exxonmobil baytown frame 6b recent work-list...

ExxonMobil Baytown Frame 6BRecent Worklist Items

Frame 6B User Group MeetingJune 6-9, 2011Greg Polasek

Baytown Cogen Vital Stats

• Located in Baytown, TX (about 25 miles east of Houston)• Supplies power & steam to Baytown Refinery &

Chemical Complex

• 3 PG-6541 Units• Commissioned in 1989• Base load, NG fuel, NOx steam injection• Between 175k – 182k fired hours

Baytown Olefins PlantRecent Work

• Fiber Optic Flame Detection

• Exhaust Plenum Replacement

• IGV LVDT Relocation

• HEPA Filtration

• Load Gear Issues

Before / After Installation

Service:

Hank MarsmanBridgewater NJ800-743-1433

Fiber Optic Scanner

BFI CFC3000UV1• Rated for temperatures up to 392°F, briefly to 572°F• Lengths up to 33 feet

Baytown Olefins PlantRecent Work

• Fiber Optic Flame Detection

• Exhaust Plenum Replacement

• IGV LVDT Relocation

• HEPA Filtration

• Load Gear Issues

Side / Side Comparison

400200

300150

300150

300150

200140

400200

550250

300300

All temperatures in degF.

Surface behind protective shield is 600 degF on original plenum. No

shield on new plenum

Service:

Fred CollinsworthTulsa OK918-274-2344

Frame 6B Exhaust Plenum

4-Piece Plenum• 2-piece box• Side Cover• Cowl• Expansion Joint• 18 Thermocouples

Baytown Olefins PlantRecent Work

• Fiber Optic Flame Detection

• Exhaust Plenum Replacement

• IGV LVDT Relocation

• HEPA Filtration

• Load Gear Issues

Service:

Pete YoderOil Quip225-751-9838

LVDT Relocation

• 3 x LVDT – medium select• Linear bearing guidance to maintain LVDT alignment of core to

housing• Improved IGV calibration (scheduling)

Baytown Olefins PlantRecent Work

• Fiber Optic Flame Detection

• Exhaust Plenum Replacement

• IGV LVDT Relocation

• HEPA Filtration

• Load Gear Issues

SGT-02 GORE Filtration Results

20

22

24

26

28

30

32

34

36

Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11

MW

86.0%

87.0%

88.0%

89.0%

90.0%

91.0%

92.0%

93.0%

94.0%

95.0%

96.0%

Eff

icie

ncy

2008 MW 2009 MW 2010 MW 2008 Eff 2009 Eff 2010 Eff Linear (2010 Eff)Linear (2009 Eff) Linear (2008 Eff) Linear (2008 MW) Linear (2009 MW) Linear (2010 MW)

Service:

Steve Medvetz

410-506-3323

Inlet Filtration

GORE H12 HEPA Filtration since 2009• Consistent performance increase of 1.5 MW-hr on Ave• Steady MW-hr production throughout entire 12 month operation• Filters replaced annually, exploring options of increasing duration• Installed in all 3 F6B machines at BOP• Do I even need to crankwash annually anymore ? ? ?

Baytown Olefins PlantRecent Work

• Fiber Optic Flame Detection

• Exhaust Plenum Replacement

• IGV LVDT Relocation

• HEPA Filtration

• Load Gear Issues

SGT-01 Major Inspection

• Scheduled gearbox overhaul

• No issues found, reused all components

• Found high shaft movement & velocity

SGT-01 – Gearbox RCFA

• 19 Possible Root Causes – Shaft rub on laby seals (oil seals) ?– Bearings pinched (crush) ?– Looseness (bolts, bearings) ?

• Checks on Reassembly (clean housings)– Bearing ID (installed without rotors)– Seal ID’s, Rotor OD’s

SGT-01 – Disassembly

• Splitline sealant – Black RTV, as prescribed by Philly– Questioned specific QC around application

• Saw blade used to apply• Spread evenly• Experience within GE & Philly

SGT-02 Annual Inspection

• Standard visual NDE thru inspection door

• Wear found at root & tips on blind side of pinion

• No vibration problems found, continue to monitor