NEW 840 MWe CCGT UNIT AT THE POČERADY POWER PLANT

Transcription

1 NEW 840 MWe CCGT UNIT AT THE POČERADY POWER PLANT WE DO BIG THINGS

2 A WORD OF INTRODUCTION The fact that ŠKODA PRAHA Invest is constructing the fi rst CCGT power plant in the Czech Republic in Počerady for the ČEZ Group attests to the important role of our Company as an advanced EPC contractor for power generation units and to our readiness to face these challenging projects. The construction of this CCGT power plant is, without any doubt, an outstanding project both for us and for all participating contractors under our leadership. This new area of power engineering has a great future when considering the growth in energy production from renewable sources and the increasing need to diversify production sources. Ing. Daniel Jiřička General Director ŠKODA PRAHA Invest WE DO BIG THINGS

3 ABOUT THE LOCATION, ABOUT THE PROJECT ABOUT THE LOCATION The Počerady power plant, where the new combined cycle unit will be located, is situated near the Počerady municipality in the Ústí nad Labem Region, roughly in the centre of a triangle formed by the towns of Louny, Žatec, and Most. There are fi ve coal units with a unit output of 200 MWe currently operating on the power plant premises. It is notable that this power plant was built by ŠKODA PRAHA from 1970 to ABOUT THE PROJECT The project is a part of renewal of the ČEZ Group production capacity in the Czech Republic, directed by ŠKODA PRAHA Invest as its EPC Contractor. This project is based on the construction of a new ČEZ Group power production unit, the first of its kind in the Czech Republic: a CCGT power plant (PPC) with an output of 840 MWe. The EPC Contractor of the entire project and construction is ŠKODA PRAHA Invest; the Investor is ČEZ. What makes the CCGT exceptional is its high operating availability, output, and environmental friendliness. The new unit is to achieve an output of 840 MWe (depending on atmospheric conditions). This is a modern, well-tested and worldwide utilised power generation concept that is highly effi cient in comparison with coal units thanks to basic confi guration of its main components: internal combustion turbines, with steam generators that supply steam to the steam turbine using the waste heat contained in the exhaust gases of the turbines. The Investor expects a maximum economic return on the investment from this new unit. This will be expressed in both a high efficiency of the unit under steady-state operation and in its operating characteristics, particularly a sufficient starting speed, the ability to rapidly change output, and the ability to operate in by-pass mode through steam turbine bypass stations. This is the fi rst CCGT unit designed and supplied by ŠKODA PRAHA Invest as a whole. Working on this project, we were still able to fully utilise our experience gained during previous technically successful projects in Egypt (New Talkha and El Kureimat, 750 MW, both completed in 2010), in which our Company served as the main contractor of critical pipework, the control system, the feeding and condensate extraction pumps and other auxiliary equipment and also EPC supply of a peak-load gas unit with an output of 45 MW in Kladno.

4 THE PROJECT IN DATES 15/9/2008 Conclusion of the EPC Delivery Contract between ŠKODA PRAHA Invest and ČEZ 30/11/2008 Decision made on the technological solution 25/6/2009 Contracts for the main technological units concluded 22/9/2009 EIA approval 2/9/2010 Decision on construction site made legally effective date 15/10/2010 Submission of the Work Raw Water Supply Line 25/11/2010 Submission of the Work Service Building 15/1/2011 Legally effective date of the Integrated permission for the Počerady power plant equipment 1/4/2011 Start of construction 15/5/2011 Submission of the Work Construction Site Installations 30/6/2011 Cable Duct, completion of the part behind the Main Generating Unit 21/8/2011 Start of the Exhaust-heat Boilers assembly 24/10/2011 Start of the foundation of the Gas Turbine 1 and 2 23/12/2011 Start of the foundation of the Steam Turbine and noise control measures 15/2/2012 Start of the Gas Turbines and Steam Turbine assembly 29/2/2012 Delivery of the Control System to the building site 2/4/2012 Start of the assembly of connecting piping in the Main Generating Unit 23/8/2012 Completion of the Gas Turbines assembly 21/9-16/10/2012 Implementation of cleaning operations 8/11/2012 The fi rst ignition of the Gas Turbine 1 26/1/2013 The fi rst start-up of the Steam Turbine 19/3/2013 Readiness of all systems for comprehensive testing 30/6/2013 Handover of the Work to the Customer (PAC)

