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Seneca Overview & Generator Rewind

Asia-Pacific Partnership. on. Clean Development and Climate. Seneca Overview & Generator Rewind. Asia Pacific Partnership United States of America Power Generation Task Force August 13 – 17, 2007. Ron Kovach/Tom Groff. Seneca Overview. Seneca: Generator Rewind. 2.

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Seneca Overview & Generator Rewind

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  1. Asia-Pacific Partnership on Clean Development and Climate Seneca Overview & Generator Rewind Asia Pacific PartnershipUnited States of AmericaPower Generation Task ForceAugust 13 – 17, 2007 Ron Kovach/Tom Groff

  2. Seneca Overview Seneca: Generator Rewind 2

  3. Seneca – View of Upper Reservoir 1/2 mi. dia. 60 ft deep 800 ft above plant asphalt lined Seneca: Generator Rewind 3

  4. Seneca – View of Plant & Lower Reservoir Seneca: Generator Rewind 4

  5. Seneca Plant • Pumped Storage Facility • 3 Units – Unit 1 218MW; Unit 2 195 MW; Unit 3 30 MW • Role of Plant • Provide generation, regulation and spinning reserve duringon-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 Seneca: Generator Rewind 5

  6. Priorities • Safety • Environmental and Regulatory Compliance • Federal Energy Regulatory Commission (FERC) • Pennsylvania Department of Environmental Protection (PADEP) • Reliability • Cost effective operations Seneca: Generator Rewind 6

  7. Staffing • On-site staffing • 6 Operators / 3 Maintenance • 1 Administrative • 2 Management • Corporate Support • Engineering • Environmental • Administrative • IT • Legal • Other • Contract labor services Seneca: Generator Rewind 7

  8. 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 Seneca: Generator Rewind 8

  9. View of Pump/Turbine 9. Lower Guide Bearing 7. Wicket Gate Servomotor 8. Wicket Gate Operating Ring 10. Turbine Head Cover 17. Spherical Valve 12. Wicket Gate 11. Stay Ring 13. Runner 14. Spiral Case 15. Draft Tube Cone 16. Draft Tube Man Door Seneca: Generator Rewind 9

  10. Typical Spherical Valve(also called High Head Guard Valve) Seneca: Generator Rewind 10

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

  12. Significant Projects • Pump-Turbine Upgrades • Unit No. 1 – 1992 • Unit No. 2 – 1991 • Motor-generator rewinds • Unit No. 1 – 1971, 1985, 2006 • Unit No. 2 – 1977, 1981, 2007 • Unit No. 3 – original • Upper Reservoir side slope paving – 2000 Seneca: Generator Rewind 12

  13. Generating Operation UpperReservoir #1 218 MW #2 195 MW #3 30 MW 21'diameterpipe, 3200' long Motor/Generator 1 2 3 Pump/Turbine 1 2 3 #3 generates to Allegheny River only #1 generates to LowerReservoir only #2 can generate to Lower Res orriver Seneca: Generator Rewind 13

  14. Penstock Rendering • Unit No. 1 – 218MW • Unit No. 2 – 195MW • Unit No. 3 – 30MW Seneca: Generator Rewind 14

  15. Pumping Operation UpperReservoir #1 220 MW #2 220 MW #3 Does not pump - used for starting #1 & #2 1 2 3 1 2 3 Units 1 & 2 draw water from the Lower Reservoir Seneca: Generator Rewind 15

  16. Operation • Upgraded Pump-Turbines – Efficiency Gain • 3% Pumping • 5 % Generating • 700,000 + MWH Annual Generation • Equivalent Forced Outage Rate (EFOR) < 2% • High starting reliability • 8 minute generate starts • 30 minute pump starts Seneca: Generator Rewind 16

  17. (Black Start Reserve) Seneca: Generator Rewind 17

  18. Seneca: Generator Rewind 18

  19. Generator Rewind Seneca: Generator Rewind 19

  20. Decision to Rewind • Last rewind occurred 20 years ago • Tax Credit • Upgrade (8MW) • Extra copper – 7% • Coil replacement • End-of-life • Proactive • Partial Discharge (PD) / Corona • Rotor Pole refurbishment • Asbestos removal Seneca: Generator Rewind 20

  21. Generator Rewind • Unit #1 – Core Iron Continuous Restack • Unit #2 – Core Repairs • Loop test criteria max • 10°C Hot Spots • Repair techniques • Thin mica sheets, between laminations • Grind and electro-mechanical etching • New Air Coolers - #1 & #2 • Crane • Engineered lift Seneca: Generator Rewind 21

  22. Stator Lifting Beams • Bolted to Stator • Pinned to(2) crane hooks • Stator weighs232 tons Seneca: Generator Rewind 22

  23. Stator Lift over Unit #3 Seneca: Generator Rewind 23

  24. W Nameplate Info • 336 Coils Seneca: Generator Rewind 24

  25. Loop Test Cables • 16x3 Turns • 2400 Volts • 300/Loop Amps • Stator Iron in3 Sections • IR Camera tolook for hot spots • 10°C or lessacceptancecriteria Seneca: Generator Rewind 25

  26. Coil Wedges • Top view of slot wedges with ripple springs behind Seneca: Generator Rewind 26

  27. Brazing • Brazing done using anInduction Machine • 264 Series Joints • 50 Jumper Joints • 50 Phase Joints Seneca: Generator Rewind 27

  28. Pole Keys • 2 per Pole • 225 RPM • 32 Poles 1 Cycle 2 Poles 225 Revolutions 1 Minute 1 Minute 60 Seconds 32 Poles 1 Revolution ) ) ( ( ( ) ) ( = 60hz (Cycles/second) Seneca: Generator Rewind 28

  29. Pole ShipmentFixture • Bottom fixture rounded to allow horizontal placement Seneca: Generator Rewind 29

  30. Thrust Bearing Shoes • Thrust Bearing Shoes in place • Oil supply hoses installed Seneca: Generator Rewind 30

  31. Wear Pattern on Thrust Bearing Shoes • Removed from Unit #1 • Units No. 1 and No. 2 • 12 shoes each • Unit No. 3 • 8 shoes Seneca: Generator Rewind 31

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