GNHWPCA

Energy Recovery Plan Unit Monthly PD&C Report

GREATER NEW HAVEN WATER

POLLUTION CONTROL AUTHORITY

Energy Recovery Plan Project

Turbine Generator Set

Performance, Diagnostics and

Consultation Report

November 30th, 2009

Reporting Period Covers New Issues From:

October 16,2009 to November 13, 2009

Prepared By:
Abdullah A. Al Beladi
Internship Engineer

Reviewed & Approved By:

Luis De La Roche
Manager, Field Solution Dept.

Contract Number:
Dresser-Rand Job Number: 000000

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TABLE OF CONTENTS
1 EXECUTIVE SUMMARY 3
2 PD&C RISK MATRIX AND RISK ASSESSMENT 4
3 SUMMARY OF CURRENTLY OPEN ISSUES 5
4 SUMMARY OF ISSUES 6
4.1 Turbine Generator Set. 6
5 ISSUE DETAILS 7
5.1 Turbine Generator Set. 7
9
6 PERFORMANCE SUMMARY - FOR CURRENT REPORTING MONTH 12
6.1 Plant Overall Performance 12
6.2 Steam Turbine Performance 13
6.3 Waste Heat Boiler Performance 14
A. APPENDIX - PD&C OVERVIEW 15
B. APPENDIX – RESOLVED ISSUES 16

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1 EXECUTIVE SUMMARY

This report covers the findings of October/November 2009 for New Haven Turbine Generator, the Energy
Recovery Plan Unit.

In general the unit running in a good condition with low risk issues need to be resolved. All the issues
were discussed in details.

The report discusses the overall plant performance, in addition to the machine performance such as
steam turbine and waste heat boiler.

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2 PD&C RISK MATRIX AND RISK ASSESSMENT

Equipment Monitored Monitoring Review Date Monitoring Review Date

16-Oct.-09 23-Oct-09 30-Oct-09 06-Nov-09 13-Nov-09

Energy Recovery Plan Unit 3 3 3 3 3

Issues are categorized according to the PD&C Risk Matrix, presented below. An issue is assessed for
probability of failure and for consequences of that failure to determine the risk level – low, medium or
high. The risk level then points to the appropriate response priority for that issue.

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3 SUMMARY OF CURRENTLY OPEN ISSUES

The PD&C analysis process identifies anomalies in machinery performance, machinery condition,
controls and/or data problems. Any such finding is called an “issue”. As time goes on it is very important
to track issues in order to ensure that they do not get dropped and also to provide feedback to the PD&C
analysis team.

Issues are reported in one of three categories:

1) new issues – any new issue identified this reporting period

2) unresolved issues – an issue identified previously that is still open; either no action has been
taken or no effective action has been taken
3) resolved issues – something has been done to correct the problem or information has been
supplied to close the issue

A history of issues that have been resolved is kept by the PD&C team. In time, this history along with
statistics on issues found constitutes useful information for reliability purposes.

