GE Service Capabilities

Ansaldo ST fleet
Fabio Franzi
26/02/2016
Imagination at work

Ansaldo ST fleet
Ansaldo Energia has installed 100,000 MW ST fleet, 700 turbines in more
than 40 countries, impulse (GE derived) and reaction (ABB/Alstom
derived, now GE) technology, 50 Hz and 60 Hz non-reheat and reheat
steam turbines range from 40 MW to 1000 MW for conventional steam
cycles, combined cycles and cogeneration applications.

Ansaldo ST is a target oOEM fleet for GE

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disclosures. Delete if not needed.

Ansaldo ST - Installed fleet

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disclosures. Delete if not needed.

Ansaldo ST fleet some design examples

Turbine type: Ansaldo 320 MW ITB
Configuration: HP/IP-LP
Fiumesanto 3 & 4 (Italy)

Turbine type: Ansaldo 150 MW ITB

Configuration: HP/IP-LP
Mohammedia 3 & 4 (Morocco)

Turbine type: Ansaldo 140 MW RTB

Configuration: HP/IP-LP
Priolo (Italy)
See tutorial regarding confidentiality
disclosures. Delete if not needed.

Ansaldo ST fleet
Our capabilities

E.ON Fiumesanto #3
320 MW
2 casings
Major Overhaul 2007

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disclosures. Delete if not needed.

Ansaldo ST fleet
Our capabilities
Advice and
operational support
Service contracts
LTSA

Field Service

Parts

Field Services
A, B and C inspections

Assessments & Analyses

Lifetime time assessment
Performance improvement
Operational analysis

Erection & commissioning

Valve & actuator overhaul
Inspections
Condition assessments

Operational support

Strategic spares
Blades / un-bladed rotors
Casing, gland housings
Blades, diaphragms,
gland segments
Bearings
Valve internals and
actuators
Control system spares

Ultrasonic rotor testing

Emergency response
planning

Logistic spares **

Remote operation support

Gaskets and seals

Start-up / Shut-down
optimization

Consumables

Repairs
Rotor
Rotor straightening
Crack removal
Creep damage mitigation
Disc-head repair
Nozzle box repair
High & low speed balancing
Casings
Casing re-rounding &
machining
Erosion / Corrosion repair

Blading
Erosion /corrosion repairs
Diaphragm repairs

Training

Retrofits & upgrades

Turbine retrofit
Inner and full module
replacement HP, HP-IP, IP,
LP

Valve retrofit / upgrade

Steam chest replacement
Valve internals upgrade
Steam Path Upgrades
HP, IP steam path

Auxiliary systems
Control system upgrade
Other: lube, gland sealing
system, etc.

Technical & technology

training

PLANT
MAINTENANCE &
OPERATIONAL
STRATEGY

OUTAGE
SCHEDULE &
BUSINESS
MODEL

OUTAGE
SCHEDULE &
MAINTENANCE
STRATEGY

FLEET FEEDBACK
&
OUTAGE
SCHEDULE

Full service capability

LONG TERM PLANS &

OUTAGE
SCHEDULES

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
Our capabilities
Capabilities

Why GE?

Planning:
Scheduling
Staffing incl. labour sourcing

Inspections

Design knowledge and maintenance

capability (ITB & RTB)

Overhaul scope:
Turbine
Valves

TFA Support

I&C and hydraulic

Auxiliaries
Overhaul activities:
Supervision, incl. site mgmt.

Retrofit
Installation

NDT inspections and assessment

Commissioning:
Cold and hot commissioning

Non-Turnkey
Inspections

Trouble shooting:
Repairs

Extensive experience GE is the OED

both for ITB and RTB fleet

Turnkey
Inspections

Turn-key capability and design

knowledge to support emergency
repairs and parts supply
Modern inspection techniques
Fleet Mgmt. to assure that global
experience is transferred to
maintenance practice
Local presence, optimized network
set-up
See tutorial regarding confidentiality
disclosures. Delete if not needed.

Ansaldo ST fleet
Our capabilities
Capabilities
Logistic parts to support outage:
Seals, bolts, gaskets, etc.

Inspection
Spare Parts

Noble parts (long lead items):

Blades, diaphragms, bearings,
etc.
Support for spare parts strategic
inventory assessment:
Minimise outage durations
Outage pre-planning including
spares prioritisation and local
inventory audit
Manufacturing and sourcing

Strategic
Spare Parts

Why GE?
Original design informations,
manufacturing data, and processes
to ensure the supply of quality parts
Global supply chain

Milled Blades

Stock material and established

supply chain enables response to
emergency requirements

Forged Blades

Fleet Management knowledge to

support parts recommendations/life
assessment

Capital
Equipment

Integration with field service

activities for one stop shop

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
Our capabilities
Capabilities

Why GE?

