900 MW CP1 nuclear steam turbine retrofit thermal effects on low pressure diaphragms

The steam turbines of the Koeberg units 1 and 2 operated by ESKOM in South Africa have been retrofitted in order to mitigate the generic problems of stress corrosion cracking of the original shrunk-on disk rotor design. As already done in Belgium and France, the implementation of welded rotors improves the turbine reliability and availability. Moreover, the new technology implemented associated with a new steam path allows a significant performance improvement. With a wealth of experience in CP1 retrofit, ALSTOM has put in place new technical features in the steam path in order to further improve the heat rate. Among them, steam balance holes drilled in the rotor disks have exacerbated the thermal sensitivity of the LP diaphragms. During the commissioning of the Unit 1 LP turbines following the retrofit, the load increase led to unacceptable vibrations. An investigation program was launched to determine the root causes of the problem. This paper presents the findings following the turbine inspection, as well as the recommendations and modifications to allow a smooth return to service of the unit. In addition, the results of the root cause analysis of the vibration incident are explained. Based on finite element calculations and site measurements, ALSTOM has established that the diaphragm thermal behavior, intensified by the steam balance holes, has led to radial rubbing. It was also established that the phenomena had no effect on the diaphragms mechanical integrity. Design changes have been proposed to ensure a safe and reliable long term operation of the units. These modifications have been successfully implemented onto the Koeberg Unit 2 Nuclear Steam Turbine commissioned in November 2012. (authors)