2. Quote Of The Day
“Every living being is an engine geared to the
wheelwork of the universe. Though seemingly
affected only by its immediate surrounding, the
sphere of external influence extends to infinite
distance.”
-Nikola Tesla
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3. About Me
■ North Carolina State University
– Senior
– Electrical Engineering & Physics
– Minor: Mathematics
– May 2018
■ Rotations with Duke Energy
– Summer 2016
■ Turbine Generator Services – Inlet Icing Prevention, ATOS Scanning
■ Managers:
– Kelly Rivera
– Jeff Biega
– Ben Meissner
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4. Leadership/Committees
■ Sustainability Corps
– By joining the Sustainability Corps I learned one of
Duke Energy’s primary goals as a sustainable
company is delivering attractive long-term returns for
its investors.
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5. Rotation Responsibilities
■ Research
– Compiled logic and ranked based on importance in relation to Duke
energy sites
– Performed calculations to determine unknown variables missing from
PI Processbook such as dew point and humidity
– Developed a tracking method using PI Processbook to find all
potential icing events
■ Training with PI Processbook, Geomagic
■ Lark Maintenance Center – ATOS Scanning, Reverse Engineering
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7. Reverse Engineering Responsibilities
■ Helped analyze and render 2nd stage buckets and
1st stage nozzles
■ Produced 3D images to help in reverse
engineering process
– Utilized Geomagic Software
– ATOS Scanning
– Photogrammetry Scanning
■ Took pin and boroscope measurements for
reference in 3D scans
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13. T G S
Major Project Overview
Anti-Icing Systems Check
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14. Anti-Icing Systems Check
■ Inlet Bleed Heat System not Preventing Ice Formation
– 4 icing events within 8 months
– Causing forced outages
– Less load output = less revenue
■ Duke Energy Icing Events
– Noblesville G3 6FA DLN 2.0
– Mill Creek G7 7EA DLN1.0
– 2 additional non General Electric units
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15. Icing
■ Ice may form on the bell mouth struts or inlet guide
vanes (IGVs), and break off during operation
■ Ice can form both during operation and while the unit is
shutting down
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16. Damages
■ What Damage is Occurring?
– Ice damage is characterized by smooth or wavy impact to the blades
in the first rotating stage.
– Ice contacts with extremely hot surfaces to cause observed damage.
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17. Causes
■ Known Causes:
– Low ambient temperature + high humidity logic is missing or
flawed
– Water Ingress or leakage at low temperatures
– IGV angle
– Manually inlet bleed heat valve is not activated
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18. Inlet Bleed Heat System (IBH)
– Injects very hot compressor discharge air into the compressor
inlet duct. This reduces the possibility of ice formation on
downstream duct components.
– Heat released through sparger tubes
– 8” header to the heating system inside the duct
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19. Inlet Air Solutions
■ GE inlet air anti-ice coil filter
– Anti-Icing system controls are automated to run ONLY when ice
detected. Logic revolves around heating system.
– Control logic allows system to be idle if icing is not present and to
activate when icing detected.
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21. Update Logic
■ Proportional Integral Derivative (PID) controller
– allows for the detection of three variables. X would
represent present error for an initial preset margin. Y
would represent past error, while z represents future
error.
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22. Investigating Logic
■ Icing Curve: In determining initial logic boundaries a GE icing curve was
referenced.
■ Icing Testing: Previous studies by ASME were also used in determining logic
boundaries.
1. Humidity >76 % & Ambient Temp. ≤ 38.9°F
2. Ambient - Dew Point ≤ 10°F & Ambient ≤ 38.9°F
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23. Method
■ Investigate desired plants with logic
1. Humidity >76 % & Ambient Temp. ≤ 38.9°F
2. Ambient - Dew Point ≤ 10°F & Ambient ≤ 38.9°F
■ Create logic filter and set time to search through
■ Filter between functioning and non-functioning
IBH Systems
■ Red = Not Functioning Green = Functioning
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24. Sites Investigated
■ Duke Energy Units:
– Mill Creek: Relative Hygrometers {General Electric} Unit G2
– Noblesville: Relative Hygrometers {General Electric} Unit G3
– Madison: Calculating Humidity {General Electric} Unit G2
– Wayne County: Calculating Humidity {General Electric} Unit G4, G5
– Smith (Richmond): Relative Hygrometers {General Electric} Unit G2, G7
– Edwardsport: Relative Hygrometers {General Electric} Unit G2
■ Evaluated: 7EA, 7FA, 6FA
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26. Logic Trend #1 – Noblesville G3
Noblesville G3 Load (MW) Valve is mirroring load drops not temperature
Compressor Inlet Temp (°F)
Relative Humidity (%) Valve should be open based on logic point #1
IBH Control Valve (%)
Humidity >76 % & Ambient Temp. ≤ 38.9°F
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27. Logic Trend #2 – Noblesville G3
Noblesville G3 Load (MW) Valve is mirroring load drops not temperature
Compressor Inlet Temp (°F)
Dew Point Temp (°F) Valve should be open here based on logic point #2
IBH Control Valve (%)
Ambient - Dew Point ≤ 10°F & Ambien ≤ 38.9°F
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28. Conclusions/Summary
■ IBH system may not be working correctly
– Calibration error
– Logic / Design specifications
– Lack of plant override
■ Scanning can be optimized to determine component lifespan
– Provides a unique strategic perspective for Duke Energy in becoming
self reliant in component specifications.
■ Areas to Consider
– Is this due to a design error?
– Are there any further logic tags that were not considered?
– Was the investigative process optimal to identifying a cause?
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29. Looking Ahead – What is the future plan?
New investigative process with revised logic
■ IGV Angle
■ Dry bulb, wet bulb, ambient temperature
■ Normalized load
■ Manual cold weather override switch
Update current plants, promote scanning
■ Add dew point and relative humidity tags
■ Update current logic to match corrective suggestions
■ Continue scanning in large scale
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30. Future Plans
■ Fall 2016
■ Continue attending North Carolina State University
■ North Carolina State University ECE power electronics undergraduate research
■ Spring 2017
■ Duke Energy – Fossil Hydro Operations 2nd Rotation
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