5 THE DESIGNING STAGE The decision on construction of a new CCGT unit using a part of the existing premises of the Počerady power plant was taken in Construction works began on April 1, 2011, and the power plant is planned to be handed over to the Customer on June 30, In 2007, the Investor identifi ed several possible locations for the construction of the CCGT unit. The Investor issued the Project Plan prepared on the basis of a number of support materials and feasibility studies in May This became the primary document for the preparation of the Design and Investment Preparation stages. Among others, the Investor chose a multi-shaft design with two gas turbines (GT) and one steam turbine (ST) as the basic arrangement of the CCGT unit. He also decided on the implementation of one naturaldraught cooling tower instead of forced-draught cooling towers, and he selected the overall layout option on the premises of the present Počerady power plant. ŠKODA PRAHA Invest fulfi lled the role of Architect / Engineer for the Project from the beginning of its development, respectively the role of EPC Contractor responsible for the Preliminary Design stage. BASIC TECHNICAL PARAMETERS The key condition for determining the parameters of the basic CCGT unit was the selection of the main PPC technology suppliers, particularly of the gas turbine. SIEMENS was selected as the gas turbine supplier, the steam generators package was awarded to SES Tlmače and the steam turbine package to ŠKODA POWER. The suppliers listed were chosen based on a competitive tender launched in the second half of 2008 and completed by conclusion of the contracts in the middle of ATMOSPHERIC CONDITIONS Ambient temperature 10 C Relative humidity 70 % Air pressure 987 mbar NATURAL GAS LHV (15 C) MJ/kg Temperature upstream GT 130 C Quantity kg/s EXHAUST GASES AT THE GT OUTLET Temperature C Quantity kg/s STEAM UPSTREAM THE STEAM TURBINE HP steam quantity kg/s HP steam temperature 550 C HP steam pressure bar IP steam quantity kg/s IP steam temperature 548 C IP steam pressure 28.1 bar LP steam quantity 27 kg/s LP steam temperature 290 C LP steam pressure 4 bar GUARANTEED PARAMETERS Gross effi ciency 58.4 % Gross output at generators terminals 838 MWe CHP consumption 13 MWe NO X, CO emissions 40 mg/nm 3 Note: HP = high-pressure, IP = intermediate pressure, LP = low-pressure FOLLOWING THE SUBSEQUENT OPTIMISATION, THE PPC PARAMETERS AS PART OF THE ELABORATION OF PROJECT DOCUMENTATION WERE SET AS FOLLOWS:

6 TECHNOLOGICAL CONCEPT WIRING DIAGRAM FUEL The fuel is combusted in two gas turbines connected to generators producing electrical energy. Waste heat contained in the exhaust gases released from the gas turbines is utilised as a heat source for two waste heat boilers producing steam for one steam turbine (CHP). Its generator produces another part of the CCGT power output. In this confi guration each generator generates about 1/3 of the total unit power output. Steam parameters are comparable with the parameters of subcritical coal power plants. A steam turbine working with steam of such parameters is a standard design. BOILER The waste heat boiler is designed as a three-pressure design with reheating, a standard design for a unit of this size ensuring maximum effi ciency at reasonable investment costs. For the maximum utilisation of the exhaust gas heat the fi nal boiler heating surfaces are a low-pressure economisers and a condensate preheating exchanger upstream the inlet of the feeding tank. CONDENSER The steam turbine condenser is cooled in a tower circuit with one natural-draught cooling tower. Water circulation is provided by two 50% cooling water pumps. The boilers are not equipped with a by-pass stack and the separate operation of gas turbines is not possible. To prevent a sudden shutdown of the gas turbines (and the consequent considerable decrease of their operation life) caused by a shutdown of the steam turbine, the by-pass stations are dimensioned to 100% of the steam output of the boilers and steam fl ows directly through them to the condenser.

