2021 Major Overhaul of ABB Nürnberg Steam Turbine - Technical Specification - ETHICS
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SILKEBORG VARME A/S 2021 Major Overhaul of ABB Nürnberg Steam Turbine Technical Specification PROJECT NO. DOCUMENT NO. 131920 131920-005 VERSION DATE OF ISSUE DESCRIPTION PREPARED CHECKED APPROVED 1.0 11.05.2020 ALEA MHJS ALEA
TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 2 CONTENTS 1 Introduction 4 2 The project 4 2.1 Unit and operating data 4 2.2 Maintenance history 5 2.3 Health, Safety and Environment (HSE) 6 2.4 Quality Assurance 6 2.5 Timeframe and scheduling 7 3 Basic Scope of Supply 7 3.1 Planning of the overhaul 7 3.2 Disassembly of turbine and gear 7 3.3 Bearings for turbine and reduction gear 8 3.4 Turbine outer casing and blade carriers 8 3.5 Balance pistons and steam glands 9 3.6 Turbine rotor 9 3.7 Main oil pump 9 3.8 Turbine valves 10 3.9 Major overhaul of reduction gear 10 3.10 Assembly of turbine and gear 11 3.11 Alignment check 11 3.12 Commissioning 11 4 Options 13 4.1 New sealing strips for the rotor 13 4.2 New sealing strips for stationary parts 14 4.3 New blades and replacement 14 4.4 High-speed balancing of turbine rotor 14 4.5 Machining of split line flange 15 4.6 Turbine bearings 15 4.7 Gear Bearings 16
TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 3 4.8 Transport of main components to workshop 16 4.9 Recommended spare parts or services 16 5 Variations 16 6 General supplies 17 6.1 Manpower 17 6.2 Spare parts 18 6.3 Tools 19 6.4 Consumables 19 6.5 On-site and off-site transport 19 6.6 Cleaning and blasting 20 6.7 NDT 20 6.8 Documentation 20 7 Supply by SV 22
TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 4
1 Introduction
Silkeborg Kraftvarmeværk A/S (SV) is planning for a major overhaul of the 24 MW ABB Nürnberg
steam turbine and reduction gear at the CCHP plant in Silkborg. The turbine was commissioned in
1995 and have since the commissioning had approximately 105600 operating hours and 4700
starts. In order to ensure reliable, safe and efficient operation of the unit a major overhaul of the
steam turbine and reduction gear is needed.
2 The project
The project includes the following main tasks:
› Basic Scope of Supply as stated in Section 3. The Basic Scope of Supply consists of:
› Major overhaul of the turbine and reduction gear
› Commissioning of the unit including vibration measurements and verification tests
› Optional scope of supply as stated in Section 4. The optional scope of supply consists of:
› Options that can be ordered before the outage
› Options that can be ordered during the outage based on fact-findings and evaluations
› Variations as stated in Section 5. Variations can consist of:
› Extra works based on findings or unforeseen tasks, which can be based on a fixed price
or the Contractors hourly rates
› Refurbishment of used components, supply of new spare parts or machining of compo-
nents
› General supplies as stated in Section 6:
› Manpower
› Delivery of spare parts
› Delivery of tools
› Delivery of consumables
› On-site and off-site transport
› Cleaning and blasting of components
› Perform NDT
› Documentation.
2.1 Unit and operating data
Turbine
Manufacturer : ABB Nürnberg
Type : V32H
Serial number : 19183
Power : 24 MW
Speed : 7500 rpm
Steam pressure : 64 bar (re-admission steam: 4,5 bar)
Steam temperature : 485˚C (re-admission steam 300°C)
Condenser pressure : HEIKO I: 0,39 barA and HEIKO II: 0,65 barA.
The turbine has four blade carriers:
› Blade carrier 1: 10 rows
› Blade carrier 2: 9 rowsTECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 5
› Blade carrier 3: 4 rows
› Blade carrier 4: 1 row.
Fig. 2.1.1 Longitudinal section of steam turbine.
It is expected that the unit will reach approximately 110000 operating hours and 5000 starts at
the outage 2021.
Reduction gear
Manufacturer : Flender-Graffenstaden
Type : IX80/5C no. 4798
Speed : 7500/1500 rpm
2.2 Maintenance history
The maintenance history of the turbine and gear is documented in reports and protocols.
OH Starts
Year Activity
approx. approx.
1995- 0 0 Turbine was commissioned in December 95, but had severe
1996 problems on vibrations and rotor rubbing during run down
and cooldown
2002 In 2002 was problems with the thrust bearing temperatures
and it was discovered, that the HP pipe connection was able
to move the turbine horizontally
2009 In 2009 the gearbox was overhauled
2011- 60300 3200 The 2011 major overhaul of turbine showed problems on
2012 oval balancing piston carrier and bolts had to be cut. The
turbine flanges was checked against deformation by blue
print and a guide (straightedge), but only across, not in the
axial direction from end to end / longitudinally. This was
clearly a mistake, and the turbine flanges were leaking. TheTECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 6
turbine bolts were retightened, but it did not solve the leak.