STATUS
NEW Risk Level
DATE 1 2 3 TOTAL
Oct-09 0 0 4 4
Nov-09 0 0 1 1

Issue Tracker - New

4.5
4
3.5
Number of Issues

3 RL 1
2.5 RL 2
2 RL 3
1.5
1
0.5
0
Oct-09 Nov-09
Month

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4 SUMMARY OF ISSUES

4.1 Turbine Generator Set.

Issue Recommended Action Probability Consequences
Number
Risk Level 1: Take immediate action
No issues to report
Risk
RiskLevel Take action
Level2:2:Perform action at
as next available
soon as possibleopportunity
No issues to report
Risk Level 3: See Recommendations
1001 ISSUE: Generator temperature TE-214C remains steady at high values Low Medium
compared to the other temperatures and dose not trend down when the machine
shuts down. See Green trace in figure below.
RECOMMENDATION:
Check the temperature sensing system (probes, cable, calibrations, settings).
1002 ISSUE: The Generator Temperature’s data for TE-214A & TE-214B have been Low Medium
1degree F since the start up of the machine.
RECOMMENDATION:
Check the temperature sensing system (probes, cable, calibrations, settings)
1003 ISSUE: The Generator Bearing temperatures trend shows different readings for Low Low
TE-212 & TE-213 when the generator shutdown.
RECOMMENDATION:
confirm different temperatures reading in the bearing house with a handheld
thermometer when the generator is shutdown for more than 24 hours.
1004 ISSUE: By referring to the below graph, noticed that the Generator vibration Low Low
reading is above zero when the machine shutdown.
Ideally, it should be Zero otherwise:
- Electrical Noise
- Vibration in the environment
- Shielding of the cables
RECOMMENDATION:
- Confirm the vibration in the environment.
- Check the vibration probe system.
1005 ISSUE: The turbine Exhaust End Radial Bearing temperature TE-203 has a flat Low Low
top, which may be a sign of transducer or signal over range.
RECOMMENDATION: confirm high range for signal and transducer and adjust if
required.

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5 ISSUE DETAILS

5.1 Turbine Generator Set.

ISSUE # 1001: New
ISSUE: Generator temperature TE-214C remains steady at high values compared to the other temperatures and dose not
trend down when the machine shuts down. See Green trace in figure below.
RECOMMENDATION:
Check the temperature sensing system (probes, cable, calibrations, settings)
Probability: low
Consequences: Medium
Risk Level: 3 – see recommendations.

New Haven TG Set: Energy Recovery Plan: Generator Windings Temp.

400 500 600 700 800 900 1000
300 300
280

TE-214B Gen Temp (deg F)

260
TE-214A Gen Temp (deg F)

250
240
220
200 200
180
160
150
140
120
100 100
80
60
50
40
20
0 0
09.10.16 09.10.23 09.10.30 09.11.06 09.11.13
Log Date
OPERATING HOURS: 1032.6 DATE: 2009.11.13 TIME: 15:00 SEQUENCE: 0
TE-214A Gen Temp (deg F) = 1 TE-214B Gen Temp (deg F) = 1
TE-214C Gen Temp (deg F) = 141 TE-214D Gen Temp (deg F) = 128
TE-214E Gen Temp (deg F) = 126 TE-214F Gen Temp (deg F) = 129

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ISSUE # 1002: New

ISSUE: The Generator Temperature’s data for TE-214A & TE-214B have been 1degree F since the start up of the
machine.
RECOMMENDATION:
Check the temperature sensing system (probes, cable, calibrations, settings)
Probability: low
Consequences: Medium
Risk Level: 3 low – see recommendations.

New Haven TG Set: Energy Recovery Plan: Generator Windings Temp.

400 500 600 700 800 900 1000
300 300
280

TE-214B Gen Temp (deg F)

260
TE-214A Gen Temp (deg F)

250
240
220
200 200
180
160
150
140
120
100 100
80
60
50
40
20
0 0
09.10.16 09.10.23 09.10.30 09.11.06 09.11.13
Log Date
OPERATING HOURS: 1032.6 DATE: 2009.11.13 TIME: 15:00 SEQUENCE: 0
TE-214A Gen Temp (deg F) = 1 TE-214B Gen Temp (deg F) = 1
TE-214C Gen Temp (deg F) = 141 TE-214D Gen Temp (deg F) = 128
TE-214E Gen Temp (deg F) = 126 TE-214F Gen Temp (deg F) = 129

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ISSUE # 1003: New

ISSUE: The Generator Bearing temperatures trend shows different readings for TE-212 & TE-213 when the generator
shutdown.
RECOMMENDATION:
confirm different temperatures reading in the bearing house with a handheld thermometer when the generator is shutdown
for more than 24 hours.
Probability: low
Consequences: low
Risk Level: (3) low

New Haven TG Set: Energy Recovery Plan: Generator Bearing Temp.