7 MACHINERY PART EXHAUST GAS STEAM BOILER 1 COOLING SYSTEM LAYOUT GAS TURBINES Gas turbines SIEMENS, type SGT5-4000F, are fi eld-tested units designed for the provision of safe, highly reliable, effi cient, and low-cost electricity. The construction characteristics of the main components were carefully assessed, resulting in an optimal harmonisation of investment costs with equipment performance as well as with its effective operation and maintenance. Exhaust gases produced by the equipment are minimised by using a Siemens dry Hybrid Burner Ring with low NO x emission. CUTOUT VIEW OF INTERNAL COMBUSTION TURBINE (Source: SIEMENS) COMPRESSOR SECTION 3D MODEL OF STEAM TURBINE UNIT WITH ACCESSORIES STEAM TURBINE The ŠKODA Steam Turbine with an output of 270 MW has a two-casing design (HP + IP, and LP part) with a condenser below the LP part. It is installed together with the generator on a monolithic concrete foundation. EXPANSION SECTION COMBINED BURNER EXHAUST-GAS STEAM BOILERS Exhaust-gas boilers using waste heat from the gas turbines have a three-pressure design with reheating without additional heating. These are cylindrical horizontal boilers with natural circulation with the exhaust gas fl owing in a horizontal plane while the coils of the individual heating surfaces are oriented vertically. COOLING SYSTEM Cooling of the steam turbine condenser is provided by cooling pumps in a 2 50% confi guration. The pumps actually exceed this value and have regulation capabilities suffi cient to ensure the operation of both gas turbines with a reduced output in the event of an outage of one of them. The pumps' output is controlled by the rotation of their impeller blades. The pumps are oriented vertically for suction from a wet sump. The 2 DN1800 supply piping joined into a 1x DN2400 pipe leading to the condenser and subsequently to the cooling tower is made of fi bre reinforced plastic and led through a compacted backfi ll. In exposed areas under roads, the piping is protected from above by a reinforced-concrete slab. Cooling water piping in the Machine Hall near the compensators and non-return valves is made of steel protected by an internal coating. The tower water branch in front of the condenser entry leads cooling water to cool the internal cooling circuit. This circuit is fi lled with demineralised water with a corrosion inhibitor.

8 ELECTRICAL SYSTEMS, HOME CONSUMPTION CONNECTION TO GRID The system of the CCGT home consumption has operating, reserve, and emergency sources at its disposal. The transition between operating and reserve sources and the connection of emergency sources is performed automatically. Operation of the CCGT home consumption system is provided by branch transformers powered by gas turbine generator outlets. These branch transformers supply two independent sections of 6kV switchgear stations. Reserve supply of the 6kV switchgear stations is to be accomplished from the present common 6kV switchgear for units 5 and 6 of the Počerady power plant. The emergency supply of secure power supply appliances, i.e. a power supply during the loss of both operating and reserve sources, is to be ensured from independent emergency sources - accumulator batteries and 0.4kV diesel-generator. The 6kV switchgears will supply the main 6kV drives and 6/0.42kV home consumption transformers for the technology and civil electrical installation. The majority of MV and LV switchgears are situated in four fl oors of a separate building designated for the control rooms and switchgears. Cable routes are led from the building cable area (-3.5 m level) around the Main Generating Unit. The concept of cabling and cable routes complies with the PPC fi re safety solution and also includes integrated fi re resistant cable systems that retain their function in the event of fi re. Note: MV = medium voltage, LV = low voltage CONNECTION TO GRID The electrical output of the PPC will be connected to the grid by a 400kV V468 line to the Výškov Switchgear. The output of each PPC generator will be connected separately through the generator circuit breaker and its own output transformer into the corresponding array of the encased 400kV switchgear. The encased switchgear utilises GIS (gas insulated switchgear) technology - SF6 gas insulation - and is located in a separate dedicated building near the line. Connection of the generators to the output transformers is designed using encased cables including connection to branch transformers and excitation transformers. Connection of the output transformers to the encased switchgear is realised by 400kV single-core cables. For these cables, a cable route is to be constructed directly adjacent the output transformer site and the encased switchgear building. The encased 400kVswitchgear is equipped with three inlet arrays that will be fi tted with 400kV output circuit breakers which will ensure independence of the individual outlets in case of partial failure while at the same time enabling control of the CHP consumption generators. A disconnector is installed in the outlet array of the 400kV encased switchgear on the V468 line. The outside part of the 400kV switchgear includes a portal for connecting V468 line cables which constitutes the battery limit with the grid as a component of the PPC Work. Both the outside and the encased part of the switchgear are equipped with instrument transformers for protection, synchronisation, and measurement. Commercial and verifi cation measurement for invoicing is also provided there. CONNECTION OF THE MAIN GENERATING UNIT BUILDINGS TO THE OUTPUT TRANSFORMERS