Turbine was opened again in 2012 to solve the leakage by
soldering. The problem was caused by the load gradients
from original commissioning
2016 In 2016 the turbine was fitted with electrical stand-by
heating for faster start up and less stress on the flanges to
limited the time for the steam turbine to reach full load.
See Appendix I for a more detailed maintenance history.
2.3 Health, Safety and Environment (HSE)
The Contractor shall ensure that all the safety and health requirements laid down by the Danish
Working Environment Authority (Arbejdstilsynet) are respected and certificates are approved in
due time before start-up on site.
The Contractor shall comply with the HSE requirements in Appendix H.
The Contractor shall prepare a Workplace Assessment (WPA) including a risk assessment for the
job. The WPA shall be sent to SV no later than six (6) weeks before starting up at the site.
The Contractor provides MSDS (Material Safety Data Sheet) on all chemical substances and
materials, which are needed for the completion of the works. The MSDS’s must be sent to SV not
later than four (4) weeks before start-up on the site. All chemicals and materials must be
removed after the overhaul by the Contractor.
2.4 Quality Assurance
As part of the final quality assurance plan (QA) Inspection & Test Plan (ITP) all information
points, hold points and witness points should be agreed with SV and it must cover all stages of
the Scope of Supply.
The Contractor and SV must jointly perform an acceptance control of spare parts when they
arrive to the power plant.
All activities in the QA/ITP must be documented. Such documentation must always be updated
and available for SV. The requirement for quality plans shall also apply for Sub-suppliers of
substantial parts.
SV shall be entitled to inspect the Contractor’s quality system and the Contractor shall provide SV
with the required assistance.
The Contractor shall inform SV immediately in writing, in case a measurement is out of tolerance
(a non-conformance report).
SV has the rights to visit workshops or other facilities of the Contractor or Sub-contractor(s) and
attend any step in the manufacturing/refurbishment process or any measurement/quality control.
All visits will be by prior agreement with the Contractor.TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 7
2.5 Timeframe and scheduling
SV must be informed immediately in writing, if the Contractor at any time during the planning or
execution phase finds any actual or expected deviations from the time schedule.
If, during the project period, SV requests to introduce changes to the time schedule, the
Contractor shall actively cooperate to organize and plan the required changes to the time
schedule to avoid unnecessary delays.
The outage is planned to start in week 23, 2021; however, it needs to be confirmed by SV. SV
reserves the right to postponement or change of the overhaul start time.
Deliveries to the power plant must be clarified with SV and must always be done within normal
opening hours.
3 Basic Scope of Supply
The Basic Scope of Supply must include, but not be limited to, the deliveries and services
described in the following subsections.
General supplies specified in Section 6 are all included in the Basic Scope of Supply when
relevant.
The Contractor has no liability for parts delivered by SV, only for the correct installation of such
parts.
Should the Contractor find it necessary to cut one or more pipelines, it rests with the Contractor
to re-establish these pipelines and produce documentation for implementation, control and
approval of the work. Cutting of any pipeline requires the approval of SV.
3.1 Planning of the overhaul
› 2 project meetings on site before the overhaul by the Project Manager in order to prepare
the overhaul in detail
› A site visit before the overhaul by the Project Manager and the Site Manager to prepare the
overhaul (inspect available spare parts, lifting equipment, site facilities, discuss time
schedule and other practicalities). The site visit could be part of the first project meeting
› A de-commissioning engineer must be available on site for making necessary records such as
pre-outage tests, check of rotor run out, oil pressure records, bearing temperature etc. when
the plant it shut down and the turbine runs down (date to be agreed later).
3.2 Disassembly of turbine and gear
› Disconnect and removal of all relevant cabling and instrumentation
› Remove all auxiliaries, valves, pipes, hoses, covers etc. to gain necessary access and cut
small drain-pipes if required. Before removal of HP- and LP-inlet pipes the off-set of flanges
must be checked and recorded
› Remove turning gear
› Opening of the bearing covers, coupling covers and gear cover
› Check and NDT of all couplings (because of many starts)
› Opening of all couplings and perform alignment measurements for the complete shaft line
(including gear/generator)TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 8
› Opening and removal of all turbine and gear bearings
› Remove turbine stop valve and control valve
› Loosen outer split line bolts and remove turbine top casing
› Loosen inner split line bolts and remove all upper parts (blade carriers, balance piston no. 1
(inner gland), balance piston no. 2 etc.)
› Remove top gland bushes
› Measure all radial and axial clearances (rotor and stator blades, sealing segments, sealing
strips etc.), including bumping point/"axial float
› Lift out turbine rotor and remove all lower parts like blade carriers, balance piston no. 1
(inner gland), balance piston no. 2, steam glands etc. from the lower casing
› Check foundation bolts for turbine and reduction gear
› Remove all sealing elements and oil deflectors.
