[CASE STUDY] Retrofit of Boryeong Coal Fired Power Plant ...
Transcript of [CASE STUDY] Retrofit of Boryeong Coal Fired Power Plant ...
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[CASE STUDY]
Retrofit of Boryeong
Coal Fired Power Plant Unit 1&2
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Contents
1. Introduction
3. Retrofit of Boryeong Unit 1&2
2. Guidelines for the Life Management
4. Conclusion
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1
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1.1 KOMIPO
12.6% out of total Korean domestic power generation facilities (74,410 MW)
SeocheonThermal P/P
SeoulThermal P/P
IncheonThermal P/P
JejuThermal P/P
YangyangP/S/P/P
BoryeongThermal P/P
Boryeong TPP
Boryeong CCPP
Seoul TPP
Incheon TPP
Incheon CCPP
Seocheon TPP
Jeju TPP
Yangyang PSPP
Renewable
Name
9,399 MW
Bituminous coal
LNG
LNG
LNG
LNG
Anthracite coal
Bunker oil / Kerosene
Hydraulic
Wind / Solar / Fuel cell / SHPP
CapacityFuel
4,000 MW
1,800 MW
387.5 MW
500 MW
1012.4 MW
400 MW
285 MW
1,000 MW
14.05 MW
Total
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1.2 Boryeong # 1,2
UnitCapacity
[MAR]Completion
Retire
[plan]
Operation
[Hour]
# of
Start-up
Average
Power
Factor [%]
Gross Generation
[Million kWh]
1 510 ’83.12
’15
141,000 190 82.2 76,102
2 510 ’84.09 138,000 150 81.3 74,395
Operation Data
Unit TBN BLR Total
Design 45.48 89.14 40.54
1 44.54 89.14 39.70
2 44.32 89.14 39.50
Efficiency
Item Emission ~ ’09 ’10 ~
SOx[ppm] 150~240 270 100
NOx[ppm] 200~290 350 150
Regulations
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1.3 Bathtub curve
Technical basis
Item EOHElapsed
Year# of
Start-up
criteria > 100,000 Hr 20 400
Technicalbasis
> 50% of Creep Worn out> 50% Fatigue
life
Bathtub curve
∙ Failure rate in accordance with aging
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2
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2.1 Design life
Design life of each plant
Item Coal fired Combined cycle Pumped storage Internal-combustion
Design Life
(year)30 30 50 25
Proper time for each procedure[D : Year of retirement]
No. Procedure Time No. Procedure Time
1 Life Assessment D – 10 4 Confirmation of Method D – 6
2 Master Planningfor Life Management D – 9 5 Planning for Execution D – 6
3 Feasibility Study D – 8 6 Execution of Project D – 5
∙ Reference life of the guideline
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2.2 Procedures for Life Management(1)
Main facilities for life assessment
TBN BLR Electric Equipment
∙ HP/IP/LP Blades & Diaphragm
∙ Rotor
∙ Casing
∙ Tube
-Waterwall, S/H, R/H, Eco
∙ Drum
∙ Main STM pipe
∙ R/H STM pipe
∙ Stator & Rotor
∙ Exciter
∙ Transformer
- Main, Aux, Start-up
Life Assessment (D-10)
∙ Reliability & Remaining life evaluation
∙ Analyzing operation and maintenance history
∙ Operating and design conditions
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2.2 Procedures for Life Management(2)
Master Planning (D-9)
∙ On the basis of life assessment report
∙ Potential life management method
∙ Following procedure and estimated budget
Feasibility study (D-8)
∙ Technical(environmental) and economical feasibility
∙ By professional organization for objectivity
∙ Optimal project method and boundary
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2.2 Procedures for Life Management(3)
Confirmation of method (D-6)
∙ Best method based on feasibility study
∙ Specific project execution plan
∙ According to the project execution plan
Execution of project (D-5)
Planning for execution (D-6)
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3
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3.1 Facility Status(1)
Item Specifications
Stage HP/IP/LP 6/5/6(Double)
Main steam Pressure /Temp 169[kg/cm2] / 538℃
Reheat steam Pressure /Temp 39[ kg/cm2] / 538℃
Maker Toshiba
Turbine
∙ 500MW regeneration reheating impulse TBN
∙ Tandem Compound 3 Cylinder
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3.1 Facility Status(2)
Boiler
∙ Sub-critical pressure
∙ Reheating and balance draft
Item Specifications
Type of Boiler Drum
The max amount of continuous vaporization 1,781 [Ton/Hr]
Fuel Bituminous Coal, Light oil
Outlet pressure of Superheater / Reheater 176.4/40.4 [kg/cm3]
Outlet Temperature of Superheater / Reheater 540/540 [℃]
Maker Bobcock and Wilcox
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3.1 Facility Status(3)
Gen.
