Power Plants 2010 Turbine Retrofit Solutions Vrnjačka Banja, 26-29/10/2010

Transcription

1 Power Plants 2010 Turbine Retrofit Solutions Piotr Czerwiński Vrnjačka Banja, 26-29/10/2010

2 Agenda Introduction to retrofitting Alstom s advanced retrofit technology Retrofit solutions Key references Financial benefits Conclusion Power Plants 2010, Vrnjačka Banja, Serbia - P 2

3 Introduction to retrofitting What is a retrofit project? - The replacement of existing equipment specifically to improve performance. - By applying many of the design elements and principles Alstom use in new equipment, performance levels can approach modern standards Retrofitting Improved Performance Lower Emissions Power Plants 2010, Vrnjačka Banja, Serbia - P 3

4 Introduction to retrofitting Retrofit vs overhaul OVERHAUL gains are : - Restoration of original operational properties - Minor performance increase - Risk of damages remains, more expensive overhauls in the future and shortening period between major overhauls - Not expensive way of equipment lifetime prolongation RETROFIT gains are: - Considerable improvement in turbine performance - High operational reliability up to end of turboset lifetime - Time between main overhauls increased to operating hours - Higher competitiveness of power generation - Reduction in gases emission (especially CO2 and NOx) Power Plants 2010, Vrnjačka Banja, Serbia - P 4

5 Introduction to retrofitting Financial Increasing demand for electricity Lower operational & maintenance costs Increasing fuel costs Need for increased revenues Technical Increasing demand for performance Increased maintenance intervals Plant life extension Change of fuel/s An approach is needed that will simultaneously address power uplift, reliability, life extension & emissions control Regulatory Environmental & emissions control Security of supply Planning constraints Power Plants 2010, Vrnjačka Banja, Serbia - P 5 What are the drivers for change?

6 Introduction to retrofitting What are the drivers for change? Emissions Operational reliability Efficiency Power Efficiency and power output Operational reliability Price driven Evaluated price driven Power Plants 2010, Vrnjačka Banja, Serbia - P 6

7 Agenda Introduction to retrofitting Alstom s advanced retrofit technology Retrofit solutions Key references Financial benefits Conclusion Power Plants 2010, Vrnjačka Banja, Serbia - P 7

8 Alstom s Advanced Retrofit Technology Alstom has both impulse & reaction technology Power Plants 2010, Vrnjačka Banja, Serbia - P 8 Reaction Technology (RTB) Pressure drop across fixed & moving blades Typically higher number of blades per row Drum rotor construction Impulse Technology (ITB) Pressure drop across fixed blades Typically fewer blades per row with larger blade chords Disk and Diaphragm construction

9 Alstom s advanced retrofit technology Advanced LP Blading Better control of highly flared 3-D flow through - Advanced blade designs - Improved end-wall contouring - Better flow control - fixed blade lean etc Improved sealing (integral shrouds) Increased Blade length - bigger exhaust areas results in lower loss Improved exhaust diffuser analysis and design Power Plants 2010, Vrnjačka Banja, Serbia - P 9

10 Alstom s advanced retrofit technology Innovation and optimization An efficient steampath is at the heart of all successful retrofits - Advanced 3D profiles - Gap masking - Advanced sealing technology - New LP last stage blades - Diffuser optimization It is not just about having the best blading performance! - Axial adaptive stage (both for impulse and reaction technology) - New turbine components (modules, admission systems, bearing pedestals, etc) - New materials for extremely high steam temperatures - Controlstream V3 Power Plants 2010, Vrnjačka Banja, Serbia - P 10

11 Agenda Introduction to retrofitting Alstom s advanced retrofit technology Retrofit solutions Key references Financial benefits Conclusion Power Plants 2010, Vrnjačka Banja, Serbia - P 11

12 Retrofit solutions Each Project is Unique! Consideration of the specific client s needs When evaluating the benefits of retrofitting, each project will be unique with its own combination of market and local factors to consider Identification of the best solution Today s market requires - Bespoke innovative solutions - State-of-the-art technology catering for a wide range of application possibilities - Reliable project execution and installation - Sustained high performance operation Power Plants 2010, Vrnjačka Banja, Serbia - P 12

13 Retrofit solutions Evaluation of turbine technical condition REPAIR OVEHAUL and SMALL MODIFICATION MODERNISATION (packages) TECHNICAL CONDITION of the UNIT INTEGRATED SOLUTIONS RETROFIT Power Plants 2010, Vrnjačka Banja, Serbia - P 13