Rotors
Mechanical cracks removal
Disc head and rotor weld
repairs
Overhauls
Casings
Casing weld repairs

Overhaul/
Field Machining
Diaphragm
Repairs

Half joint repairs

Blades
Welding repairs

Valve
Repairs

Welding of new shrouds

Valves
Weld repair of cracked valve
casings
Valve internals repair and
modification

Accumulated experience on Ansaldo

RTB (Alstom/GE) and Ansaldo ITB (GE)
turbines
Repairs verified versus original
design and manufacturing
requirements
Leader in all kinds of rotor welding
repairs
Many repairs can be done on site

Stat/Rot Blade
Repairs
Complex
Repairs
See tutorial regarding confidentiality
disclosures. Delete if not needed.

Ansaldo ST fleet
Retrofits and Upgrades
Capabilities

Why GE?
Life Time Assessment:

Consultancy:
Life Time Assessments

Plant Flexibilty
Performance assessment

Modern process that takes full

life-cycle into consideration

Upgrades:

Upgrades & Repowering:

Control System Upgrade

Valve Upgrade

Valve upgrades and modifications

Steam path upgrades and resizing
Retrofits:

Top end components (e.g. ST

governor)
Reduced scope upgrades due to
detailed design data
Retrofits:

ST retrofit

World leadership > 500 oOEM

cylinder retrofits

Full arc and partial arc

Heat rate improvement up to

5%
Output increase up to 7 %

ST upgrade and retrofit solutions

for RTB & ITB turbines

Excellent post retrofit

performance

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
ST major overhaul (ITB)
Position

Details

Customer, PP, Location

E.ON (ex-Endesa),
Fiumesanto 3&4, Italy

ST details

Ansaldo, 320 MW (ITB)

Project scope

Year of execution

2008, 2010 and 2015

Customers drivers

Restore efficiency
Life extension
Vibration problem solving

Achievements

All deliveries and

performance guarantees
were met

Major overhaul
Repairs
Capital parts supply
Commissioning

Major overhaul 2008 Unit 4

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
ST rehabilitation (ITB)
Position

Details

Customer, PP, Location

ONEE, Mohammedia 3&4,

Morocco

ST details

Ansaldo, 150 MW (ITB)

Project scope

Year of execution

2007 and 2008

Customers drivers

Restore efficiency
Life extension
Problem solving

Achievements

All delivery and performance

guarantees were met

Major overhaul
Control system upgrade
Capital parts supply
Repairs

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
ST minor overhaul and LSB feathering (RTB)
Position

Details

Customer, PP, Location

Elpedison, Thisvi, Greece

ST details

Ansaldo, 140 MW (RTB)

Project scope

B inspection
LP L-0 blades dismantling
with closed casing
LSB feathering in the
workshop
LP L-0 blades re-assembly
Commissioning

Year of execution

2013

Customers drivers

Planned maintenance
LSB issue solving (some
cracks already suffered)
Minimize outage time

Achievements

All delivery and performance

guarantees were met

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
ST Retrofit (ITB): LP module
Position

Details

Customer, PP, Location

Enelpower, Ponti sul Mincio

2, Italy

ST details

Ansaldo, 160 MW (ITB)

Project scope

LP retrofit
Installation
Major overhaul
Control system upgrade
Capital parts supply

Year of execution

2003

Customers drivers

Increase efficiency and

prepare for repowering
Life extension
LPs already retrofitted

Achievements

All delivery and

performance guarantees
were met
Service contracts secured
and performed
afterwards

ST layout: Pre-retrofit

ST layout: Post-retrofit
See tutorial regarding confidentiality
disclosures. Delete if not needed.

Ansaldo ST fleet
Typical Packages for 320 MW ST
Steam Admission Valves:
Cracks on seats
Seats moving out
Stem sticking

Seats repair / substitution

Stem / Bushing substitution

Nozzles chamber and nozzles profiles:

Cracks on welding (breaking in some case)
Cracks on stellite sleeves
Solid particle erosion
Cracks on trailing edge

X-over:
Cracks on bellows

Cracks on L-2 and

L-1R blades-disks
attachment

Cracks on L-1R
blade shrouds &
lashing wires

Detect & Repair

Repair or Blades
substitution

Last rotating blade:

Erosion on Stellite

Welding & repair

Welding & repair /

Nozzle chamber substitution

Stellite substitution

Sealing devices damaged

Seal ring substitution

Cracks on extraction bellows

HP / IP rotating blade:
Shroud detachment

1st & 2nd IP rotating blades & shrouds:

Heavy Erosion (SPE)

1st & 2nd IP nozzles / Diaphragms:

Heavy Erosion (SPE) - Damages
Bellows substitution

Blade substitution

Blade substitution

Diaphragm Repair (welding)

See tutorial regarding confidentiality

disclosures. Delete if not needed.

Ansaldo ST fleet
Typycal Packages for 320 MW ST - Upgrading
Nozzle chamber of different design

Advanced design Nozzles to prevent

solid particle erosion

IP blade section:
high efficiency new profiles
high efficiency sealing

HP blade section:
high efficiency new profiles
high efficiency sealing
New Design Components:
rotor, blades, diaphragms, nozzles,
nozzle chamber, inner cylinder

Last stage substitution

with higher blade
and advanced profiles

Control System conversion:

From MHC to EHC LP or HP

New inner cylinder, diaphragms and rotor

See tutorial regarding confidentiality

disclosures. Delete if not needed.