Item Specifications
Rated capacity 613,000KVA
Rated voltage 22,000V
Rated current 16,088A
Rated Frequency 60Hz
Cooling
Stator windings Water
Stator core Hydrogen
Rotor windings Hydrogen
Maker Toshiba
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3.2 Retrofit Project
• Life assessment for unit #2’03. 07
• Life assessment for unit #1’03. 12
• Master planning’04. 11
• Feasibility study’05. 02
• Planning for retrofit’06. 04
• Execution of retrofit’08. 10
• Output increasing : 25MW
• Efficiency increasing : 0.8%
• Lifespan extension : 10 years
Goals
Procedures according guideline
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3.2 Retrofit Project
Life assessment (#1: ’03.12 / #2 : ’03.07)
∙ During major inspection
□ Turbine
- Low efficiency due to worn out blade and nozzle
- Erosion of IP TBN
□ Boiler
- Remaining life of S/H & R/H : 40,0000 Hr
- Need to Slope tube replacement
□ Generator
- Retaining ring of rotor was corroded
- Stator winding degradation
∙ Overall facility degradation
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3.2 Retrofit Project
Master planning (’04.11)
∙ Plan to emergency maintenance during next inspection
ex) 1st Stage of IP TBN & Boiler slope tube
Feasibility study (’05.02)
• KEPCO E&C (former KOPEC)Service company
• Turbine : Toshiba
• Boiler : Bobcock & WilcoxTechnical consultation
• Konkuk UniversityEconomical consultation
∙ Retrofit project as a life management method
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3.2 Retrofit Project
Retrofit methods
Method Description Action Plan
1Life Extension
+ Improvement of Thermal EfficiencyHIP Remodeling
2 Case ⅠWay 1 + Improvement of Output
HIP Remodeling
2 Case Ⅱ HIP & LP(L-0, L-1) Remodeling
3 Case ⅠWay 2 + Rise of R/H STM Temp(28℃)
HIP Remodeling
3 Case Ⅱ HIP & LP(L-0, L-1) Remodeling
Ref. Minimal Facility replacement and reinforcement
Performance comparison
Unit Before
Methods
12 3
Ref.Case Ⅰ Case Ⅱ Case Ⅰ Case Ⅱ
Output [MAR] MW 510 515 535 535 535 535 510
Eff.
BLR % 88.09 88.49 88.49 88.49 88.54 88.54 88.09
TBN % 44.32 45.05 45.02 45.27 45.22 45.48 44.32
Total % 38.10 38.92 38.90 39.12 39.10 39.33 38.10
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3.2 Retrofit Project
Range of facility replacements
Item
Methods
1
2 3
Ref.Case
ⅠCase
ⅡCase
Ⅰ
Case
Ⅱ
BLR
Tube of Secondary S/H, R/H ○ ○ ○ ○ ○ ○
∙ Expand Heating surface for R/H STM
∙ Eco tube → Primary S/H× × × ○ ○ ×
TBN
HIP Rotor, Nozzle Box
HP/IP Nozzle Diaphragm
HP Inner Casing
○ ○ ○ ○ ○ ○
IP Inner Casing × × × ○ × ×
LSB L-1 Blades & Nozzle × × ○ × ○ ×
LSB L-0 Blades & Nozzle
LP Nozzle Packing× × ○ × ○ ○
LP 1st Nozzle × × ○ × ○ ○
Ele. Eq. GEN Rewinding/AVR & DCS Replacement ○ ○ ○ ○ ○ ○
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3.2 Retrofit Project
Balance for ’08~’24 under current power market situation
Unit
Methods
12 3
Case Ⅰ Case Ⅱ Case Ⅰ Case Ⅱ
Income billion
Dollar
362 379 378 378 377
Cost 231 237 236 236 235
Profit 131 142 142 142 142
∙ Under variable scenario of domestic power market
∙ Case 1 & 2 of method 2 & 3
Cost for Retrofit
Item Unit
Methods
12 3
Ref.Case Ⅰ Case Ⅱ Case Ⅰ CaseⅡ
Costmillion
Dollar104 105 118 136 149 104
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3.2 Retrofit Project
Synthetic analysis
Item Unit
Methods
12 2 3 3
Ref.Case Ⅰ Case Ⅱ Case Ⅰ Case Ⅱ
Cost USD 104 m 105 m 118 m 136 m 149 m 104 m
Efficiency % + 1 + 1 + 1 + 1 + 1 -
Output % - + 5 + 5 + 5 + 5 -
Economic feasibility - Bad Good Good Good Good Bad
Facility Reliability - Bad Normal Normal Good Good Bad
Investment Risk - Low Low Low High High Low
• Case II of Method 2Optimum
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Turbine(1)
3.3 Facility Improvements
After
Before
HP 6 Stage IP 5 Stage
HP 7 Stage IP 6 Stage
HP/IP Stages
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Turbine(2)
3.3 Facility Improvements
Bucket Type (HP 1st stage)
Before After
Tangential Entry Dovetail Axial Entry Dovetail
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Turbine(3)
3.3 Facility Improvements
Bucket Cover Type (HP/IP)
Before After
Tenon Covered Bucket Integral Covered Bucket
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Turbine(4)
3.3 Facility Improvements
Diaphragm (HP 1st stage)
Before After
Nozzle Box Type Nozzle Plate Type
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Turbine(6)
3.3 Facility Improvements
Result
UnitEfficiency [%]
Output[MW at MAR]
HP IP LP TBN Total Avg.
