CASE STUDY FOR RETROFIT OF TURBINE INLET COOLING IN BATAM, INDONESIA www.tas.com
Introduction About Medco Power About TAS Turbine inlet cooling the impact Indonesia project execution Operating results Conclusions
About Medco Power Independent power developer based in Jakarta Subsidiary of Medco Energi Internasional Recent projects: PT Dalle Energi Batam 2 X RB211 PT Mitra Energi Batam 2 X RB211 340 MW Sarulla Geothermal Power Project in Indonesia
About TAS
TAS Experience - Worldwide
Turbine Inlet Chilling the Impact www.tas.com
Temperature Degradation % MW 120 110 100 90 80 70 Combined Cycle Simple Cycle ~14 % Incremental Capacity? 0 10 20 30 40 50 60 70 80 90 100 110 120 Ambient Temperature - F
Capturing High Value Markets Large daily demand peak AND price peak benefit TIC Generation mix will determine the value of off-peak power Weather profile contributes to power demand & price peak
Incremental Energy & Efficiency Representative Plant Performance Curve 6410 255 6400 250 6390 6380 245 Heat Rate (BTU/KWH) 6370 6360 6350 6340 240 235 230 Output (MW) 6330 225 6320 6310 220 6300 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 215 Temperature Mid-Points (F) UnChilled MW Chilled MW UnChilled Heat Rate Chilled Heat Rate 7FA CC evap cooled vs. Full TES
Chilling vs. Other Options (Metric) Target turbine inlet Common design dry bulb Adiabatic Cooling The limit of fogging and evaporative technologies Mechanical Chilling 7 C 32 C
Economics of inlet chilling Capital Cost (installed) Base MW (35ºC) Heat Rate (BTU/KWH) Non-Fuel O&M Fuel Cost Total Generation Costs 209FA $315M ($492/KW) 658 6,385 $4/MWH $34.8/MWH $38.8/MWH 209FA Chilled $336M ($465/KW) 740 6,425 (+0.6%) $0.8/MWH (chiller) $3.64/MWH (both) $35.0/MWH $38.6/MWH (-0.5%) Assumptions: 1. Non-fuel O&M: GT parts, labor, maintenance, repairs, water treatment 2. US$ 5/MMBTU Gas Improvement in Generation Economics
PT Dalle Energy Batam System installed in parallel with new unit installation as a retrofit not in base design Owner is PT Dalle Energy Batam Located in Batam Performance guarantees critical Integration with site activities
Project Execution System design Manufacturing Shipping Installation Startup and commissioning Actual Results
Choosing a Design Point RH Plotted against DB 100% 90% 80% Note that there are typically no high RH incidents at high dry bulb temperatures! 70% RH (%) 60% 50% 40% TAS Design Point 32 C/68% 30% 20% 10% 0% - 20 40 60 80 100 120 10 C 20 C 30 C 40 C Dry Bulb (F)
Site conditions: Batam Summary 32 C dry bulb & 27 C wet bulb Cooling to 13 C 20% incremental power - +9MW Net 1-2% heat rate improvement Incremental personnel: 0 No impact on GT maintenance intervals or costs Chiller non-fuel O&M costs: US$0.50/MWH
RB211 Air Flow Exhaust Gas Conditions Exhaust Gas Temperature (Deg.C) 600 550 500 450 400 350 115 110 105 100 95 90 85 80 75 Exhaust Mass Flow (kg/sec) 300 70-50 -40-30 -20-10 0 10 20 30 40 50 Ambient Temperature (DegC) Exhaust Temperature Exhaust Mass Flow
RB211 6761 Power & Heat Rate Power and Heat Rate 40000 11000 10500 35000 10000 Power Output (kwe) 30000 25000 20000 5.5 MW gross per GT 9500 9000 8500 8000 Heat Rate (kj/kwe.hr) 7500 15000-50 -40-30 -20-10 0 10 20 30 40 50 Ambient Temperature (DegC) 7000 Power Heat Rate
Batam Site Prior to Chiller
Delivering the Solution Site visits to confirm conditions and dimensions saved much time and effort Knowledgeable owner required Quality local supply of external structures and piping available no issues Minimizing site interference is critical
Project Execution (cont.) Experienced shipping personnel necessary, but with this, process went well Local contractors had a learning curve on chilled water systems Modular solution critical to the overall solution Solutions provided required for startup and commissioning
Modular Retrofit Kit
Chiller Package On Site
Retrofit in Place Prior to Connection
Filterhouse Complete
Actual Measured Results Total project costs on budget Heat Rate 1-2% less than base plant +9 MW NET for 2 X RB211 at 32 C
Summary Turbine inlet cooling is accepted worldwide For power producers that need more power great value proposition The humidity in Asia is not a problem Simple cycle plants running well for long periods Combined cycle plants benefit also as proven by installation on advanced GT s