9 ADJUSTMENTS TO THE EXISTING POWER PLANT UNITS The Počerady power plant operates fi ve units with an output of 200 MWe. The units, respectively their pairs (-, 2), (3, 4), (5, 6), are connected through triple-wound unit transformers T401, T402, T403 via 400kV lines (V467, V468, V469) to the Výškov Switchgear. Disconnectors are located only at the 400kV side of the unit transformers. Line cut-out switches are on the Výškov side. 400kV V468 line, which serves the existing units 3 and 4, will be released in advance for connection of the new CCGT unit to the grid. These units will be connected to V467 line which is currently in use of unit 2. Concerning internal unit connections and connection to the 400kV grid, a new generator triplet will be created from the existing unit pairs. SINGLE-LINE DIAGRAM

10 M M M M TECHNOLOGY PROCESS CONTROL CONTROL SYSTEM ARCHITECTURE The technology process control will be based on modern programmable equipment of a high industry standard, communicating together through communication buses to ensure functionality, reliability, performance, resistance to environmental infl uences and quality assurance requirements. The automatic technology process control system will allow the listing of the event sequence during breakdowns, long-term archiving of measured technological process values, process equipment diagnostics, and other support functions. A unifi ed distributed control system connected to autonomous control systems for gas turbines, steam turbine, and a chemical water treatment plant will be used for PPC technology control as a whole. With these linked systems, the control system is designed to constitute one integrated system able to optimally and automatically control the Main Generating Unit and other power plant technology nodes both during stable and transient operating conditions. The individual systems will be connected at the level of automation and application buses, through HW signals, and via communication connections. The critical components of the system and its power supply will be redundant to achieve high operational system reliability. Standard protection methods will be implemented to protect the control system against external attack. To ensure high operation safety, the part of the control system and protection circuits will be produced with the required security level to ensure the reliability of security functions. p y g Demilitarized Zone Central Control Room - CCR Large Screen Optional: SIEMENS Remote- Service Plant Management System 52'' 52'' WIN-TS Firewall VPN Tunnel Historian / Engineering Shift Supervisor BOP / TCS Operator BOP / TCS Operator BOP / TCS Operator delivered by E F PR Optional: Performance Monitoring RAID TC TC TC TC TC Application Highway Option : Performance Monitoring Server ApS (red) Router Color Laser Printer BW Laser Printer Alarm Printer Automation Highway CM104 CM104 CM104 CM104 CM104 Router Router Redundant Serial Link: Non Redundant Serial Link: to clarify Power Control Center - PCC Power Control Center - PCC PS 09 Electricals MV Switchgear PROFIBUS PS 10 APCS Switchyard IEC Link PS 12 Compressor station Cisco Link PS 06, 16, 18 CHUV CEMS (MODBUS TCP/IP) delivered by E F PR G1UBA01 delivered by E F PR G2UBA01 PS 21 Modifications in the existing blocks Other Supplier Central Dispatch, PTIS, DAMATIC, OT ČEPS G1UBA02 OT G2UBA02 OT OT G1CJT01 G1CJT01 G1CJT01 Connection to third party system to be clarified ApS ApS SFC SEE SEE Special Systems SPecial Meassur ET200 ET200 xxx xxx xxx AuS (red) AuS (red) SPPA-T3000 SPPA-T3000 SPPA-T3000 SPPA-T3000 SPPA-T3000 SPPA-T3000 AuS (red) AuS (red) AuS (red) ST ST ST HRSG Area Water Treatment Area Electrical Area Electrical Building Scope by others Scope by Siemens Firewall Access Server Terminal Server TC TC Firewall Firewall Data Server GPS GPS Gas Turbine 1 Gas Turbine 2 Steam Turbine WIN-TS LAN WIN-TS LAN Profibus Profibus SPPA-T3000 Special Systems SPecial Meassur ET200 ET200 SPPA-T3000 AuS (red) AuS (red) AuS (red) AuS (red) Data logger I/O modules Wobbe I/O modules I/O modules Data logger I/O modules Wobbe I/O modules I/O modules I/O I/O I/O Turbine control Flame monitorin ARGUS I/O modules I/O modules Turbine control Flame monitorin ARGUS I/O modules I/O modules Cabinet Cabinet Cabinet Turbine governo Speed monitorin ARGUS I/O modules I/O modules Turbine governo Speed monitorin ARGUS I/O modules I/O modules Fast I/O module Turbine Trip Sy I/O modules Fast I/O module Turbine Trip Sy I/O modules 2x 2x 2x HW HW HW HW HW HW ACCS GT G1 Field Devices GT G2 Field Devices ST Field Devices Field Devices

