The Steam Turbine Retrofitting of Six Boiling Water Reactor Units Using Innovative Engineering and Laser Scanning Techniques

Alstom Power is executing the steam turbine retrofit of six nuclear units for Exelon Generation in the USA. The existing turbine-generators are an 1800 RPM General Electric design originally rated at 912 MWe and 1098 MWe and powered by Boiling Water Reactors. 18 Low Pressure inner modules will be replaced, with the first due to be installed in March 2010. This project is particularly challenging — the aggressive retrofit installation schedule is compounded by the requirement to handle radioactively contaminated equipment and also comply with demanding regulations applicable to BWR plant. The author’s company has extensive experience in the steam turbine retrofit business, having supplied around 800 retrofit cylinders globally since the 1970’s. However, this LP upgrade challenges the established techniques used in the business and requires extraordinary effort. Traditional retrofit engineering and installation principles have been interrogated and developed to meet the specific requirements of this project. Innovative techniques are introduced, including the extensive use of the Leica HDS 6000 laser scanner to model the existing plant. The approach has advanced the field of steam turbine retrofit design and installation significantly. The first section of this paper focuses on the extraordinary considerations of the project and the challenges surrounding BWR plant. The second part describes the laser scanning technique and the application of scan data. It outlines the innovative solutions which have been developed.