During the dissambly of the turbine SV must be granted access to:
› Take test samples of the deposits at the blade airfoils in order to examine the salt contents
per row before cleaning
› Perform inspections of the outlets (for the district heaters)
› Perform inspections of the inlet for the secondary steam
› Holding points for this SV activities must be included in the Contractor's time schedule.
An initial (visual) fact-finding must be performed on-site before any parts are being shipped for
overhaul in a workshop.
It is very important for SV that the the initial fact finding, and identification of necessary repairs
and replacements are finalized as early as possible. Therefore, disassembly works must be
finalised as soon as possible.
3.3 Bearings for turbine and reduction gear
› General cleaning externally and internally
› Visual inspection of bearings, including pedestals, - keys and shims
› Perform PT of white metal (Babbitt), and UT to check bonding according to DIN/ISO 4386-
1:2019 or similar standard. Replacement of Babbitt parts depends on inspection results;
reference is made to section 4 Options
› Check of the bearing clearances (before and after)
› Check bearing electrical insulation
› Check bearing shaft seals and clearances (before and after).
3.4 Turbine outer casing and blade carriers
› General cleaning of outer casing including carefully preparation for NDT by hand cleaning at
the grooves for the blade carriers, balance pistons and steam glands and other critical areas
› 100% blast cleaning of all blade carriers
› Visual inspection of all parts for cracks, rubbing, scaling, erosion, corrosion etc.
› Perform NDT (according to detailed NDT plan provided by Contractor) as a minimum 100%
at blades and areas with smaller radius/transitions, high loads and other critical places
› Check of turbine casing and blade carriers for roundness, dimensions etc. In case of
transport to a workshop must this be perform before shipment
› Check the joint faces of the outer casings and blade carriers for erosion and steam leakage
and verify it by blue print. The blue dye print must be performed as soon as possible during
the disassembly process. The Contractor must perform necessary scraping/polishing by hand
of the split line flanges to have clean surfaces. It must be with close attention to the frontTECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 9
part where the casing has been deformed. If repair or machining of a split line flange is
performed must it be verified by a blue dye check test (cost for repair/machining and extra
blue dye check is not part of the Basic Scope of Supply, but must be carried out as extra
work/Variation)
› Inspection of flange bolts including cleaning by blasting, NDT and length measurement. The
loosening of the bolts must be made according to bolt design, and provision of all equipment
needed for loosening of the bolts is included in the Basic Scope of Supply
› Perform test to verify that the blades are correctly fixed and secured
› Check of supports for lower parts (axial and lateral keys), sliding ability of DEVA plates,
condition of guide wedge, clearances etc. (see Appendix I for pictures).
3.5 Balance pistons and steam glands
› General cleaning
› 100% blast cleaning of all parts
› Visual inspection of all parts for cracks, rubbing, scaling, erosion, corrosion etc.
› Perform NDT (according to detailed NDT plan provided by Contractor)
› Check for roundness, dimensions etc.
› Check the joint faces for erosion and steam leakage and verify it by blue dye check. The
Contractor must perform necessary scraping/polishing by hand of the split line flanges to
have clean surfaces. If repair or machining of a split line flange is performed must it be
verified by a blue dye check test (cost for repair/machining and extra blue dye check is not
part of the Basic Scope of Supply but must be carried out as extra work/Variation).
3.6 Turbine rotor
› Check the condition of the rotor sealing strips
› Cleaning of complete rotor (by blasting). Unless seal strips are deemed too worn or damaged
at the initial visual inspection, they must be covered to avoid being damaged during blasting
› Visual examination of all surfaces (including shaft journals, rotor blades, shrouds, wires and
locking pieces)
› Perform NDT at the coupling holes, shaft journals, rotor blades, areas with smaller radius
and transitions and other critical places.
› Check and document the size, distribution and condition of balancing weights
› Measure rotor straightness
› Check magnectic and electrical run-out in areas with induction sensors
› Check wheel for speed sensors
› Check and document rotor blade off-set
› Perform test to verify that the blades are correctly fixed and secured (klang-test)
› Transport of rotor on-site and off-site including delivery of transport stands (the rotor
transport support frame must be verified and approved for the purpose by the Contractor's
insurance company. The relevant documentation must be made available for SV upon
request).
3.7 Main oil pump
› Dismantle main oil pump
› Assembly and alignment of main oil pump and checking of lube oil pressure and flow
› Test of function.
No overhaul of main oil pumps is part of the basic scope of supply.TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 10
3.8 Turbine valves
Major overhaul of HP Emergency Shutdown Valve (HP ESV, which includes the control device) and
HP Control Valves (HP CV), LP Emergency Shutdown Valve (LP ESV) and LP Control Valves (LP
CV) including blue dye check of seats and flanges.
Removal of control valve seats is only due if they are found unfit for further, long-term operation.