400 500 600 700 800 900 1000
300 300

TE-213 Brg Temp. NDE (deg F)

TE-212 Brg Temp.DE (deg F)

280
260
250
240
220
200 200
180
160
150
140
120
100 100
80
60
50
40
20
0 0
09.10.16 09.10.23 09.10.30 09.11.06 09.11.13
Log Date
OPERATING HOURS: 559.6 DATE: 2009.10.24 TIME: 22:00 SEQUENCE: 0
TE-212 Brg Temp.DE (deg F) = 81 TE-213 Brg Temp. NDE (deg F) = 87

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ISSUE # 1004: New

ISSUE: By referring to the below graph, noticed that the Generator vibration reading is above zero when the machine
shutdown.
Ideally, it should be Zero otherwise:
- Electrical Noise
- Vibration in the environment
- Shielding of the cables
RECOMMENDATION:
- Confirm the vibration in the environment.
- Check the vibration probe system.
Probability: low
Consequences: low
Risk Level: (3) low

New Haven TG Set: Energy Recovery Plan: Generator Vibration

400 500 600 700 800 900 1000
1.0 1.0
0.9

VE-304 Gen Brg Vib. (mils)

VE-303 Gen Brg Vib. (mils)

0.8 0.8
0.7
0.6 0.6
0.5
0.4 0.4
0.3
0.2 0.2
0.1
0.0 0.0
09.10.16 09.10.23 09.10.30 09.11.06 09.11.13
Log Date
OPERATING HOURS: 518.6 DATE: 2009.10.23 TIME: 5:00 SEQUENCE: 0
VE-303 Gen Brg Vib. (mils) = 0.03 VE-304 Gen Brg Vib. (mils) = 0.06

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ISSUE # 1005: New

ISSUE: The turbine Exhaust End Radial Bearing temperature TE-203 has a flat top, which may be a sign of transducer or
signal over range.
RECOMMENDATION: confirm high range for signal and transducer and adjust if required.

Probability: Low
Consequences: low
Risk Level: (3) Low

New Haven TG Set: Energy Recovery Plan: Turbine Bearing Temp.

800 900 1000

180

TE-201 IE ThrBrg Tem (deg F)

TE-200 IE JrnBrg Tem (deg F)

170
160
150 150
140
130
120
110
100 100
90
80

09.10.16 09.10.23 09.10.30 09.11.06 09.11.13

Log Date
OPERATING HOURS: 1032.6 DATE: 2009.11.13 TIME: 15:00 SEQUENCE: 0
TE-200 IE JrnBrg Tem (deg F) = 113 TE-201 IE ThrBrg Tem (deg F) = 113
TE-202 IE ThrBrg Tem (deg F) = 145 TE-203 EE JrnBrg Tem (deg F) = 131

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6 PERFORMANCE SUMMARY - FOR CURRENT REPORTING MONTH

6.1 Plant Overall Performance

No data were received from the client about the actual feed rate.

New Haven TG Set: Energy Recovery Plan: Feed Rate(Ton/Day) Vs Power (KW)
800
PARAMETER INFORMATION
Feed Rate: Ton/Day
No Data
700
PW-100 Gen Power Out: kW
0
600
PW-100 Gen Power Out

CURSOR INFORMATION
Operating Hours: 1032.60
500 Date: 2009.11.13

Time: 15:00
400 Sequence Number: 0

ADDITIONAL PARAMETERS
300

200

100

0
20 30 40 50 60
Feed Rate

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6.2 Steam Turbine Performance

The efficiency of the steam turbine appears high as per the start up data. The overall
performance of the turbine is an excellent comparing to the initial performance curve.

