1. PROJECT STATUS UPDATE Hyatt Modernization Program
Pump-Turbine Refurbishment,
Units 2, 4, and 6
January 11, 2006
Farshid Falaki, PE

2. Hyatt Powerplant Pump/Turbine Refurbishment
CV=+$99,012
SV=+$801,304
CPI=1.007
SPI=1.06
CSI=1.07

3. Hyatt Powerplant Pump/Turbine Refurbishment
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
$655,000
$3,585,500
$14,997,000
Est.
$1,107,000
$4,035,500
$4,078,500
$3,914,500
$3,781,500
$17,711,000
Latest
$94,421
$255,855
$258,522
$277,663
$618,067
$1,031,000
$1,168,500
$292,599
$20,000
$4,016,627
$1,540,271
$5,500,000
$5,000,000
$1,425,379
$13,465,650
$2,158,338
$6,531,000
$6,168,500
$1,717,978
$17,482,277
$1,785,387
$622,153
$3,912,068
Actual
$2,755,427
$5,154,575
$9,450,273
Cost
$4,540,814
$5,776,728
$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.

4. Hyatt Powerplant Pump-Turbine Refurbishment – Contract schedule
Work Item
Original Date
Actual Date
Notice To Begin Work
11/05/2001
11/07/2001
Complete Model Testing
10/23/2002
12/12/2003
Begin Disassembly of 1st Unit
10/01/2004
Complete Installation of 1st Unit
03/25/2005
06/03/2005
Begin Disassembly of 2nd Unit
09/01/2005*
10/03/2005
Complete Installation of 2nd Unit
03/15/2006*
Begin Disassembly of 3th Unit
10/03/2006*
Complete Installation of 3th Unit
03/15/2007*
Close Contract
09/15/2007*
* Revised schedule for 2nd and 3th units.

5. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
After disassembly, all components were shipped to GE facilities for repair and refurbishment. Work is being performed both in the field and in the various manufacturing shops.
After sand blasting the unit, several cracks were discovered on the stay vanes/stay rings and on the casing.
Cracks on the stay vane/stay rings: On November 4, 2005, the Department discovered several cracks that were mostly shallow except for a few that seemed to have propagated through the entire thickness of the stay ring. Based on our investigations, the cause of these cracks were shrinkage porosity that probably occurred during the original casting.
These cracks were excavated to the depth of 2 inches and repairs were completed on 11/19/2005.

6. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2

7. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
Cracks on the casing: On November 21, 2005, GE Hydro began to replace the drum head due to discovery of cracks on the weld. However, numerous cracks were found behind the drum head on the spiral case. This was the first unit with these types of defects on the casing.
Due to the specialized nature of welding T-1 steel, the Department requested that the same GE subsidiary repair these cracks as had repaired previous cracks found around spiral case access doors. This was mutually agreed up on since GE indicated that they do not have the expertise in-house to repair these type of cracks.
WSI completed the repair of the cracks on December 14, 2005.

8. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2

9. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2

10. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2

11. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
Drum Head Third
Party Repair
Casing Crack Heat
Treatment

12. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
Drum Head Grouting
Drum Head Stiffeners

13. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
On November 7, 2007, GE completed the as found measurement of the unit.
On November 11, 2005, GE Hydro started in-place machining of the spiral case and completed the machining on November 22, 2005 and removed the machining equipment.
On December 5, 2005, GE Hydro informed the Department that the lower wicket gate mounting flange is out of level by inches. It seems that GE inadvertently used an out of caliber measuring instrument causing error in many of their readings.

14. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
On December 16, 2005, GE Hydro re-installed the machining equipment (after all repair welding on the casing was completed) and re-machined the spiral case machined surfaces.
This issue is impacting the schedule since GE was not able to provide the stack height to Lachine manufacturing facility for refurbishment of turbine components in Canada until all field machining was completed and verified.
This has delayed the delivery of the turbine components from mid December 2005 to mid January 2006.
Based on GE’s latest schedule, the Unit completion date has been changed from 3/15/06 to 4/7/06.

15. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
Machining O-Ring
Surface
Machining Weld Seal
In Draft Tube

16. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
After disassembly, GE Hydro provided the shaft run-out, shaft coupling bore, and chord measurements. Due to excess run-outs, Department directed GE to correct shaft coupling bore misalignment and chord misalignment. All shafts (except for generator shaft) were shipped to Hitachi Canadian Industry in Saskatoon for shaft string correction work.
After detailed measurement of each shaft in the shop, it was determined that majority of the dimensions were within IEEE 810 standards.
It is believed that the excess TIR problems on the shaft are associated with poor design of the thrust collar installation on the shaft.

17. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2

18. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
Polishing Intermediate
Shaft, 12/14/05

19. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
The runner for unit 2 was mostly manufactured in Norway and shipped to Lachine, Montreal to be completed.
In Norway, GE had performed numerous NDTs on the runner utilizing ultrasonic testing (UT) method. The tests showed 24 m of defects on the runner. 10 Meters of the alleged defect was excavated prior to shipping the runner to Canada; however, no defects were detected.
In Lachine, the excavated area was repaired. Due to numerous false indications by UT tests, GE decided to use RT rather than UT to perform NDTs.
As the result of RT tests, GE found 5 inches of defects, which the defected area was excavated and repaired.

20. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 2
Second Runner –
Repairing Defects after RT
Examination

21. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 4
After partial failure of the coating on unit 4, GE was asked to proceed with re-coating of the entire spiral case and repair the coating in the draft tube as warranty work.
Department issued a clearance on unit 4 on November 28,2005 for sand blasting and coating.
Department directed GE to replace the original EnduraFlex coating in the spiral case with Chesterton to eliminate the problems associated with transition between two dissimilar coatings.
The coating was completed on December 21, 2005.

22. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 4
Spiral Casing Coating,
9/29/05

23. Hyatt Powerplant Pump/Turbine Refurbishment – Unit 4
Spiral Case New Coating,
12/16/05
Spiral Case After
Sand Blasting

24. Hyatt Powerplant Pump/Turbine Refurbishment
The Department conducted Unit 4 field performance tests in turbine mode and pump mode on 10/26/05 and 10/29/05 respectively:
Guaranteed weighted efficiency of the unit in turbine mode at the head of 615 feet: 92.2%
Guaranteed pump-turbine efficiency in the pump mode at the head of 592 feet and 1870 cfs : 90.9%
The preliminary test results of unit 4 field performance tests are as follows:
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%
Contract specifications allows 1.5% allowance for instrument uncertainty. The above test results are shown without adding instrument uncertainty allowance.

25. Hyatt Powerplant Pump/Turbine Refurbishment
QUESTIONS?