Drives in Power Generation - Are you human? · PDF file · 2017-09-15Drives in...
Transcript of Drives in Power Generation - Are you human? · PDF file · 2017-09-15Drives in...
© ABB Group September 3, 2010 | Slide 1
Drives in Power Generation
Franz Frank ABB Switzerland
Mauricio Rotella ABB Chile
© ABB Group September 3, 2010 | Slide 2
Agenda
� Power generation “hot topics”� Energy saving with VSDs
� Power generation segments with VSD applications� VSD applications in thermal power plants
� Pump and fan control with VSDs� VSD applications in gas turbine power plants� VSD applications in pump storage power plants
� References � Energy savings case example
© ABB Group September 3, 2010 | Slide 3
Usefulenergy
50%transport
conversionefficiency line losses
productionprocess
net energy
motor efficiency
Primaryenergy
Electricalenergy
Trans-mission &Distibution
IndustrialPlant
Motors &Drives Buildings
Energyinput
Energy use
Energy Value ChainEnergy Efficiency: Improvement Targets
© ABB Group September 3, 2010 | Slide 4
Power generation “hot topics”
� Global warming and choice of primary energy sources
� Rising fuel costs
� CO2 emissions (trading, capturing, storage?)
� Nuclear power on the rise again
� Profitability
� Minimize costs of production, necessity to raise efficiency
� Growing energy demand
� Ageing of existing plants (� requirement for overhaul, upgrade, expansion)
� Requirement for new plants
© ABB Group September 3, 2010 | Slide 5
Three items to focus on
1. Alternative primary energy sources(wind, solar, biofuel etc.)
2. Capture and storage of CO2
3. Increasing the efficiency of the conversion process for saving energy resources and reducing the CO2 emissions.
© ABB Group September 3, 2010 | Slide 6
Energy saving through variable speed drives Electrical auxiliary consumption in a coal fired power plant
80%
20%Electric motors
Others (heating,lighting etc.)
dedicated to processes driven by electric motors
� 5 - 10% of the produced power is dedicated to electrical auxiliary consumption in the power plant (i.e. “losses”)
� Processes driven by electric motors typically consume 80% of this electricity
� By applying electrical variable speed drives (VSDs), total losses can be reduced by ~20%
� In an 800 MW power plant there exists a reduction potential of >8 MW
© ABB Group September 3, 2010 | Slide 7
variable speed drivesfor
soft startersfor
Applications
Segments
-hydro turbines of pumped
storage power plants(LCI.SO)
HYDROPump Storage
feedwater pumpsgas turbine(LCI.ST)
THERMALGAS Turbine
feedwater pumps,condensate pumps,
FD and ID fans,district heating pumps
-THERMAL(Solid fuelled)
Power generation segments with MV VSD applications
© ABB Group September 3, 2010 | Slide 8
Boiler feed pump2000-20000 kW
Boiler recirc. pump
100-400 kWCooling water pump
300-2300 kW
Condensate pump100-1200 kWFeed water
booster pump
Thermal power plant Pump applications
Aux. consumption of a thermal PP: 5-10%
© ABB Group September 3, 2010 | Slide 10
H2 = 0,64
Q2
= 0,
7
Q2
= 0,
7H2 = 1,27
89.027.1*7.0P =≈
Power demand Throttling control versus VSD control
�
�
H1 = 1Q
1 =
1
45.064.0*7.0P =≈
�
H1 = 1
Q1
= 1
�
Throttling VSD Control
Design Point
Design Point
© ABB Group September 3, 2010 | Slide 11
Energy Efficiency of Pump Control Methods
Pump Control
0
20
40
60
80
100
120
0 30 40 50 60 70 80 90 100
Flow
Po
wer
Dem
and
Bypass Control
Throttling Control
Hydro Coupling
VSD Control
Theoretical PowerDemand
