performed numerous NDTs on the In Norway, GE had performed numerous NDTs on the runner utilizing ultrasonic testing (UT) method. The tests runner utilizing ultrasonic testing (UT) method. The tests showed 24 m of defects on the runner. 10 Meters of the showed 24 m of defects on the runner. 10 Meters of the alleged defect was excavated prior to shipping the alleged defect was excavated prior to shipping the runner to Canada; however, no defects were detected. runner to Canada; however, no defects were detected.

In Lachine, the excavated area was repaired. Due to In Lachine, the excavated area was repaired. Due to numerous false indications by UT tests, GE decided to numerous false indications by UT tests, GE decided to use RT rather than UT to perform NDTs. use RT rather than UT to perform NDTs.

As the result of RT tests, GE found 5 inches of defects, As the result of RT tests, GE found 5 inches of defects, which the defected area was excavated and repaired. which the defected area was excavated and repaired.


Second Runner – Repairing Defects after RT

Examination


After partial failure of the coating on unit 4, GE After partial failure of the coating on unit 4, GE was asked to proceed with re-coating of the was asked to proceed with re-coating of the entire spiral case and repair the coating in the entire spiral case and repair the coating in the draft tube as warranty work. draft tube as warranty work.

Department issued a clearance on unit 4 on Department issued a clearance on unit 4 on November 28,2005 for sand blasting and November 28,2005 for sand blasting and coating. coating.

Department directed GE to replace the original Department directed GE to replace the original EnduraFlex coating in the spiral case with EnduraFlex coating in the spiral case with Chesterton to eliminate the problems associated Chesterton to eliminate the problems associated with transition between two dissimilar coatings. with transition between two dissimilar coatings.

The coating was completed on December 21, The coating was completed on December 21, 2005.2005.


Spiral Casing Coating,9/29/05


Spiral Case New Coating,12/16/05

Spiral Case After Sand Blasting


The Department conducted Unit 4 field performance The Department conducted Unit 4 field performance tests in turbine mode and pump mode on 10/26/05 and tests in turbine mode and pump mode on 10/26/05 and 10/29/05 respectively:10/29/05 respectively:

Guaranteed weighted efficiency of the unit in turbine mode at the Guaranteed weighted efficiency of the unit in turbine mode at the head of 615 feet: 92.2%head of 615 feet: 92.2%

Guaranteed pump-turbine efficiency in the pump mode at the Guaranteed pump-turbine efficiency in the pump mode at the head of 592 feet and 1870 cfs : 90.9% head of 592 feet and 1870 cfs : 90.9%

The preliminary test results of unit 4 field performance The preliminary test results of unit 4 field performance tests are as follows:tests are as follows:

The weighted turbine efficiency at the head of 615 feet: 91.52%The weighted turbine efficiency at the head of 615 feet: 91.52% The pump efficiency at the head of 625 and 1635 cfs: 89.44%The pump efficiency at the head of 625 and 1635 cfs: 89.44% Contract specifications allows 1.5% allowance for instrument Contract specifications allows 1.5% allowance for instrument

uncertainty. The above test results are shown without adding uncertainty. The above test results are shown without adding instrument uncertainty allowance. instrument uncertainty allowance.


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PROJECT STATUS UPDATE Hyatt Modernization Program Pump-Turbine Refurbishment, Units 2, 4, and 6...

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