Improving Flexibility of the Combined Cycle Power Plant Hamm Uentrop to Cover the Operational Profiles of the Future

Transcription

1 Improving Flexibility of the Combined Cycle Power Plant Hamm Uentrop to Cover the Operational Profiles of the Future Dr. Martin Buschmeier, Trianel Gaskraftwerk Hamm GmbH & Co. KG Thomas Kleinwächter, Trianel Gaskraftwerk Hamm GmbH & Co. KG Dr. Andreas Feldmüller, Siemens Energy Philipp Köhne, Siemens Energy POWER-GEN Europe 2014, Cologne, June 3-5, Track 6, Session 4 Trianel GmbH 1

2 POWER-GEN Europe 2014, Cologne, June 3-5, Track 6, Session 4 Agenda + The plant and the German market conditions + Improved secondary frequency response + Plant flexibility - Flex-Power Services TM + Conclusions Trianel GmbH 2

3 The plant and the German market conditions Main Facts (May 2014) Unit 10 Unit 20 Trianel Combined Cycle Power Plant Hamm Uentrop, Germany First Fire Starts EOH OH Last HGPI May 2010 ( EOH) Last Minor Inspection August 2013 ( EOH) Major (50k) May/June 2014 ( EOH) May 2010 ( EOH) August 2013 ( EOH) April/May 2014 ( EOH) Trianel GmbH 3

4 The plant and the German market conditions Trianel Combined Cycle Power Plant Hamm Uentrop, key data Siemens CCGT Power output SCC5-4000F; combined cycle, single shaft 2 x 424 MW = 848 MW Efficiency > 57,5 % Gasturbine V94.3A (4) SGT F (4) (278 MW) Year of construction: 2006 Steam Turbine HE SST (146 MW) Condensing turbine with reheater, axial condenser (SCon-1000) H-Turbine Type H IL-Turbine Type IL30-1x12,5 Generator THRI BIC SGen H (Siemens Westinghouse) Heat Recovery Steam Generator Owner Operation & Maintenance HRSG (Ansaldo) 3 stage generator with reheater HP: Once-through boiler IP: Natural circulation boiler LP: Natural circulation boiler Trianel Gaskraftwerk Hamm GmbH & Co. KG Fortum Trianel GmbH 4

5 The plant and the German market conditions Trianel - The communal network, February shareholders Trianel GmbH 5

6 The plant and the German market conditions Operating conditions of the plant Hamm Uentrop Standard week 5 starts / shut downs per week (Monday - Friday) Weekend, if needed (depending on price of electricity) app. 250 starts / shut downs per year Designed for up to 8000 operating hours / year Both units in 2013 app full load hours > 5200 operating hours Long-term gas contract Ancillary services e.g. Secondary frequency response Tertiary frequency response (minute reserve) Production planning managed by Trianel utilizing specialized software Stochastic optimization algorithms to improve the profit margin Trianel GmbH 6

7 The plant and the German market conditions Issues and Challenges of the German Energiewende One year Future, (monthly average, Euro/ MWh) 1) monthly average annual average Energy production renewables [TWh] Energy production lignite [TWh] Energy production natural gas [TWh] CO 2 -emissions [gco 2 / kwh] Low price on EEX power exchange Declining price of electricity traded on the power exchange Uncontrolled expansion of renewable energy (23,5% in 2012) because of national sponsoring by law (EEG) Rising prices to end customers Low CO 2 -Price (4,5 /to CO 2 ) -> increasing CO 2 emissions Increasing power generation of hard coal and lignite Decreasing generation of CCGT Slow-pace advancement of power grid expansion can lead to grid instability Trianel GmbH 7

8 The plant and the German market conditions Operating pattern with high and frequent load changes Delivery of maximum tertiary and secondary frequency response (- 171 MW) Changed load schedule for 15 minutes (e. g MW) Delivery of tertiary frequency Response (minute reserve) for 15 minutes (- 50 MW) Trianel GmbH