Energy savings potential of VSD Control versus Throttling Control
© ABB Group September 3, 2010 | Slide 12
Thermal power plant Fan applications
Coal pulverizer fan100-400 kW
Gas recirc. fan400-1500 kW
Force draft fan400-4500 kW
Primary air fansecondary air fan
400-4000 kWInduced draft fan
400-9000 kW
Induced draft fan (booster)400-9000 kW
See notes for add’l info
106
106
© ABB Group September 3, 2010 | Slide 13
Performance of a fixed speed fan with damper control
Fan Characteristic Design Point / TB (Test Block condition) various contingency factors considered
Flow Rate
Pre
ssur
e
Fan EfficiencyLevels
Damper Positions
25% Flow ReductionEfficiency drop from
85.3% to 40% ���� 45% losses
Operating point / MCR (Maximum Continuous Rating)
“The power demand for the TB rating is significantly larger than for the MCR with the MCR rating being between 60 and 75 percent of the TB rating.”[IEEE Std 958-2003]
System Characteristic
© ABB Group September 3, 2010 | Slide 14
Performance of a variable speed controlled fan
FanCharacteristic
depending on Motor/Fan
Speed
Design Point / TB
Pre
ssur
e
Flow Rate
25% Flow ReductionEfficiency drop from 89% to 87%
���� 2% losses
System Characteristic
Fan EfficiencyLevels
© ABB Group September 3, 2010 | Slide 15
Fan Control
0
20
40
60
80
100
120
0 30 40 50 60 70 80 90 100
Flow
Po
wer
Req
uir
ed
Outlet Damper Control
Inlet Guide Vane Control
Electrical VSD Control
Theoretical PowerDemand
Energy Efficiency of Fan Control Methods
Energy savings potential of VSD Control versus Damper Control
© ABB Group September 3, 2010 | Slide 16
variable speed drivesfor
soft startersfor
Applications
Segments
-hydro turbines of pumped
storage power plants(LCI.SO)
HYDROPump Storage
feedwater pumpsgas turbine(LCI.ST)
THERMALGAS Turbine
feedwater pumps,condensate pumps,
FD and ID fans,district heating pumps
-THERMAL(Solid fuelled)
Power generation segments with MV VSD applications
© ABB Group September 3, 2010 | Slide 17
Combined-cycle power plant applications
(HRSG) Boiler feed pump1100-4500 kW
Boiler recirc. pump
100-400 kW
Cooling water pump100-1500 kW
Condensate pump100-1100 kW
District heating recirc. pump100-1500 kW
Co-Generation(COGEN)
Fuel-gas booster compressor
1100-4000 kW
Aux. consumption of a CCPP: 3-4%
© ABB Group September 3, 2010 | Slide 18
LCI.ST
Gas turbine starterStarting Frequency Converter (SFC)
� Megadrive LCI.ST
� Load Commutated Inverter topology, using thyristor semiconductors
� Proven technology
� > 750 units delivered
� Air cooled design
� Sequential starting of several generators possible with one single LCI.ST
© ABB Group September 3, 2010 | Slide 19
� Start-up sequence� Break away and ramp-up to about
30% speed
� GT (and HRSG) purging
� Continue ramping up and GT ignition
� Continue ramping up in field weakening, GT gradually taking over
� Turn-off SFC
� Turn on main excitation
� Synchronize to grid
How does a Start-up work?
© ABB Group September 3, 2010 | Slide 20
variable speed drivesfor
soft startersfor
Applications
Segments
-hydro turbines of pumped
storage power plants(LCI.SO)
HYDROPump Storage
feedwater pumpsgas turbine(LCI.ST)
THERMALGAS Turbine
feedwater pumps,condensate pumps,
FD and ID fans,district heating pumps
-THERMAL(Solid fuelled)
Power generation segments with MV VSD applications
© ABB Group September 3, 2010 | Slide 21
� In a pumped storage the water is flowing through the turbine and the machine is generating when demand is high.
