Turbine Inspection at a Power Plant

Discussion in 'Off-Topic' started by sluggo, Mar 7, 2016.

  1. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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    In the Monria Team Ambassadors private discussion I mentioned my limited time over the next six weeks due to my work schedule and explained some of the stuff I do for a living. It was suggested that I post it here because it was interesting.

    For those who are curious, I work in the power plant and we have a major outage right now, I have two 200 Megawatt turbines torn apart for overhaul and a lot of other jobs as well and it will last until about Mid April. Power plants don't go down much, maybe once a year or every two years for all the work to fix the stuff. This is for obvious reasons, people love their electricity and when we are down, that means we have to buy power if we can't generate enough on our own. They don't like generators NOT spinning so busy we are to get them back up as quickly as safely possible. Experience teaches me that towards the very end, 12 hour days turns into 18 and 20 hour days, sometimes more come crunch time. Last outage I did 38 straight hours getting the generators back online the final two days but we did it. Anyways that's why I am a bit scarce lately.

    I mean how many people get to say they have 230 KV a few feet above their heads while working though it is a bit un nerving at times when your hair starts to stand on end or you see the fog sprites... gulp...

    On that though, security has tightened up a bit over the years so we can't really stream it BUT, back in 2012 we did one of our other turbines, this was a 300 megawatt CFB steam unit, we did an open and inspect and some work on the turbine. My group had a major electrical re work to do as well, we moved the entire control room... anyways, we mounted a camera on a handrail out of the way with a shutter speed of one frame i think it was every 60 seconds and tied it all into a movie. I didn't but one of the guys in our group did this.

    Here is a youtube link if you want to see a fast forward turbine tear down and re assemble.


    P.S. There is another power plant down the road from us, back in the days they could not stay online to save their souls, so we nick named them 'The Dark Side' since the lights were always out and 'dark' over there... the nick name kind of stuck so that is the mention of 'dark side' here in the video.

    sluggo
     
  2. DarkMoonEnigma

    DarkMoonEnigma Connecting Moon Dots Staff Member Moderator Monria Yamato Pilot Community Manager MCAT Team Member Monria Media Team Chief Fun Officer

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    That IS interesting, especially since I would venture to say that for a lot of the creature comforts that we enjoy, we really don't give thought to those who work as hard as they do to provide them. Seems we notice when we're without them, and then some basically complain if the service isn't back online and functioning properly fast enough.

    Much respect for what you do Sluggo, because that has got to be an enormous undertaking. :thumbsup

    PS --> Love the reference to "The Dark Side" :D
     
  3. Kendra

    Kendra Moon Marketer and Virtual shopper Staff Member Moderator Official Moon Shopper Monria Media Team

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    Which one were you Sluggo? lol
    But seriously WOW that looked like a mammoth undertaking day and night I loved watching that,
    and the Benny hill music was so appropriate ... too funny

    Thanks so much for posting
     
  4. Maximus Cashicus

    Maximus Cashicus Well-Known Member

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    Such a brilliant name for the other plant, the dark side, love it. Hope it all goes smoothly and safely for you and the crew Sluggo!
     
  5. Superraine raine r456

    Superraine raine r456 Well-Known Member

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    Very interesting work. Aways was interested in seeing processes of repairs and how things work. Probly why im a tool room machinist. I used to work as an operator in our machine shop and ran big 30 inch steel sleaved centrifugal clutches that i was told go to pwer plant hydro generators like that. And always wanted to see em used but never got the chance. Was wandering if uve seen t.b. woods clutches on ur repair jobs
     
  6. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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    Our turbines are direct coupled. I think 200 MW is a bit too big for a clutch. They use either steam or a gas turbine to power them so you vary the speed to synch up with the grid then close the breaker. Oddly enough we use the grid to start the gas turbine generators up, we turn them into a huge motor until they come up to speed then swap the current flow and they are generators once again. Well that's a very simplistic way of putting it but in a nutshell. Here are some more pictures. We had a bushing goto ground in the switch yard a few months back, this was caught on one of the security camera's, hence the graininess of the photo. You do NOT want to be around when stuff like this appens, that arc is about 20 foot tall FYI.

    switchyard 1 small.jpg switchyard 2 small.jpg
     
  7. Superraine raine r456

    Superraine raine r456 Well-Known Member

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    Thanks sluggo for the info. Appticiate it alot. Very cool working with that much power. Be safe out there.
     
