LCC Quick Notes, Steam Turbine Controls Modernization Task Steps


    Projects to modernize steam turbine controls have a natural progression of tasks which need timely completion to enable a desired completion in time for an outage installation.  We are often asked what lead times are for "typical" system orders.  Although there really is no "typical" order, this Quick Notes presents a task time estimate which is good for planning.

 

Task Set #1, Purchaser/Vendor Determine the Scope of the Retrofit

◘    DURATION:    About two to three months.

◘    PURPOSE:    Define what turbine control functions are to be assumed by the new system and what functions will be retained under existing components.

◘    METHOD:      Discussions with Plant Management, Operators, and System Engineers, and Vendors.  Reviews of maintenance histories.

◘    QUESTIONS TO RESOLVE:

        ◘    Include New Governor Valve Operators?

        ◘    Include New Stop Valve Operators?

        ◘    Include Simplex, Duty/Standby, or 2-of-3 Auctioned Digital Governors?

        ◘    Include New Speed Wheel and Speed Probes?

        ◘    Include DCS Interface?

        ◘    Include Operator Control Stations?

        ◘    What Power Feeds are Available?  Are they to be Redundant?

        ◘    What ASME, IEEE, ANSI Specifications should be applied?

        ◘    What are the EMI/RFI Qualifications?

        ◘    What sort of Factory Acceptance Testing is needed?

        ◘    Who will provide Installation Craft Labor?

        ◘    What sort of Engineering Technical Direction help is needed for Installation and Startup.

        ◘    Is a formal Operator Training Course needed?

        ◘    Is a formal Instrument & Control Technician Training Course needed?

        ◘    Is a formal Mechanical Maintenance Training Course needed?

        ◘    What Spare Parts should be included?

ELAPSED TIME:    3 MONTHS

 

Task Set #2,  Purchaser Submits Specification to Vendors

◘    DURATION:    About two months should be provided for vendor bid response.  Shorter time periods are common, but force vendors to estimate more cost details.

◘    PURPOSE:    Obtain bids to Specification.

◘    METHOD:      Qualify vendors first...  It is a very poor business practice to request a bid from a company that you have no intention of using.

ELAPSED TIME:    5 MONTHS

 

Task Set #3, Purchaser Bid Review and Award

◘    DURATION:    About one month.

◘    PURPOSE:    Select Vendor.

◘    METHOD:      Price with Quality and meeting specification.

ELAPSED TIME:    6 MONTHS

 

Task Set #4,  Vendor Provides Construction Drawing Set

◘    DURATION:    About one month.

◘    PURPOSE:    Drawings provided for Purchaser Review prior to manufacturing and assembly. If no dispositions are to be determined, skip this task.

◘    METHOD:      Manufacturing Outline Drawings, Installation Drawings, Field Wiring Diagrams Provided.

ELAPSED TIME:    7 MONTHS

 

Task Set #5, Purchaser Construction Drawing Approvals

◘    DURATION:    About one month.

◘    PURPOSE:    Drawings provided for Purchaser Review prior to manufacturing and assembly. If no dispositions are to be determined, skip this task.

◘    METHOD:      Purchaser utilizes in-house or consultant reviews of drawings to approve manufacture.

ELAPSED TIME:    8 MONTHS

 

Task Set #6, Vendor Equipment Manufacture, Assembly

◘    DURATION:    6 months typical.

◘    PURPOSE:    Full system manufacture and assembly.  Instruction Manual Publication.

ELAPSED TIME:    14 MONTHS

 

Task Set #7, Factory Acceptance Test (If so specified)

◘    DURATION:    About one month.

◘    PURPOSE:    A full, live equipment simulated closed-loop test of the new system including actuator loading and speed feedback when applicable.

◘    METHOD:      Formal line-by-line test observation sign offs.

ELAPSED TIME:    15 MONTHS

 

Task Set #8,  Vendor Packaging and Shipment

◘    DURATION:    About two weeks

◘    PURPOSE:    Appropriate packaging for shipment of all system components, spare parts, and final documentation issue.

 

ELAPSED TIME:    15-1/2 MONTHS

 

Summary

Given the task progression above, a major turbine controls project can be installed sixteen (16) months from conception and ten (10) months from contract award.

 

 

 

 

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