Experience in Reconstructing the PT-60-90 Turbine by Reconditioning Heat Treatment of the High-Pressure Cylinder Shell

Abstract

Experience in reconstructing the PT-60-90 turbine at Salavatskaya CHPP upon the operation for more than 350000 h is described. In the course of reconstruction, the life of the turbine was restored, its economic efficiency was increased, process extraction of 1.27–1.57 MPa was changed to uncontrolled extraction, and additional extraction of 3.43 MPa was arranged. The high-pressure cylinder (HPC) shell was restored by reconditioning heat treatment (RHT), and the rotor was replaced by a new modernized one. To select the optimal conditions of the reconditioning heat treatment of the HPC shell (of the PT-60-90 turbine) manufactured from 20CrMoPL grade steel, the results of previously conducted tests of the shell metal of the same grade were integrated. The heat treatment was carried out on modernized furnace equipment using means of and methods for controlling the temperature and heating and cooling rates. Detailed nondestructive inspection of the upper and lower HPC halves was performed. The locations, distribution, sizes, and types of the defects were identified. The detected defects and austenitic build-ups were removed, welded with pearlite electrodes, examined, and subjected to heat treatment (tempering). The actual heat treatment conditions were analyzed and, based on the obtained data on the mechanical properties of the metal, the tempering temperature and time were specified. Complete investigation of the metal of both HPC halves was conducted prior to the reconditioning heat treatment. The reliability of the metal of the cylinder shell after RHT was evaluated by the mechanical properties, such as tensile strength, critical ductile-to-brittle transition temperature (crack resistance), and stress-rupture strength. It was established that, after RHT, the characteristics of the metal, such as yield strength, ultimate strength, elongation per unit length, contraction ratio, hardness, and impact toughness, significantly improved and, on the whole, the quality of the metal met the requirements of the normative documentation for newly manufactured castings. The heat resistance of the metal of the cylinder shell after RHT also increased, which can ensure the operation of the HPC shell for more than 200 000 h provided that the recommendations for regular inspections of its condition are followed.