9 Improved secondary frequency response 4/2013: Implementation of Combined Cycle Load Gradient 8/2013: Implementation of 26 MW/min Fast Load Gradient (GT) Effective power [MW] per unit 135 MW/5 min +75 MW 69 MW/5 min 60 MW/5 min + 9 MW 4/2013 8/2013 Trianel GmbH 9

10 Improved secondary frequency response Old feedwater CS Test: MW/min 2 Ramps Closed-loop control Evaporator behavior during rapid load changes (overheating yellow) T 58 K Modified feedwater CS Test: MW/min 4 Ramps Feedforward control concept Four additional thermocouples in HRSG T 20 K Trianel GmbH 10

11 Improved secondary frequency response Implementation steps and results 8/2013: Implementation of 26 MW/min GT load gradient with modified feedwater control, ST start-up mode normal 12/2013: Change to ST start-up mode fast 02/2014: Implementation of new ST EOH counter 02/2014: (Tests: advanced temperature control) 02/2014: Implementation of modified release criteria (release time versus EOH) To be discussed and evaluated: Implement advanced temperature control to further reduce release time Time until release of 26 MW/min load gradient [min] Original ST EOH counter [%]* *) average EOH of starts in % of worst case New ST EOH counter [%]* design value of ST start up mode fast Trianel GmbH 11 [min] [%]*

12 Improved secondary frequency response Comparison of steam turbine EOH counts using original and new EOH counter for typical starts Warm start after weekend stop, ST mode fast Hot start after night stop, ST mode normal [%]* *) average EOH of several starts in % of worst case design value of ST start up mode fast Trianel GmbH 12

13 Plant flexibility - Flex-Power Services TM Aspects of Siemens Flex-Power Services TM Flex-Power Services TM Activity of Siemens Energy Service Targets all aspects of plant operation Integrated approach Trianel GmbH 13

14 Plant flexibility - Flex-Power Services TM Start up improvements under consideration for Hamm Uentrop Improved combined cycle start-up concept steam turbine hot start on the fly Fast GT Load Gradient for start-up Improved start-up concept Trianel GmbH 14

15 Plant flexibility - Flex-Power Services TM Start up improvements under consideration for Hamm Uentrop Fast GT Load Gradient of Siemens SGT5-4000F for start-up Modified compressor vane carrier vane ring grooves Done in FY2014 outage to be prepared for future needs High stresses in compressor vane ring grooves during Fast Start Up Increase of corner radii required in order to prevent crack initiation Modification is restriced to the vicinity of the horizontal joint, where maximum stresses occur Applicable in an ehgpi (hot gas path inspection with compressor lift) Trianel GmbH 15

16 Steam cooling during operation Plant flexibility - Flex-Power Services TM Fast cooling may significantly shorten outage durations - Hamm Uentrop first time application of automation Improvement Represents HP and IP rotor temperature of approximately 100 C in case of fast cooling Shut down Stop rotor turning after Fast Cooling Stop rotor turning after natural cool down Trianel GmbH 16

17 Conclusions Changing energy markets New operating profiles with higher flexibility requirements Successful increase of load gradients at the CCPP Hamm Uentrop Improved secondary frequency response capabilities Flex-Power Services TM of Siemens Energy Service Integrated plant solutions for enhanced flexibility requirements Close cooperation between Trianel and Siemens Optimizing the Combined Cycle Power Plant Hamm Uentrop Keeping it in excellent shape for the needs of today and the future Trianel GmbH 17

18 POWER-GEN Europe 2014, Cologne, June 3-5, Track 6, Session 4 Thanks for your attention! Trianel GmbH 18

19 Disclaimer with respect to Siemens content of the paper This document contains forward-looking statements and information that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as expects, anticipates, intends, plans, believes, seeks, estimates, will or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens filings with the SEC, which are available on the Siemens website, and on the SEC s website, Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated. Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners. Trianel GmbH 19