Retrofitting & Modernisation - Bilfinger Piping Technologies GmbH

Retrofitting & Modernisationof pipe and pressure components in thermal power stationsRange of servicesConventional power stations have to compensate for theunsteady supply of renewable energies. This means more andmore start-up and shut-down processes with extreme stresson power station components – intensified further by theever-increasing outputs that must be readily available.Existing power stations are not designed for this mode ofoperation with extreme load changes, leading to early materialfatigue and therefore to shorter-than-planned power stationlifecycles.The complex tasks to retrofit and modernise power stations areundertaken by BHR as an all-round expert partner. The“Retrofitting & Modernisation“ team provide a comprehensiverange of services. Analysing, testing, retrofitting/modernising– from the first recording of the actual state through torecommissioning. For example: Analysing the level of fatigue,technical calculation and checking the piping systems on site,replacing single highly strained components such as mouldedbodies, bends and headers, or the replacement of entire steampipe systems.All this work has been undertaken by BHR specialists successfullymany times both at home and abroad. The replacementcomponents can be produced to a large scale at the shops inEssen and Dortmund, Germany. The production scale is limitedonly by transport and stipulated plant conditions.AnalysingComparing the design calculation with today's state of the artSystem analysis (elasticity calculation) to determine thedemands on pipe systems and the stress on adjacentcomponentsCalculating the creep fatigue based on operating instructionsAnalysing load change processes such as start-up andshut-down, cold starts, warm starts, etcEvaluating the remaining lifetime in accordance withDIN EN 12952Analysing tension for pipe components such as headers,T-pieces, Y-pieces, also using fenite element method2

TestingDetermining the material’s actual status usingnon-destructive testing methodsRecording the microstructure status using ambulantcomponent metallographyChecking the pipe components using elongationmeasurementChecking the geometry and motion characteristics of thepipes using actual state recordings in a cold and warm stateTesting of pipe system’s slopesChecking the hanger functionality using actual staterecordings in a cold and warm stateRetrofitting/ModernisingCreating a catalogue of measures based on the analysis resultsEstablishing retrofit measures in collaboration withoperatorsPlanning the retrofitting process with the dismantling ofworn-out and the fitting of new pipe componentsConstructive checking of the pipe systems and theiroptimisation in comparison to the latest state of the artReplacing pipe components with new, state-of-the-artmaterials to improve start-up and shut-down ratesOngoing documenting of the pipe systems with planning forfurther material testingEstablishing the actual status of the pipes on-site anddetermining the actual operating data during the entireoperating periodChecking the valves3

AnalysingTo upgrade power stations to the latest state of the art, BHRprovides comprehensive and in-depth analyses. Being theredetermining design characteristics and the actual modeof operation and matching them with new technologies.This develops and implements an optimised and efficientmodernisation in collaboration with the customer.Matching the original design with today'sstate of the artIt makes sense to check the original design of the componentsdue to the changeover from national regulations such as DINand TRD to European DIN EN regulations. This process alsoincorporates relevant results from research and developmentprojects. This enables weakness to be discovered which maybecome a problem with changed parameters in future operation.System analysisThe result of flexibility analysis is data on the tension anddeformation in the pipe system. This also enables stress onadjacent components such as the boiler, turbines and condenserto be determined and evaluated for their admissibility.The use of conventional, numerical calculation proceduresallows the dynamic requirements to be specially evaluatedin much greater detail, eg as a result of a quick-action turbine,than was possible at the time that older plants wereconstructed.Tension analysisTension analyses reveal which components in a pipe system areunder the greatest stress. Detailed tension analyses, if necessaryusing finite element methods, provide information about thescale and distribution of the tension.Calculating the level of fatigueA calculation of the level of fatigue and remaining lifetimeis required for components under a great deal of stress. Thisinvolves analysing the two phenomena of creep fatigue andload change fatigue. As the calculated level of fatigue andremaining lifetime are theoretical values which are influencedby many factors, a verification using non-destructive testingmethods is essential.BHR's extensive experience in power station technologyis an ideal basis for maintaining and optimising powerplants.State-of-the-art technologyGreater operating safetyTimely and efficient service provision4

Retrofitting/ModernisingBHR provides the complete spectrum of services for retrofittingand modernising pipe systems. After analysing and testing, adecision is made with the operator about whether high-stresscomponents should only be retrofitted or if the entire pipesystem should be replaced and modernised, taking efficiencyand planned downtimes into account.The analysing, re-adjusting and, if necessary, replacement ofconstant and spring hangers is undertaken by BHR specialists.They also test valves for corrosion damage and leakages. Anysuch defects are repaired on site if possible.BHR’s own shops provide most of the prefabrication of the components.This shortens on-site working times and means plantsare up and running again more quickly. BHR has been activelyresearching and developing for years, and worked on theEuropean standard (DIN EN 13480) as well as on enhancing andissuing important VGB and FDBR factsheets. This means thatBHR is always ready to adapt to innovations quickly and alwaysworks with state-of-the-art technology.6

Use of moulded bodies with optimised geometry with regardsto tension distributions in components and the flawlesstesting of buttweldsUse of moulded bodies made from suitable materials toreduce start-up and shut-down timesPlanning the retrofitting and modernising with thedismantling of worn-out and the fitting of new pipecomponentsAnalysing and re-adjusting/replacing constant and springhangersAdvantagesLonger lifetimeGreater operating safetyLower maintenanceIncrease in performanceIncrease in efficiencyLower emissionsAnalysing and retrofitting valves7

BHR Hochdruck-Rohrleitungsbau GmbHWolbeckstr. 25 I 45329 Essen I GermanyPhone: +49 201 3645-0 I Fax: +49 201 3645-111E-mail: info@bhr.bilfinger.com I www.bhr.bilfinger.comOverview DivisionsSteam GeneratorsEngineering, Delivery, Fabrication,Construction, CommissioningEntire PlantsPressure Parts, DuctsFiring SystemsPulverizers & ClassifiersCoal Feeding & Ash Removal SystemsHeat UtilizationWaste Heat Recovery SystemsWet CoolingTurbine ServiceEnergy & EnvironmentalTechnologyEngineering, Delivery, Construction,CommissioningFlue Gas DesulphurisationSelective Catalytic NOx Reduction (SCR)DedustingNuclear Systems & ComponentsWaste Conditioning SystemsDecommissioning & DismantlingSpecial Magnets & CoilsNuclear ServicePiping TechnologyEngineering, Fabrication, ConstructionConventional & Nuclear PipingSystemsFittings, Induction & Cold PipeBendingUnderground PipingPlant InstallationElectric, Instrumentation &Control TechnologyFittings & Flow MeasurementEngineeringMechanical Engineering &Process EngineeringFabrication & MachiningProcess Engineering & Heat ExchangersComponents for Gas, Steam & Water TurbinesComponents for Nuclear TechnologyComponents for Aircraft and AerospaceStructural Steel PipesOffshore FoundationsRehabilitation of Thermal Turbines& Water TurbinesPlant Engineering & SpecialMechanical Engineering2188 eng/200/032012