New Haven TG Set: Energy Recovery Plan: Steam Flow(lb/hr) Vs Power (KW)
800
PARAMETER INFORMATION
FI-110 Steam Flow: lb/hr
7676.00
700
PW-100 Gen Power Out: kW
494.00
600
PW-100 Gen Power Out

CURSOR INFORMATION
Operating Hours: 852.60

*
500 Date: 2009.11.06

Time: 3:00
400 Sequence Number: 0
line
ase ADDITIONAL PARAMETERS
pb
rt u
300 Sta

200

100

0
0 2000 4000 6000 8000 10000 12000 14000
FI-110 Steam Flow

Daily Trend of Power Deviation From Baseline

50
40
30
20
10
0
%

-10
-20
-30
-40
-50
11/1
11/2
11/3
11/4
11/5
11/6
11/7
11/8
11/9
10/14

10/16

10/21

10/23

10/30
10/15

10/17
10/18
10/19
10/20

10/22

10/24
10/25
10/26
10/27
10/28
10/29

10/31

11/10
11/11
11/12
11/13
11/14
11/15

Date

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6.3 Waste Heat Boiler Performance

No data were received from the client about the actual feed rate.

New Haven TG Set: Energy Recovery Plan: Heat Input Vs Output

1000
PARAMETER INFORMATION
Heat Input Parameter:
900 No Data

Output Parameter:
800
8.44E6

700 CURSOR INFORMATION

Output Parameter

Operating Hours: 937.60

Date: 2009.11.09
600
Time: 16:00
500 Sequence Number: 0

ADDITIONAL PARAMETERS
400

300

200

100

0
0 200 400 600 800 1000
Heat Input Parameter

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A. APPENDIX - PD&C OVERVIEW

• PD&C Description

Dresser-Rand’s field engineers and/or Customer X personnel capture data from each module
on a weekly basis. There is usually a compromise; the available data are generally fewer than
the optima. As a result, some operating characteristics and/or failure modes cannot be tracked
or predicted. These data are logged using log sheets, vibration scanners, unit control panels,
and other databases or spreadsheets. The data are sent to Dresser-Rand via email to
drpdc@dresser-rand.com. The Dresser-Rand Technical Support team reviews the data on a
weekly basis and will immediately contact Customer X with any major concerns. D-R takes the
weekly data and compiles them into monthly, more in-depth reports. Dresser-Rand Technical
Support will coordinate a monthly review meeting and conference call with Customer X, once
the report has been issued. This monthly report will be available in hard copy as well as pdf.

• General Condition and Performance

This aspect of the PD&C monitoring program is based on operating data from the control
system. The data sets are comprised of process pressures, temperatures, flow rates, machine
speeds, component temperatures (e.g. bearings), lube oil pressures and temperatures and any
other available parameter useful for condition or performance analysis.

The Dresser-Rand PD&C process evaluates these raw data inputs for trends and compares
them to allowable levels. Then various condition and performance indicators are developed
through relevant calculations. Such indicators are linked to specific performance measures,
such as a degradation of efficiency, or to certain mechanical faults, such as a bearing failure.

• Vibration Surveys

Monthly vibration analyses are performed to provide more information on the mechanical
condition of each unit. Various kinds of vibration data are collected at pre-selected points;
mostly at bearings, with readings collected in horizontal, vertical and axial directions. The
analysis tools produce detailed, high resolution spectra or signatures of the vibration at each
point.

With the assistance of the analyzer system, a rotating machinery engineer interprets these
signatures. The process involves:
- evaluating the overall or total level of vibration
- looking for energy at frequencies where specific faults will appear if present in the
machine
- evaluating the level of energy at these “fault frequencies”
- looking for trends or changes in the overall and fault frequency levels
- making a judgment call on the severity and risk associated with any anomalies detected

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B. APPENDIX – RESOLVED ISSUES

All of the previously resolved issues, not resolved during this reporting period, dating back to
the beginning of this PD&C contract are included in this section. To obtain any other
information regarding these past issues, please contact Dresser-Rand technical support at
drpdc@dresser-rand.com

Issue Unit Name Recommended Action Probability Consequences

Number
Risk Level 1: Take immediate action
No issues to report
Risk Level 2: Take action at next available opportunity
No issues to report
Risk Level 3:See Recommendations
No issues to report

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