› Dismantle and open actuators and clean all parts. Delivery and exchange of all soft materials
and internal springs in the actuators are parts of the basic scope of supply
› Dismantle and open both 2 out of 3 trip blocks, clean all parts. Delivery and exchange of all
soft materials
› Visual inspection of the casings for cracks and erosion (hand cleaning and thorough visual
inspection of the complete inside)
› Clean and check steam strainer
› Blast cleaning of all internal components and bolts
› Perform NDT inspection inside and, if needed, outside (according to the NDT plan provided
by the Contractor),
› Visual inspection of internal components (valve seats, valve heads, spindles, bushings,
sealings etc.) for cracks, deformity and erosion and wear
› Perform NDT of all internal components (valve seats, valve heads, spindles, bushings,
sealings, strainer etc.)
› Inspection of all the spindles for wear/erosion and measure deformity
› Check of the bushings and seats for rubbing/wear
› Verify flanges and valve seats/heads by blue print. Light machining by hand is part of the
scope
› Assembly of both 2 out of 3 trip blocks and actuators, adjustment and functional test
› Check clearances and tolerances
› Replacement of all consumables.
3.9 Major overhaul of reduction gear
Major overhaul of the reduction gear includes:
› Opening and disassembly of all auxiliaries, oil pipes, sensors, valves, covers etc. in order to
gain necessary access to all the internal gear parts
› Remove the bull gear and pinion gear from housing to inspect the parts
› Check and cleaning of all parts
› NDT all teeth for cracks and wear with penetrant
› UT of all teeth
› Check tooth contact pattern by dye check
› Check of backlash prior to disassembly and verification after reinstallation of gears
› Check shafts runout
› Check surface condition of journals
› Visually inspection and NDT of couplings
› Check pump drive coupling
› Check of SS coupling for turning gear.
› Move motor and coupling to a overhauled gear
› Coupling type and data for oil pump must be stated in the documentation
› Install new gaskets
› Assembly and test run (during commissioning).TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 11
3.10 Assembly of turbine and gear
› Install all lower parts, bearings, rotor, gear and coupling shaft. All needed shims, keys and
guiding elements for adjustment is part of the scope
› Measure all radial and axial clearances (rotor and stator blades, glands, balance piston,
sealing strips etc.)
› Assembly of turning gear and SS coupling
› Assembly of gland seals top part
› Place all upper parts and tighten split line bolts
› Place top outer casing and tighten split line bolts
› Proper surface contact shall be verified by blue-check where relevant, e.g. on bearing
saddles, covers, gear housings, casings, blade carriers, valve seats and flanges etc.
› Assembly of all bearings, couplings and covers
› Assembly of all auxiliaries, valves, pipes, hoses etc.
› Reinstallation and re-connection of all affected cabling and instrumentation
› Check operation of auxiliary equipment.
3.11 Alignment check
It lies with the Contractor to ensure the alignment of the entire shaft line (turbine, gear,
couplings, generator). The alignment check includes all necessary coupling measurements/checks
(run out, parallelism, concentricity, gab etc.).
Measurements must be checked during disassembly and verified during assembly.
Historically there has been some challenges with the gear alignment and destroyed pinion
bearings. A third party made a analysis in 2017 an concluded that the pinion shaft did not have a
parallel lifting movement. This issue need to be adressed during the alignment check (with special
focus on the many starts) and agreed with SV.
In case of alignment are found not covered by the Basic Scope of Supply, such works will be
charged as additional work.
The procedure to ensure the alignment is to be described by the Contractor and agreed with SV
prior to execution.
3.12 Commissioning
The Contractor is responsible for the re-commissioning of the turbine and gear after the overhaul
but SV will support with the operational staff, steam, oil, cooling water ect.
The Contractor shall prepare a commissioning program and time schedule that shall be presented
to SV for approval.
The following is as a minimum included:
› Cold commissioning
› Test of instrumentation
› Post outage tests and checks
› Valve curvesTECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 12
› Start up and test of oil systems
› Inspection and test of safety systems
› Run-down out test from of unit from turning operation.
Please note that it may not be possible to perform Hot commissioning immediately after the Cold
commissioning. It depends on the possibility of operation for district heat production.
› Hot commissioning
› Test of steam gland systems
› Tightness test of turbine valves
› Full speed no load
› Run-down test of unit from full speed
› Operating data recording
› General commissioning tests
› Electronic over speed test
› Synchronization
› Tests in different load points – decision of and performed by SV
› Vibration verification measurement (reference measurement prior to outage and
verification during commissioning)
› Balancing if needed (cost for balancing is not part of the Basic scope of Supply but will
be considered a Variation).
3.12.1 Vibration measurements
The vibration level must be measured during the hot commissioning.
The Contractor will get access to vibration data prior the overhaul from the I&C system and these
measurements are considered as base line.
The Contractor is responsible for performing the vibration measurements after the overhaul,
analyse the data and if measures are needed to bring the vibration level at an acceptable level a
on-site balancing may be required.
