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English V94.2 CCGT Power Plant – GT Exhaust Metal Bellow to Fabric Retrofit in Wales
The replacement and upgrade of the existing metallic expansion joint with another metal expansion joint would have required a full NDT, splicing in new section of bellow and extremely delicate welding. Alternatively, a fabric expansion joint retrofit boasted multiple advantages...
Barry Power Station is a 230 MW gas-fired power station eight miles west of the Welsh capital, Cardiff. This CCGT power station has one 160 MW Siemens V94.2 gas turbine feeding exhaust gas at 544°C to a Heat Recovery Steam Generator (HRSG). The generator on the gas turbine was rated at 180 MVA and had a terminal voltage of 15 kV; the steam turbine’s was 11 kV.
| Total Output: |
230 MW |
| Date Operational: | 1998 |
| Location: | Wales, UK |
| Primary Fuel: | Natural Gas |
Original: Standard Metallic Bellow
The OEM arrangement was a pre-stressed steel expansion joint, installed at the turbine outlet, to compensate for the thermal expansion between a V94.2 gas turbine and the diffuser.
Regular problems caused by this design:
- Cracking from the circumferential weld to top of convolution.
- Scuffing of internal liner plate.
- Damage to cladding and insulation.
Solution: DEKOMTE Fabric Expansion Joint
The replacement and upgrade of the existing metallic expansion joint with another metal expansion joint would have required a full NDT, splicing in new section of bellow and extremely delicate welding. Alternatively, a fabric expansion joint retrofit boasted multiple advantages, including:
- Individual adjustment and modular build-up of every bellow layer.
- Outstanding vibration dampening features.
- Low shipping and mounting expenditure and low net weight.
- No power transmission to duct connecting elements due to negligible low adjusting forces.
- Outstanding insulation possibilities through targeted thermodynamic design under consideration of heat transfer mechanisms.
| Operating Temperature: | 600°C |
| Movement: | Axial: +/-60mm Lateral: 3mm |
This project was installed within 12 days and involved the following steps:
- Removal of cladding, lagging, weather shield and existing metallic bellow.
- Modification of adjacent duct insulation support pins and welding of new frames externally on the diffuser.
- Installation of pinned internal insulation bolsters and gas-tight closing of fabric expansion joint. Finally, torque fixings and installation of adjacent external insulation.
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