14 Retrofit solutions Modernization packages - example M01 Oil system modernization Forced turbine M02 cooling system Modernization of M03 control system M17 Improved HP impulse blading system M10 Modernization of HP control valves Individual M11 actuators of HP control valves Modernization of M08 jacking oil system M12 Modernization of IP control valves M13 Cooling of LP casing M19 LP blading diaphragm modernization Modernization of M08 jacking oil system Control system modernization: Binary control and starting automatics Control system modernization Measurement: sensor assembly data transmission and visualisation M06 M21 M14 Holes for endoscope inspection. M16 Hydraulic prestress of casing bolts M20 Pedestals modernization M08 Modernization of jacking oil system M04 Bypass system M05 Modernization of gland steam system M07 Electrohydraulic. Control system of IP-LP bypass system HP stop valve chest M09 modernization M05 Modernization of gland steam system Improved IP M18 impulse blading system M05 Modernization of gland steam system Adaptation for M15 process steam and heat extraction Power Plants 2010, Vrnjačka Banja, Serbia - P 14

15 Retrofit solutions Retrofit packages - example R01 HP part retrofit including control and protection system, oil system, sealing system, thermal limitations unit R01 IP part retrofit including control and protection system, oil system, sealing system, thermal limitations unit R02 LP retrofit RS29B RS33 RS41C RS33G RS37 R03 Condenser retrofit Type CM Power Plants 2010, Vrnjačka Banja, Serbia - P 15

16 Retrofit solutions Main restrictions for retrofit example for HP turbine existing outer casing existing valve configuration live steam parameters gland sealing system pressure in cold reheat Power Plants 2010, Vrnjačka Banja, Serbia - P 16

17 Retrofit solutions Impulse or reaction technology? - Main assumptions for retrofit: Existing outer casings Existing pressures to be kept Performance maximization - Technology applied: HP impulse or reaction IP impulse & reaction LP reaction Power Plants 2010, Vrnjačka Banja, Serbia - P 17

18 Retrofit solutions Alstom has the widest technology portfolio to suit the customer Possible higher live steam conditions HP Power Plants 2010, Vrnjačka Banja, Serbia - P 18

19 Retrofit solutions Alstom has the widest technology portfolio to suit the customer Modules optimized for constant pressure operation Dolna Odra 2, 7, 8 Turów 4 6 Power Plants 2010, Vrnjačka Banja, Serbia - P 19

20 Retrofit solutions Alstom has the widest technology portfolio to suit the customer Modules optimized for sliding pressure operation new admission system existing admission system Power Plants 2010, Vrnjačka Banja, Serbia - P 20

21 Retrofit solutions Alstom has the widest technology portfolio to suit the customer Possible higher live steam conditions IP Power Plants 2010, Vrnjačka Banja, Serbia - P 21

22 Retrofit solutions Alstom has the widest technology portfolio to suit the customer Pre-Retrofit Post-Retrofit welded rotor (small forgings) Power Plants 2010, Vrnjačka Banja, Serbia - P 22

23 Retrofit solutions LP Blade Portfolio Extensive range of LP Blade Products: - Best from Alstom legacy organisations - New products (38/45 & 42/49 LSB) - Each LP product identified by LSB, and characterised by LSB Area Blade products are carefully positioned: - Cover market requirements - Area, Performance, Cost, No. flows Alstom LP portfolio has been successful for new equipment & retrofit (Alstom OEM and Third Party applications) In some retrofit applications, the existing hardware prohibits the use of the optimal LSB product Performance for Hypothetical LP Products Power Plants 2010, Vrnjačka Banja, Serbia - P 23

24 Retrofit solutions Alstom has the widest technology portfolio to suit the customer Power Plants 2010, Vrnjačka Banja, Serbia - P 24

25 Retrofit solutions Repowering concept example for 200 MW units Original 200 MW turbine 207 MW < 37% Original turbine + 2 x GT13E 485 MW 51,8% P = 12,7 MPa T 535 C T = 535 C P = 6,8 MPa T = 493 C P = 7,0 MPa T = 308 C T = 493 C P = 6,0 MPa T = 522 C T = 525 C P = 13,7 MPa T = 565 C T = 565 C Retrofitted turbine + 2 x GT13E 495 MW 53,1% Original turbine + GT MW 56,6% Retrofitted turbine + GT MW 59,3% Power Plants 2010, Vrnjačka Banja, Serbia - P 25

26 Retrofit solutions Alstom s retrofit designs incorporate: - Sustained performance using impulse or reaction machines - Solid Particle Erosion (SPE) and moisture erosion resistance - Welded rotor technology - Proven standard component and exhaust configurations optimized for plant output and site conditions - Full portfolio of high performance LP last stage blades with integral tip shrouding up to the penultimate stage - Dedicated technical support for maintenance and operational issues Power Plants 2010, Vrnjačka Banja, Serbia - P 26

27 Agenda Introduction to retrofitting Alstom s advanced retrofit technology Retrofit solutions Key references Financial benefits Conclusion Power Plants 2010, Vrnjačka Banja, Serbia - P 27