3.12.2 On-site balancing
An on-site balancing of the entire turbine shaft may be needed after the overhaul. It must be
guaranteed that the shaft and pedestal vibration level of the turbine set is acceptable during run
up, run-down and normal operation. Measurements from the I&C system will be used prior to and
after the overhaul. The measurements prior to the overhaul are considered as base lines.
The field balancing (if necessary) includes new weights and must result in vibration levels within
Zone B or better, according to ISO 10816 and ISO 7919 latest versions.
3.12.3 Tests and performance guarantees
Tests to verify the performance of the unit will be carried out before and after the overhaul.
These tests will determine whether the operational data (power, efficiency, vibration etc.) after
the overhaul of steam turbine are comparable to the operational data before the overhaul or
better.
SV may carry out a performance test and prove the turbine efficiency by using the operating
instruments prior to and after the overhaul at comparable load and operating conditions.TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 13
SV has the right to claim a compensation or a remedy (including re-opening of the steam turbine
if deemed relevant for a root-cause analysis) if the operational data are not comparable or better
after the overhaul. The Contractor will get access to all test results.
3.12.4 Handover
When the Supply is hot commissioned, and verification tests have been executed and the
performance is to SV’s satisfaction, the Contractor is entitled to request hand-over.
At the request of the Contractor, SV convenes a Hand-over Meeting where the Contractor and SV
in cooperation will inspect the Supply. When this inspection has been performed to SV’s full
satisfaction and a punch list has been produced with milestones for their remedy, the Supply will
be handed over to SV. This hand-over is conducted in writing and must be signed by project
managers from both parties.
Putting into service or using the supply fully or in part does not as such constitute approval of
hand-over.
4 Options
General supplies specified in Section 6 are all included in the optional scope of supply when
relevant.
4.1 New sealing strips for the rotor
The following must be included, as a minimum:
› Install rotor in the lathe
› Remove old sealing strips
› Clean sealing strip grooves
› Fabricate new sealing strips
› Install new sealing strips (caulking)
› Machine sealing strips to correct dimensions (height)
› Supply report included clearances, tolerances and findings.
The cost of new sealing strips is based on the following:
› A start-up cost for placing/preparing the rotor in lathe machine
› Prices per sealing strip to be replaced for:
› Between blades (total of 69)
› Balance piston I (information unavailable)
› Balance piston II (information unavailable)
› Front gland (information unavailable)
› Rear gland (information unavailable).TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 14
4.2 New sealing strips for stationary parts
The following must be included, as a minimum:
› Install blade carriers in machine
› Remove old sealing strips
› Clean sealing strip grooves
› Fabricate new sealing strips
› Install new sealing strips by stemming
› Machine sealing strips to correct dimensions
› Supply report included clearances, tolerances and findings.
The cost of new sealing strips is based on the following:
› A start-up cost for placing/preparing one blade carrier in vertical lathe machine
› Prices per sealing strip to be replaced for:
› Blade carrier 1 (total of 30)
› Blade carrier 2 (total of 27)
› Blade carrier 3 (total of 9).
4.3 New blades and replacement
Manufacturing and installation of the following new blades have been offered:
› Row 1 of rotor blades
› Row 19 of rotor blades (shrouded)
› Row 23 of rotor blades (free standing)
› Row 1 of stator blades
› Row 23 of stator blades.
The cost shall include removing old blades, delivery and installation of new blades (incl. shims,
keys, locks etc.), preparation of blade groove and machining shrouds to correct diameter.
If a row of rotating blades needs to be replaced option 4.4 High-speed balancing of turbine
rotor will be required by prior agreement.
4.4 High-speed balancing of turbine rotor
A high-speed balancing can be required in case replacement or repair works have been performed
on the rotating blades or the rotor itself. The minimum rotor work that will trigger the Contractors
requirement for a high-speed balancing is stated in the Tender.
The following must be included, as a minimum:
› Transport to balancing bunker
› Needed and approved transport frame/box
› Road transport permit (if applicable)
› Transport insurance
› Install rotor in bunkerTECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 15 › A balancing according to ISO 11342 and 1940-1 class G 2,5 › Perform over speed test to verify that the blades are still correctly fixed and secured › Remove rotor from bunker › Transport to site › Balancing report (the report must be in English). The scope shall include needed bearing(s) for the high-speed balancing. The Contractor shall inform SV if a slot for the high-speed balancing of the rotor must be booked up front to make sure that a bunker is available during the outage. 4.5 Machining of split line flange Due to experiences from previous overhauls truing of the outer casing horisontal split line flange is expected to be required in order to obtain sufficient tightness. A blue dye print and gap measurements must be obtained as early as possible during the dissassembly of the turbine to determine the exact (if any) need for machining of outer casing flange of the upper and/or lower part. Consequences for critical, internal surfaces must be observed, and eg. diameters for blade carrier supporting ribs must be dressed accordingly. Included in the option all required to perform correction of plane surfaces and diameters in order to restore the proper tightness of said surfaces. The price is according to the tender list and the following must be included, as a minimum: › Planning and engineering › Equipment for the mobile machining › All needed alignment, adjustment and machining › All needed manpower › All needed working environment measures to avoid noise, dust, etc. › Transport in case of shipment to a workshop and back to power plant. Machining of the outer casing split line flange is the base option and machining of inner diameters is extra options according to the tender list: › Machining of outer casing split line flange, both upper and lower parts › Price for machining of the first diameter › Price for machining of every additional diameter. 4.6 Turbine bearings Inspection, white metal condition and bonding check is included in the Basic Scope of Supply, outcome of this work determines if bearings are unfit for further, long-term operation and are to be replaced. Offer for re-babbitting of journal radial bearings (front and rear) and the axial bearing have been provided as a unit price per bearing.
TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 16 4.7 Gear Bearings Inspection, white metal condition and bonding check is included in the Basic Scope of Supply, outcome of this work determines if bearings are unfit for further, long-term operation and are to be replaced. Offer for re-babbitting of pinion and bull gear bearings have been provided as a unit price per bearing. 4.8 Transport of main components to workshop In case the Contractor plan to perform all works on site, prices for shipping any main components must be included as an option. The following must be included, as a minimum: › Transport to workshop and back to power plant › Supply of transport frame/box approved for transport › Road transport permit › Transport insurance. 4.9 Recommended spare parts or services Spare parts or services not mentioned in this Technical Specification should be recommended in case the Contractor finds them necessary to successfully complete the major overhaul of turbine and gear. Recommendations must include breakdown prices for all recommended parts and services. All recommended spare parts must hold a unique ID as well as delivery time. 5 Variations General supplies specified in Section 6 are all included in the variations when relevant. Refurbishment and repair of dismantled components and parts, and supply of new components not included in the Basic Scope of Supply or defined as options may be required and will be considered as extra work. Ordering of extra work can be based either on a fixed price offer from Contractor or on the Contractor's hourly rates depending on the nature of the work. Price sheet with the Contractor's hourly and daily rates for the relevant personnel shall be included in the tender and the rates must include travel time, travel cost, daily allowances, transport, PPE (Personal Protective Equipment) etc. For extra work carried out based on hourly rates the Contractor’s weekly timesheets must be approved by SV before the work can be invoiced.
TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 17
Any extra work or additional supply is to be agreed with SV in writing (a Variation). If a Variation
have not been signed by SV, then SV has the right to reject any cost related to the additional
supply or extra work claimed by the Contractor.
6 General supplies
6.1 Manpower
The work is to be organised, manned and supervised by the Contractor.
6.1.1 Project management
The Contractor must appoint a Project Manager with the required experience and competence to
oversee the project planning and execution who communicate efficiently in English or Danish.
The Contractor must participate in coordination meetings with SV and other Suppliers, as
required. One (1) weekly meeting during the outage must be expected.
6.1.2 Site personnel
The Contractor must estimate the need for staffing in his offer, and must as a minimum provide
the following personnel for the overhaul:
› 1 Site Manager who communicates efficiently in English or Danish
› 1 turbine Supervisor per shift
› All needed mechanical fitters. The Contractor shall provide enough manpower during the
overhaul, to ensure that it is finished according to the time schedule
› Certified crane drivers
› All needed assistance for cleaning
› Fact-finder
› NDT specialist(s) according to the NDT plan
› Balancing/vibration specialist available during start-up
› A Commissioning Engineer must be available at site during shut-down and start-up until the
plant is operating normally.
Project Manager do not need to be onsite during the complete overhaul. Access via e-mail or
phone is accepted.
The Site Manager can leave site in case all main parts have been shipped to a workshop.
The Basic Scope of Supply includes all travel and accommodations cost. Additional cost for extra
days on‐site to be informed and will be settled according to hourly rates.
Replacement of key personnel can only be done by prior agreement with SV.
