lower baker unit 4 startup, commissioning, and the efforts ... · lower baker unit 4 – startup,...
TRANSCRIPT
![Page 1: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/1.jpg)
Lower Baker Unit 4 –
Startup, Commissioning,
and the Efforts to Resolve
Vibration & Performance
Issues on a New Hydro
Installation
Shane Richards, PE
Mechanical Engineer/Project Manager
Hydro Group
2015 NWHA Tech Seminar
Hood River, OR
May 7th, 1 pm
![Page 2: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/2.jpg)
2
What will you learn?
Background on LBU4
Timeline of Issues (2013 Startup & Commissioning)
What is Going On?
Steps Towards Resolution
Ultimate Conclusions
Questions
![Page 3: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/3.jpg)
3
Where is LBU4?
South of Mt. Baker on WA
State Hwy-20 just outside
Concrete, WA – Approx. 2
hours north and east of
Seattle, WA
![Page 5: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/5.jpg)
5
FERC License Required Improvements
2x Floating Surface Collectors (FSCs)
Adult Fish Trap (AFT)
Fish Hatchery Upgrades
Various Auxiliary Investments
New Powerhouse – LBU4 ***
![Page 6: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/6.jpg)
6
Lower Baker Unit 4
~$50 MM Design-Build Contract for design & construction (PCL Construction, Black & Veatch Engineering)
~$11 MM Turbine Supply Package (Litostroj-Koncar – Slovenia/Croatia)
30 MW or 1500 cfs Minimum Instream Flow Turbine
SBV included – For ensuring flow continuation
~$20 MM ARRA Funded Tax Grant
My Role – Project Mechanical Engineer
![Page 7: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/7.jpg)
7
Lower Baker – Before & After
![Page 8: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/8.jpg)
8
~$90MM Later
![Page 9: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/9.jpg)
Early Commissioning Timeline - 2013
May 21 – Bearing Heat Runs
May 28 – Balancing Adjustments Made
June 2 – First Sync to the Grid
June 3 – Load Rejections, High Vibrations @ 85%
June 4 – Lower Generator Guide Bearing Adjustment Work
June 12 – High Vibrations at LGB Persist
June 14 – Dewatered and Discovered Missing Seals
June 20 – Air Vent Making Loud Noises
June 26 – Index Test Prelim results not favorable, vibrations
analysis ongoing, vibrations persistent 9
![Page 10: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/10.jpg)
What is going on?
Bearing Vibrations?
Unbalanced Unit?
Seals Issue?
Air Vent Problems?
Efficiency Issues?
Other Problems? Von Karman Vortices?
10
![Page 11: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/11.jpg)
Unit Disassembly – August/September ‘13
August 12 – Start Reshaping Guide Vanes
August 24 – Reshaping Completed, Different Hz Vibration
August 30 – Re-run Unit, No Vibrations to 100%
September 9 – Drop Bottom Ring, Machine it, Replace Seals,
Recoat Spiral Case
October 10 – Re-run Unit, Vibrations Return @ 85%
11
![Page 12: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/12.jpg)
Vibration Timeline (June – October 2013)
12
![Page 13: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/13.jpg)
Before & After Reshaping (CFD Modeling)
13
![Page 14: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/14.jpg)
Axial WG Vibration Measurements
14
Guide Vane AXIAL vibration
0
2
4
6
8
10
12
14
16
18
20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Gui de Vane Nr . [- ]
A [
mm
/s
]
2013.06.04 - BEFORE Stay Vane trailing edge modification
2013.08.24 - AFTER Stay Vane trailing edge modification
2013.10.07 - AFTER bottom ring machining
![Page 15: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/15.jpg)
Unit Underperformance (Shifted Curve)
15
![Page 16: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/16.jpg)
Review Design & On Site Testing - 2014
Planned Model Test Design & Prep – 1st half of 2014
June 2014 – Model Testing in Blansko, Czech Rep.
Final proposed solution – New Runner Only
August 2014 – Resumed site testing, removed paint
16
![Page 17: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/17.jpg)
Stay Vane Strain Gages & Testing (Aug ’14)
17
![Page 18: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/18.jpg)
Effect of Improper Coating
18
![Page 19: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/19.jpg)
Ongoing Testing & New Runner
19
![Page 20: Lower Baker Unit 4 Startup, Commissioning, and the Efforts ... · Lower Baker Unit 4 – Startup, Commissioning, and the Efforts to Resolve Vibration & Performance Issues on a New](https://reader034.vdocuments.net/reader034/viewer/2022051803/5b0316d87f8b9a3c378baf84/html5/thumbnails/20.jpg)
Conclusions & Lessons Learned
Coating Actually Matters
CFD versus Real Life makes a difference
Avoid changing too many variables at one time
There’s varying levels of commissioning (contractor,
equipment provider, owner)
Patience pays off (hopefully)
Thanks for the support
20