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Seneca Overview & Generator Rewind Ron Kovach/Tom Groff Asia Pacific Partnership United States of America Power Generation Task Force August 13 – 17, 2007.

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Presentation on theme: "Seneca Overview & Generator Rewind Ron Kovach/Tom Groff Asia Pacific Partnership United States of America Power Generation Task Force August 13 – 17, 2007."— Presentation transcript:

1 Seneca Overview & Generator Rewind Ron Kovach/Tom Groff Asia Pacific Partnership United States of America Power Generation Task Force August 13 – 17, 2007

2 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Seneca Overview 2

3 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Seneca – View of Upper Reservoir 1/2 mi. dia. 60 ft deep 800 ft above plant asphalt lined 1/2 mi. dia. 60 ft deep 800 ft above plant asphalt lined 3

4 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Seneca – View of Plant & Lower Reservoir 4

5 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Seneca Plant n Pumped Storage Facility n 3 Units – Unit 1 218MW; Unit MW; Unit 3 30 MW n Role of Plant –Provide generation, regulation and spinning reserve during on-peak hours –Provide an energy sink off-peak (11 P.M. – 7 A.M.) to allow Fossil and Nuclear plants to remain more fully loaded (Base-Load Strategy) –Black Start capability 5

6 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Priorities n Safety n Environmental and Regulatory Compliance –Federal Energy Regulatory Commission (FERC) –Pennsylvania Department of Environmental Protection (PADEP) n Reliability n Cost effective operations 6 Seneca: Generator Rewind

7 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Staffing n On-site staffing –6 Operators / 3 Maintenance –1 Administrative –2 Management n Corporate Support –Engineering –Environmental –Administrative –IT –Legal n Other –Contract labor services 7 Seneca: Generator Rewind

8 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind View of Motor/Generator 1. Exciter 2. Upper Guide Bearing 3. Motor/Generator Rotor 4. Motor/Generator Stator 5. Thrust and Guide Bearing 6. Main Shaft 8

9 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind View of Pump/Turbine 7. Wicket Gate Servomotor 8. Wicket Gate Operating Ring 9. Lower Guide Bearing 10. Turbine Head Cover 11. Stay Ring 12. Wicket Gate 13. Runner 14. Spiral Case 15. Draft Tube Cone 16. Draft Tube Man Door 17. Spherical Valve 9

10 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Typical Spherical Valve (also called High Head Guard Valve) 10

11 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Equipment Suppliers n Newport News Pump-turbines – Voith Runners n L & S Governors n Westinghouse motor – generators / National Electric coil rewinds n Westinghouse voltage regulators n BLH spherical valves n ABB 230kv GCB’s n Allis Chalmers 220MVA Step-up transformers n Pascor Atlantic 230kv Phase reversal switches n 400kva Emergency generator 11 Seneca: Generator Rewind

12 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Significant Projects n Pump-Turbine Upgrades –Unit No. 1 – 1992 –Unit No. 2 – 1991 n Motor-generator rewinds –Unit No. 1 – 1971, 1985, 2006 –Unit No. 2 – 1977, 1981, 2007 –Unit No. 3 – original n Upper Reservoir side slope paving – Seneca: Generator Rewind

13 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Generating Operation #1 generates to Lower Reservoir only #3 generates to Allegheny River only #2 can generate to Lower Res or river #2 can generate to Lower Res or river #1 218 MW #2 195 MW #3 30 MW 21' diameter pipe, 3200' long Upper Reservoir Motor/Generator Pump/Turbine 13

14 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Penstock Rendering n Unit No. 1 – 218MW n Unit No. 2 – 195MW n Unit No. 3 – 30MW 14 Seneca: Generator Rewind

15 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Pumping Operation Units 1 & 2 draw water from the Lower Reservoir #1220 MW #2220 MW #3 Does not pump - used for starting #1 & #2 123 Upper Reservoir

16 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Operation n Upgraded Pump-Turbines – Efficiency Gain –3% Pumping –5 % Generating n 700,000 + MWH Annual Generation n Equivalent Forced Outage Rate (EFOR) < 2% n High starting reliability –8 minute generate starts –30 minute pump starts 16 Seneca: Generator Rewind

17 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind (Black Start Reserve) 17

18 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind 18

19 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Generator Rewind 19

20 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Decision to Rewind n Last rewind occurred 20 years ago n Tax Credit –Upgrade (8MW) –Extra copper – 7% n Coil replacement –End-of-life –Proactive –Partial Discharge (PD) / Corona n Rotor Pole refurbishment –Asbestos removal 20

21 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Generator Rewind n Unit #1 – Core Iron Continuous Restack n Unit #2 – Core Repairs –Loop test criteria max –10°C Hot Spots –Repair techniques –Thin mica sheets, between laminations –Grind and electro-mechanical etching n New Air Coolers - #1 & #2 n Crane –Engineered lift 21

22 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Stator Lifting Beams n Bolted to Stator n Pinned to (2) crane hooks n Stator weighs 232 tons 22

23 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Stator Lift over Unit #3 Seneca: Generator Rewind 23

24 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation W Nameplate Info n 336 Coils Seneca: Generator Rewind 24

25 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Loop Test Cables n 16x3 Turns n 2400 Volts n 300/Loop Amps n Stator Iron in 3 Sections n IR Camera to look for hot spots n 10°C or less acceptance criteria Seneca: Generator Rewind 25

26 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Coil Wedges n Top view of slot wedges with ripple springs behind 26

27 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Brazing n Brazing done using an Induction Machine n 264 Series Joints n 50 Jumper Joints n 50 Phase Joints Seneca: Generator Rewind 27

28 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Pole Keys n 2 per Pole n 225 RPM n 32 Poles Seneca: Generator Rewind ( ( ) ) 225 Revolutions 1 Minute 225 Revolutions 1 Minute ( ( ) ) 60 Seconds 1 Minute 60 Seconds ( ( ) ) 32 Poles 1 Revolution 32 Poles 1 Revolution ( ( ) ) 1 Cycle 2 Poles 1 Cycle 2 Poles = = 60hz (Cycles/second) 28

29 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Pole Shipment Fixture Seneca: Generator Rewind n Bottom fixture rounded to allow horizontal placement 29

30 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Thrust Bearing Shoes n Thrust Bearing Shoes in place n Oil supply hoses installed 30

31 Asia Pacific Partnership Aug , 2007 FirstEnergy Corp. & Duke Energy Corporation Seneca: Generator Rewind Wear Pattern on Thrust Bearing Shoes n Removed from Unit #1 n Units No. 1 and No. 2 –12 shoes each n Unit No. 3 –8 shoes 31


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