6.1.3 HSE
It is required that the Contractor provides an HSE Coordinator during the overhaul, who can
communicate in Danish or English and has knowledge on the Danish working environment rules
and legislation.TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 18 The Contractor’s Site Manager, Supervisor and Shift Leaders must participate in safety evaluation and planning of the work to be performed. Furthermore, employees working on-site must be introduced to SV's HSE system. The Site Manager must attend health and safety meetings on-site when needed (minimum one per week). Duration approximated one (1) hour. Operator certificates to be acknowledged and approved by SV and the Danish authorities. It is required that the Contractor participates at a safety meeting in due time before the overhaul starts. 6.1.4 Commissioning, balancing and testing The Contractors’ Site Manager, Commissioning Engineer and at least two (2) fitters are to be present on site during the commissioning and the Contractor is responsible for the turbine operation until the end of commissioning and possible balancing. The Contractor is to specify and execute required inspections and tests on the turbines prior to and during the commissioning. A Balancing Specialist is to be standby during the first starts during the commissioning to perform vibration measurements and on-site balancing, if needed. The costs for a Commissioning Engineer at SV's site for two (2) days (plus travel time) and accommodation costs, are included in the Basic Scope of Supply. It also includes an extra travel for the Commissioning Engineer between cold and hot commissioning (it must be the same Commissioning Engineer for cold and hot commissioning). SV may accept that the cold commissioning is performed by the site manager, depending on his experience. Cost for additional days on site will be according to hourly rates for the personnel concerned. 6.2 Spare parts The Contractor has the full responsibility for the supply of spare parts and replacement works, and the acquisition of all necessary spare parts as well as handling of parts supplied from other suppliers if needed during the overhaul. New flange bolts must have rolled thread unless otherwise agreed and material should be stated and be compliant. SV has some spare parts available in stock to be used in connection with the turbine overhaul if needed and if possible. Main spare parts in stock are listed in Appendix F (Note: Condition of the spare parts need to be evaluated later and SV have several minor spare part at stock which can be used during the overhaul. A final overview need to be finalized in the planning phase together with the Contractor). Optional spare parts specified in Appendix E can be ordered before the outage or during the outage based on fact-findings and evaluations and possible recommendations. The following must be included in the price and delivery time, as a minimum: › Reverse engineering (if required) › Fabricate and deliver new spare parts to site › Remove the old parts › Install the new spare parts
TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 19
› Machine to correct dimensions if needed
› Test of function.
Upon delivery, spare parts shall be packed and preserved for long-term storage.
The packaging of individual parts shall be marked with the following information:
› Silkeborg Varme A/S
› Kejlstrup Tværvej 14, DK8600 Silkeborg
› Purchase order number and date
› Position number as per order or requisition
› Description
› Drawing number, position number, spare part number
› KKS number (if applicable)
› Contractor
› Name of SV contact person.
6.3 Tools
A tool container including hand tools is part of the Basic Scope of Supply. In addition, special
tools, lifting equipment, supports, rotor stands (also for transport if needed) must be included.
Tools for untightening and tightening of flange and coupling bolts are to be provided by the
Contractor, whether it is by induction, heating rods or hydraulic wrenches.
The large split line bolts are tightened with heating rods.
Prior to use during the overhaul all tools must be tested and approved in accordance with
relevant regulation. The approval certificates must be available to SV upon request.
6.4 Consumables
Ordinary consumables like gaskets, O-rings, rags, lubricants, chemicals, cleaning materials, small
bolts/pins/ nuts etc. are included in the Basic Scope of Supply. Typical specification for gaskets,
O-rings etc. used during overhauls should be mentioned in the offer.
All personal safety equipment are included in the scope.
6.5 On-site and off-site transport
The Basic Scope of Supply includes all on-site and off-site transportation and handling of parts.
› All needed on-site and off-site transport (to workshops) are included in the basic scope, also
for any option and for extra work
› The Contractor is solely responsible for the organization of the transport. All cost related to
the transportation shall be included in the offered prices. This includes, but is not limited to
transportation cost, packing, needed transport frame/box, road transport permit, insurance
coverage during transportation of equipment and parts etc.
› The transport company must be qualified to transport high value items
› All transports from and to site must be dedicated transports without reload/transfer
› All transports/shipping is DPU.TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 20
6.6 Cleaning and blasting
All cleaning by hand and blasting is part of the Basic Scope of Supply.
Component cleaning is to be performed by hand, blasting or whichever method required. The
extent of blast cleaning and method of the cleaning is described in the NDT plan provided by the
Contractor.
If the Contractor prefer to carry out the blasting on site, the provision of a blasting tent with
proper ventilation, all needed working environment measures (to avoid noise, dust, etc.) and
removal of used blasting material is part of the Basic Scope of Supply. The Contractor is
responsible for all cleaning after blasting.
Blasting equipment, blasting media and skilled personnel are provided by the Contractor. Disposal
of used blasting media must be agreed with SV.
SV will assign a location within the premises for erection of the blasting tent.
6.7 NDT
All components are to be inspected for wear and damages by NDT and evaluated accordingly.
All NDT activities included in the NDT plan prepared by the Contractor and agreed upon is part of
the Supply.
Based on (visual) fact-finding SV can ask the Contractor to perform additional NDT (Variation).
6.8 Documentation
The Contractor must thoroughly record all inspections, measurements, repairs, and materials for
each component inspected, refurbished or manufactured. All documents must be traceable for
each component.
SV have protocols from previous inspections.Templates for dimension check protocols and fact-
finding report are provided by the Contractor for SVs approval prior to the outage start. The
templates must be in accordance with the historic record sheets to facilitate the comparison with
the records of the 2021 overhaul.
6.8.1 Status reports
The Contractor must supply documentation for the status of the overhaul during the execution.
The status reports have to contain information regarding all field-service activities for parts sent
to the Contractor's workshop or elsewhere, and for parts staying on site.
