Retrofits and power uprates can be economical solutions to improve
performance and electrical output; however, there are many technical
challenges which must be managed to ensure a successful turbine and
generator design, manufacturing process, and installation. ENTRUST is unique
in that we have over 15 former turbine and generator OEM engineers on staff
– covering design, manufacturing, and field engineering. The ENTRUST team is
supplemented by former Utility engineers, who have successfully managed
similar uprate and retrofit projects, as well as our operations, analytical
and training staff.
ENTRUST has the OEM, utility, and consulting experience to develop robust
specifications which includes lessons learned and best practices from dozens
of similar retrofit and uprate projects. Proposals can also be reviewed for
technical merit and offerings.
ENTRUST routinely provides structured engineering design reviews of new and
retrofit units. This allows for detailed vetting of long-term reliability
and performance of proposed designs at a time when changes can still be
incorporated. This process typically leads to multiple design enhancements.
ENTRUST has a large staff of former OEM engineers who can help oversee the
quality of the manufacturing process. This starts with support negotiating
witness points with the OEM and can include in process checks from initial
forging inspections at sub-suppliers through final acceptance testing of the
purchased hardware.
ENTRUST has decades of experience in power plant performance testing and
guarantee conditions. This typically includes review of performance
acceptance test procedures, correction curves, 3rd party evaluation of
acceptance test data and performance improvement recommendations.
System torsional frequencies are impacted by changing of the turbine(s)
and/or generator. ENTRUST can complete independent torsional frequency
modeling and torsional testing if analysis frequencies are inside the ISO
avoidance zones.
All projects of the magnitude of a retrofit/uprate will have manufacturing
non-conformances. ENTRUST can quickly inform you on the risks and
recommended path forward. When needed, ENTRUST can provide OEM level FEA and
engineering analysis work to assess risk levels of observed conditions.
ENTRUST has the experience planning major maintenance, including timing,
budgets, and contingency items. Outage planning support can include
preoutage unit condition assessment, service bulletin review, bid
specification development, participation in pre-outage meetings, and shop/
vendor vetting.
Retrofit designs often include new technologies which can introduce
additional risks or uncertainty, which ultimately can impact insurance
premiums. ENTRUST can provide a review of the design and technical
considerations, as well as mitigating strategies to help manage insurance
risks.
ENTRUST has the OEM, utility, and consulting experience to assess retained
equipment to ensure compatibility, and the condition supports continued use.
ENTRUST has experience providing on-site retrofit installation oversite and
commissioning service, both from a field engineering and project management
standpoint.
ENTRUST offers both engineering and operator/ maintenance technician
training customized to your site and powerplant equipment
ENTRUST provides a complete set of testing and modeling services for
generator control and projection systems and the required documentation to
satisfy NERC compliance requirements for MOD025, MOD-026, MOD-027, PRC-019,
PRC-024, PRC-025, PRC-026, PRC-027, VAR-501-WECC, and other regional/ISO
specific requirements.
ENTRUST can provide a review of the excitation system ratings, auto-voltage
regulator tuning, limiter/ protection settings, and power system stabilizer
tuning in support of an uprate. This includes decades of experience
associated with excitation control retrofits, commissioning, and tuning of
nearly all OEMs and prime mover types.
ENTRUST also offers outage based in-the-loop testing of excitation and power
system stabilizer controls to ensure proper dynamic performance of the
closed-loop controls at new higher power levels prior to bringing the unit
online. This includes both site and factory acceptance testing support.
ENTRUST performs analysis to determine the reactive power capability range
of the generator based on the generator and step-up transformer ratings,
transformer tap settings, and system voltage conditions. This information is
often required by system operators in association with an uprate.
ENTRUST offers modeling and simulation study services associated with
uprates and retrofits. This includes control system tuning and dynamic
response studies and providing preliminary models for submission to the
system operator for approval.
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