11 CIVIL PART LAYOUT GROUND PLAN COOLING TOWER GAS TURBINE MACHINE HALLS STEAM TURBINE MACHINE HALL The architectural and civil layout design has been determined by technological requirements and complies with noise protection and fire safety requirements as well as with environmental limits. THE CRITICAL CIVIL STRUCTURES ARE: The Main Generating Unit (Machine Halls for Steam and Internal Combustion Turbines) The Natural-Draught Cooling Tower The Cooling Water Pumping Station and the Fire Fighting Water Pumping Station The Encased Switchgear Building The Make-up Water Treatment Plant The Boiler House, Machine Halls for Steam and Internal Combustion Turbines, Control Rooms, Switchgears, Compressor Station and piping areas objects constitute a structurally single compact Main Generating Unit. The Main Generating Unit layout is composed of individual operating parts, its main dimensions being approx x 82.6 m. The individual parts of the Main Generating Unit are placed at different heights. The total built-up area is 8,367 m2 (excluding stack foundations and cooling pits). Foundations, footings, underground areas and ducts will be constructed of reinforced-concrete; above-ground structures will be made of steel. There are underground cable areas below the switchgears under part of the Main Generating Unit. The space is composed of a concrete sump upon which the structure of control rooms is founded. The foundation is shallow, composed of a foundation slab, the cable space ceiling is a slab-and-girder monolithic type in accordance with the requirements for floor openings and it is supported by concrete pillars. COOLING AND FIRE FIGHTING WATER PUMPING STATIONS ADMINISTRATION BUILDING EXHAUST-GAS BOILERS VIEW OF THE MAIN GENERATING UNIT, COOLING WATER PUMPING STATION, AND COOLING TOWER FROM THE NORTH

12 OPERATING ATTRIBUTES A distinct feature of all CCGT plants is the dependence of their output on external conditions, i.e. on air temperature, altitude and relative humidity. The most signifi cant is the infl uence of temperature, where the output of the gas turbines declines considerably with the increasing ambient temperature while the parameters of released exhaust gases change and affects the steam part of the combined cycle. This is caused in particular by the change of mass fl ow through the inlet air compressor due to the changing specifi c density of air. PPC OUTPUT DEPENDENCE ON AMBIENT TEMPERATURE GT, ST OUTPUT 305 MW UNIT OUTPUT 870 MW 300 MW 860 MW 295 MW 850 MW 290 MW 840 MW 285 MW 830 MW 280 MW 820 MW 275 MW 810 MW 270 MW 800 MW 265 MW 790 MW 260 MW 780 MW 255 MW 770 MW 250 MW 760 MW 245 MW 750 MW 240 MW 740 MW AMBIENT TEMPERATURE GT OUTPUT ST OUTPUT UNIT OUTPUT

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14 VISION IS THE FIRST STEP TO ACTION WE ARE AN EPC CONTRACTOR AND DEVELOPER OF INVESTMENT PROJECTS IN THE ENERGY SECTOR We are the largest Czech engineering contractor able to deliver power generation projects from the design through implementation and assembly to commissioning and securing of both warranty and extended warranty service. We also supply balance of plant. We provide service tasks. We are active primarily in conventional and nuclear power, but also in heating plants, CCGT power plants and renewable energy sectors. We are implementing the Czech industrial project of the decade, the Renewal of the ČEZ Group production capacity. As part of this project we are performing the comprehensive and environmentally benefi cial renewal of the Tušimice II and Prunéřov II power plants; we are constructing a new production unit with supercritical steam parameters in the Ledvice power plant and a new CCGT plant in the Počerady power plant. We are also implementing complex delivery projects for nuclear power plants as well as output improvement projects and nuclear unit modernisation. We also operate in the fi eld of renewable energy sources. We excel in a strong professional know-how that we have been building under the ŠKODA PRAHA trademark for 60 years. During that time, we have delivered more than one hundred power generation units with a total output of 40,000 MW to 25 countries around the world. We deliver energy generation works that stand out due to their high technological quality, effi ciency, reliability, and are environmentally friendly. WE DO BIG THINGS

15 NEW 840 MWe CCGT UNIT AT THE POČERADY POWER PLANT APRIL 1, WE DO BIG THINGS