1 85.36 91.87 91.95 45.3745.46
(44.43, +1.03)
535
(510, +25)2 84.97 92.17 90.41 45.54
∙ Short manufacturing time (Diaphragm)
∙ Easy to disassemble and assemble (Bucket)
∙ Easy to repair and replace (Diaphragm)
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Boiler(1)
3.3 Facility Improvements
Tube Material Upgrade (S/H & R/H)
Tube
Tube material Allowable Temp.
Before After Before After
SSH Inlet SA213T12 T22, T91,T92 538 542
SSH Outlet SA213T22 T91 602 649
R/H #3 Interm SA213T12 T22 538 542
R/H Outlet SA213T22 T91 602 649
- Long-term use, tube scale, diversification of coal
∙ Life consumption rate was about 50~60%
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Boiler(2)
3.3 Facility Improvements
Restoring S/H
Before After
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Boiler(3)
3.3 Facility Improvements
Expanding Eco.
Before After
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Boiler(4)
3.3 Facility Improvements
Result
Efficiency of boiler [%]
Unit Before After Balance
1
89.14
89.96 + 0.82
2 90.63 + 1.49
∙ Total heating surface increased by 3,350 m2
∙ Heating surface of the primary S/H increased by 2,264 m2
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3.3 Facility Improvements
Gen.
Gen. & AVR
AVR
∙ Rewinding
- Minimizing the power loss : 1,840 → 1,263 kW (-577kW)
- Improving the insulation class ( class B → class F)
∙ Retaining ring material upgrade ( 18Mn-5Cr → 18Mn-18Cr)
∙ Rated capacity : 613 → 626 MVA (+13MVA)
∙ The exciter transformer capacity increasing (4.9MVA → 5MVA)
∙ 3 phase controlled rectifier(PCR)
∙ Static type digital controller tripling
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3.3 Facility Improvements
Control System
Control System Before After
Turbine Analog(Toshiba EHC)
Digital(Emersion, Ovation)Boiler Analog(Bailey 820)
Burner Analog(Bailey 861)
∙ Manufacturing was discontinued
∙ Lifespan expired
∙ Over the maintenance limit
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3.3 Facility Improvements
Environmental Facility(1)
Desulfurization facilityDeNOx facility
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3.3 Facility Improvements
Environmental Facility(2)
Regulations and emission
Item ~ ’09Emission
[before]’10 ~
Emission
[after]
SOx 270 150 ~ 240 100 80
NOx 350 200 ~ 290 150 80
Dust 40 10 ~ 30 30 8
Result
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3.4 Result of Retrofit Project
Synthetic Result
□ Project period
#1 : 2009.1.14 ~ 7.25 #2 : 2008.10.23 ~ 2009. 3.31
□ Cost : 225 million dollar
□ Performance improvement of worn-out coal fired power plants
○ Output : Increasing of 25MW(510 → 535MW at MAR)
- Saving construction cost of 42 million dollar
○ Efficiency of power plant : Increasing by 1.44%
- Saving fuel cost of 112 million dollar per 1 unit
□ Life extension by 10 years
Item Before After Remark
Output 510 MW 535 MW + 25MW
Efficiency 39.60% 41.04% 1.44%
Lifetime 2015 2025 + 10 years
Control System Analog Digital
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4
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4. Conclusion
Boryeong #1,2
• Worn-out
• Reinforced regulation
• Experience of 500MW class retrofit projectPride
• Share experience & contribute globallyCooperation
Retrofit project
• Output
• Efficiency
• Lifespan
Guidelines
for life management
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Q & A
Seongwoo YiPower generation department
Korea Midland Power Co., Ltd.(KOMIPO)
Email : [email protected]
Phone : 82 – 70 – 7511 – 1326
Thank you for your attention.
Contact Information