28 Key references Dolna Odra 2,7,8 (13K215 turbine retrofit) Power output = 232 MW Power Plants 2010, Vrnjačka Banja, Serbia - P 28 Live steam parameters: 12,8 MPa / 535 C Reheat steam parameters: 2,4 MPa / 535 C Condenser pressure: 4,2 kpa

29 Key references Tahkuluoto P.P. (240 MW LMZ turbine) reaction impulse Live steam parameters: 18,1 MPa / 535 C Reheat steam parameters: 2,5 MPa / 535 C Condenser pressure: 2,9 kpa IP efficiency +4% HP efficiency +6% Power Plants 2010, Vrnjačka Banja, Serbia - P 29

30 Key references Seinäjoki P.P. reasons for retrofit - OEM Skoda - First commissioning HP efficiency measured in 2001 < 76% - Skoda repair efforts has failed - Operation hours before retrofit: hrs Reasonable payback time coming from HP retrofit Power Plants 2010, Vrnjačka Banja, Serbia - P 30

31 Key references Seinäjoki P.P. - retrofit solution Live steam parameters: 14,6 MPa / 538 C Reheat steam parameters: 4,3 MPa / 538 C Condenser pressure: 2,8 kpa Power output +4 MW Overall Heat rate -2 % Signature of Contract with Alstom July 2003 Turbine modernization works at site 18. June 17. July 2004 Starting of trial run 18. July 2004 Take Over 16. August 2004 Power Plants 2010, Vrnjačka Banja, Serbia - P 31

32 Key references Bełchatów 6 (integrated project) Power output +24 MW Live steam parameters: 18,3 MPa / 567 C Reheat steam parameters: 4,3 MPa / 568 C Condenser pressure: 6,8 kpa Power Plants 2010, Vrnjačka Banja, Serbia - P 32

33 Key references Claus C (repowering project) Conversion of one steam turbine unit with gas-fired Boiler into KA26-3 Original turbine (640 MW from Siemens) Existing STPP Location of repowering plant New Equipment, main components - 3 x GT x Generators - 3 x Triple Pressure Reheat HRSG Modernisation - Retrofit of Steam turbine bundle - Direct cooling, switch over to cooling tower Re-use of Existing Equipment - Main Cooling water systems - Civil in brown field - ST Generator with auxiliaries - Demineralization Plant - C&I existing Power Plants 2010, Vrnjačka Banja, Serbia - P 33

34 Key references Claus C (repowering project) Project award: Dec 2008 Commissioning: 2011 Power output increase from 630 MW to 1275 MW Efficiency increase from 39% to 58.46% CO 2 decrease from 520 g/kwh to 325 g/kwh Power Plants 2010, Vrnjačka Banja, Serbia - P 34

35 Key references Total number of modernized modules: 833 own fleet 3 rd party - HP modules HP/IP modules IP modules LP modules Power Plants 2010, Vrnjačka Banja, Serbia - P 35

36 Agenda Introduction to retrofitting Alstom s advanced retrofit technology Retrofit solutions Key references Financial benefits Conclusion Power Plants 2010, Vrnjačka Banja, Serbia - P 36

37 Original design life Net Income Financial benefits Lifetime extension Improved Efficiency / Capacity / Load factor; Reduced costs Decommissioning costs Original unit Commissioning costs Power Plants 2010, Vrnjačka Banja, Serbia - P 37

38 Financial benefits Steam turbine retrofitting the cost effective solution - A steam turbine retrofit represents a fast, cost-efficient way to achieve extra power at a low cost-to-kilowatt ratio. This is of particular benefit to: Utilities looking to increase output and/or get an additional years out of their existing plant Operators who wish to raise the competitive level of their plant by reducing heatrate and/or increasing MW and viability/reliability Power Plants 2010, Vrnjačka Banja, Serbia - P 38

39 Financial benefits Steam turbine retrofitting Key benefits - Fuel savings from increased efficiency - Cheaper cost per kw than new build - High rate of project return - Fast return on investment (due to fast installation and on-time delivery) Power Plants 2010, Vrnjačka Banja, Serbia - P 39

40 Agenda Introduction to retrofitting Alstom s advanced retrofit technology Retrofit solutions Key references Financial benefits Conclusion Power Plants 2010, Vrnjačka Banja, Serbia - P 40

41 Conclusion Changing power market conditions and the diversity of plant owners' original equipment Alstom continues to develop solutions to meet the customers needs (ranging from single cylinder replacement to integrated retrofit projects) Efficiency Alstom invests in R&D for impulse and reaction steam path technologies Capacity Reliability Alstom is perfectly positioned to help you find the optimal retrofit solution for your Power Plant Power Plants 2010, Vrnjačka Banja, Serbia - P 41

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