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Case studies

Laser tracker - real time thermal analysis

The 13 MW steam units were installed around 2003 and have never been able to operate at capacity. EthosEnergy properly aligned them using real time thermal analysis, allowing them to operate at peak efficiency.

Goals
  • Increase Power Output
  • Increase Steam Production
Sectors
  • Power generation
Asset
  • Steam turbines
  • Generators
  • Field services
Location
USA, North America
Laser tracker - real time thermal analysis

Project Overview

The 13 MW steam turbine units were installed around 2003 and have never been able to operate at capacity. High vibration limited the generator output and caused the unit to trip or shutdown due to shaft misalignment. Several vendors including the OEM had attempted to improve the running condition of the units and in one case damage was caused resulting in a major overhaul of one of the turbine and generator sets.

Key Challenges

(3) 13 MW steam turbines with vibration significantly limited the generator output. This was caused due to the turbine moving in an unpredictable direction during the start-up and generator loading procedure.

The unit would operate at full speed but as the generator output was increased vibrations due to shaft misalignment would increase and trip the unit.

The thermal growth of the turbine and align the shafts, was operated at a less than optimal (in some cases 50%) condition.

Outcome

The units were properly aligned using real time thermal analysis allowing them to operate at peak efficiency. Not only was there a vast improvement in performance but the reliability also improved. This plant primarily provides steam to the University campus so the ability to start, regulate and shutdown the units without thermal issues is critical. Power generation is a secondary function of this facility but has a large impact on the amount of power purchased.

Project Highlights

The units that have undergone our Real Time Thermal
Analysis were properly aligned allowing them to
operate at peak efficiency. Not only was there a vast
performance improvement, but the reliability also
enhanced. 

 

Acquiring accurate data

To ensure proper alignment and achieve optimal machinery performance

The laser tracker captures X, Y, Z data

This gives the customer a full understanding of the movement of machinery from end to end and top to bottom

Customer Confidence

The ability to measure multiple points at various locations to ensure repeatability and customer confidence

WATCH: About laser tracking metrology

About our unique in-house metrology service utilizing the Leica AT960 laser tracker

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