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.
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.
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:
This project was installed within 12 days and involved the following steps:
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