As a minimum, the following is to be included:
› Daily updates from the Site Manager on ongoing activities on the site (short daily reports)
› Weekly status reports for all field-service activities on-site and off-site (Contractor's
workshop and Sub-Contractor's workshop).TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 21
6.8.2 Fact-finding report
Fact finding check list (to be discussed and delivered as soon as possible after inspection has
been completed) including statements with agreed actions and repair and a fulfilling description of
all works performed and recommendations given
The fact-finding report is an ongoing document that should be updated on regularly basis as
inspections are performed.
Minimum requirements for the fact-finding report:
› It has to be delivered as an open file with the possibilities to text search in in order easy to
find relevant information
› It must have bookmarks and Index for easy overview and navigation
› It must be divided into main groups (like rotor, outer casing, inner casing, bearings, steam
glands, etc.)
› There must be a column describing the component
› There must be a column with the findings and comment
› There must be a column with the Contractor recommendation, including cost and time
schedule if possible (or a statement why it isn't possible)
› There must be a column with the SV decision (performed or not)
› A statement if a measurement is out of tolerance
› A statement for not accepted NDT
› Pictures to see the fact finding.
Results from inspections are discussed on a daily basis, and major findings must be presented to
SV immediately upon discovery.
A preliminary fact-finding report has to be delivered as soon as possible after the inspection and
according to the agreed time schedule as would be discussed as part of a final fact finding
meeting.
It is of highest priority for SV to have an overview and follow the progress in the
overhaul, at all time.
6.8.3 Inspection report
The inspection report includes all visual inspection and NDT findings. As a minimum, the following
is to be included:
› Measurement of bolt lengths, as well as calculation for tightening and permanent stretch
› Measurements of all rotor-stator clearances before disassembly and after assembly
› Clearances at the bearings during disassembly and at assembly
› Measurements of rotor straightness
› Measurements of roundness/dimensions of casings, blades carriers, balance pistons, steam
glands etc
› Size and distribution of balance weights
› Result from inspection of rotor and stator blades, including NDT
› Check for steam leakages and contact surfaces at casings, bearing saddles, covers, housings
and end frames etc.
› Result from blue print of casing and other contact surfaces
› NDT reports of all relevant components (NDT plan, part of offer)
› Measurements of alignment at the couplings during disassembly and assembly.TECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 22
6.8.4 Final documentation
The final documentation is delivered in Danish or English in an electronic copy on a portable HD
drive. All documents of the final documentation should be one open PDF file with all reports
included. It should include bookmarks/index for an easy overview and navigation and divided into
main groups (like: Fact finding report, protocols, commissioning, new spare parts).
The Contractor must submit a draft of the table of contents where SV can get an overview of the
structure of the document before start of commissioning.
Drawings (if required) shall be delivered in .DWG or .DXF and .pdf.
All documents (reports, datasheets, protocols etc.) shall be delivered in latest versions of
Microsoft Office (Word, Excel, Project) or as open .pdf.
The identification system for Power Stations (KKS) must be used where applicable (delivery of
spare parts, fact findings, protocols).
The documentation must be submitted on a continuous basis and the final version must include
the following as a minimum:
Minimum requirements for the final documentation:
› It must be delivered as an open file with the possibilities to text search for relevant
information
› It must have bookmarks and index for easy overview and navigation
› It must be divided into main groups for the Field-service activities, like:
› NDT reports
› Fact-finding reports including statements with agreed actions and repairs
› All inspection reports
› Commissioning report
› Balancing report, if applicable
› All relevant pictures as electronic version (.jpg-format). As a minimum, the naming of the
photos used to for illustrations in the fact-finding report must include a reference to the fact-
finding report
› Manufacturing drawings and material certificates for all new components manufactured by
the Contractor or his sub-contractor.
7 Supply by SV
SV will be responsible for the following supplies and services:
› Removal and re-assembly of the turbine/gear noise screen
› Cover and marking of the turbine hall floor where relevant
› Removal and renewal of the turbine insulation is handled by SV or third party
› Scaffolding
› LOTO (lock out / tag out)
› Ensuring the double isolating shutting off live steam (witnessing and approval by the
Contractor)
› Execution of a performance test / recording parameters of the turbine set before and after
the overhaul of the turbine (if decided)
› Inspection of lubrication oil and hydraulic systems
› Changing of filters in lubrication oil and hydraulic systems
› Power outlet 1 x 230 VAC, 16 A and 3 x 400 VAC 16/63A CEE
› Pressurized air approx. 7 barTECHNICAL SPECIFICATION - 2021 MAJOR OVERHAUL OF ABB NÜRNBERG STEAM TURBINE 23
› Site facilities high-speed internet connection, sanitary facilities (shower facilities), locker
room, water (potable and service water).
› Access to SV’s workshop for the Contractor only by prior agreement
› Crane at site can be used (by Contractor's certified personnel only).You can also read