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  8. Kendra

    Kendra Moon Marketer and Virtual shopper Staff Member Moderator Official Moon Shopper Monria Media Team

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    yeah wear rubber shoes dude ;)
     
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  9. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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    The funny thing is, when we roll out the switches on the high sides of the generator transformers they DO make us wear rubber gloves and a face shield... while standing on a metal grate. I guess the reason is so that if something does happen, they have a few molecules of us left to positively DNA the remains!

    Now... who was it again that likes to play with electric nano chips? Sparky????

    sluggo
     
  10. DarkMoonEnigma

    DarkMoonEnigma Connecting Moon Dots Staff Member Moderator Monria Yamato Pilot Community Manager MCAT Team Member Monria Media Team Chief Fun Officer

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    Pick ME, Pick ME --> :clap
     
  11. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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    Well here we are a month into the outage and it is not going as expected, (Ironically that IS expected :D )
    Both turbines had significant damage and we need our rotors overhauled. This means the outage will be going until the middle of may probably, although our work hours have slacked off a bit for the time being, im not holding my breath that they will stay this way. The first pay period, we get paid every 2 weeks, I put in 208 hours on my time card :x

    These rotors now are not small things, they are in essence, the core of the engines that drive the generators. The pictures I am about to show you are of the rotors from inside a GE 7FA type turbine rated at about 180 megawatts. These rotors weigh roughly 120 000 Lbs each, that would be roughly 55 000 Kilo's for you metric types so this wasn't just a normal crane job here.

    These first two pics are of the rotors themselves, the new one that is going in and the old one that came out.
    I have a power point presentation with a few pictures in it of the extraction process, I somehow don't think I can put a PPT file to the forum here, especially since it's 4 meg or so, so will have to drag the pictures out of it one by one and post them later for you to see.

    THIS is why I have not been around as often as I would like to be.
    Sluggo rotor 1.jpg
     
  12. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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  13. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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    Ill get the other pics later
    Thank you
    sluggo
     
  14. Eleni Von Estlla

    Eleni Von Estlla Well-Known Member

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    I bet you guys do amazing delicious jam and soup with that!! im kind of jealous....

    Nah seriously it looks like a monster work lol, just dont lift it on your own and dont overhlem yourself :p
    And dont shut the power in the whole contry hee hee :hi
     
  15. John Strike X3

    John Strike X3 Well-Known Member

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    You just couldn't use regular 150W hand mixer could u? :D
    [​IMG]

    Joking of course. Epic video for a bit i was feeling like watching:
    "Really Big Things" on Discovery Channel
    Ty for sharing :)
     
  16. New York Rose

    New York Rose Well-Known Member

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    That is a great video..love the music it is set to ( on fast forward too!) I am wondering who broke it? Next time there is a power outage,I'm getting Sluggo on the turbine hotline! :eek:rder:pillowfight:

     
  17. Maximus Cashicus

    Maximus Cashicus Well-Known Member

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    Thanks Sluggo for the pics, that's mad!
     
  18. sluggo

    sluggo Official PED Donator, Friend of Lootius Shop Owner

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    Oh I know, throw a whole cow in one end, get cooked hamburger out the other! People like to wake up in the morning and flip the switch and the lights come on, and that's all the thought the give to it, they have no idea what goes on in the background to keep that electricity as reliable as it is.... until it goes out :D then I'm the bad guy hehe.

    Were hoping to get the first turbine back together and on the line first part of may and the second one a few weeks after that if all goes well. I'll work on those pics a bit later tonight and try to get them on here late tonight or tomorrow.

    sluggo
     
  19. Kendra

    Kendra Moon Marketer and Virtual shopper Staff Member Moderator Official Moon Shopper Monria Media Team

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    Wow Sluggo those rotors are massive!!

    The guys look like lego men beside them :eek:rder
     
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