� When demand is low and electricity is cheap the generator (running as motor) drives the turbine, pumping water back into the reservoir
� Starting frequency converter needed to start-up the generator/motor
Pumped storage power plant
© ABB Group September 3, 2010 | Slide 23
Agenda
� Power generation “hot topics”� Energy saving with VSDs
� Power generation segments with VSD applications� VSD applications in thermal power plants
� Pump and fan control with VSDs� VSD applications in gas turbine power plants� VSD applications in pump storage power plants
� References � Energy savings case example
© ABB Group September 3, 2010 | Slide 24
Case exampleHelsinki Energy, Finland
� Retrofit of fixed-speed motors withACS 1000 VSDs, operating four boilerfeedwater pumps (FWPs), each 4500 kW
Benefits:
� Improved power plant efficiency(as FWPs are one of the biggestenergy consumers in a power plant)
� Reduced maintenance costs
© ABB Group September 3, 2010 | Slide 25
� An US university power plant installed a 1,000 hp ACS 1000 MV drive for its scrubber booster fan
� Energy efficiency improved by 25% against that of inlet vanes
� Energy saving: about 1’460’000 kWh/year
� Reduction of CO2 emissions: 730’000 kg/year
� Other benefits� Better process controllability� Less maintenance by soft starting� No more start-up problems
Case exampleUniversity of Illinois power plant, USA
© ABB Group September 3, 2010 | Slide 26
� Refurbishment of the 280 MW boiler at block 6 of the GKM power plant
� Retrofitting 2 of 3 boiler feedwater pumps with ACS 1000 VSDs, by replacing the old hydraulic couplings (with poor efficiency)
� ABB scope of supply:
� 2 x water cooled ACS 1000 VSD incl. dry type transformers, 4000 kW
� General overhaul and star-delta reconnection of the 6kV motors
Benefits:
� 20 – 25 percent energy savings:around 12’000 MWh/year
� Reduction of CO2 emissions:10’000 t/year
Case example Grosskraftwerke Mannheim, Germany
Fully containerized solution
© ABB Group September 3, 2010 | Slide 27
New 900 MW coal fired power station(Block 9) in the city of Mannheim
� Customer‘s goal: all major motors to be VSD controlled in order to optimize plant efficiency
� ABB scope of supply:
� 2 x 70% feedwater pumpsACS 5000W, rated for 21.5MW induction machines
� 12 x ACS 1000 in the power range of 800kW to 3000kW for- condensate pumps- cooling water pumps- district heating pumps- coal pulverizer fans
New reference Grosskraftwerke Mannheim, Germany
© ABB Group September 3, 2010 | Slide 28
New reference ESKOM – Medupi Power Plant
New 4800 MW coal fired power plant, consisting of 6 blocks
� Variable speed driven condensate extractionpumps (each consiting of 6 blocks)
� 6 x air cooled ACS 5000 with integratedtransformer, each 1800 kW
Medupi construction progress April 2009 (source: www.eskom.co.za)
Medupi construction progress Dec. 2009 (source: www.eskom.co.za)
© ABB Group September 3, 2010 | Slide 29
New reference ESKOM – Majuba, Kendal, Matimba Power Plant
LCI refurbishment project for 3 coal fired4000 MW power plants, each consitingof 6 blocks
� 6 x 3 feedwater pumps (12MW @ 6000rpm) per power plant
� 22 x LCI drives order
� ABB high speed machines, WMT 630
© ABB Group September 3, 2010 | Slide 30
New referenceMühleberg Switzerland / Nuclear Power Plant
Refurbishment project, replacing two LCI feed water pump drives, 3.4 MW / 3000 rpm, delivered in 1987/88
• 2 x LCI feedwater pump drives, 3.4 MW
• 1 x ACS 5000 additional pump drive, 3.4 MW
• 2 x ACS 1000 reactor circulation pumpdrives, 1.1 MW
© ABB Group September 3, 2010 | Slide 31
Agenda
� Power generation “hot topics”� Energy saving with VSDs
� Power generation segments with VSD applications� VSD applications in thermal power plants
� Pump and fan control with VSDs� VSD applications in gas turbine power plants� VSD applications in pump storage power plants
� References� Energy savings case example
© ABB Group September 3, 2010 | Slide 32
Payback of applying electrical variable speed drivesCase example
� Feedwater pump, average operating time / year = 8’000 h
� Average electrical power consumption = 4’000kW
� Resulting electrical energy demand = 32’000 MWh
� Energy savings due to applying VSD = 20%
� Resulting energy savings per year = 6’400 MWh
� Energy cost savings = 320’000 EURbased on el. energy costs of 5 ct/kWh
� resulting in a payback time of only two years
� total savings over 20 years lifetime = 5’760’000 EUR
� Additionally !
� Reduction of CO2 emissions of ~5’000 t/year
© ABB Group September 3, 2010 | Slide 33
92%
6%2%
Lifetime costs of a VSD system
� Total investment costs < 6 % of the total lifetime costs
� Customer benefit:Big savings on energy consumption, not on investment costs
Energy costsInvestment costsMaintenance and overhaul costs
20 years total lifetime costs
© ABB Group September 3, 2010 | Slide 34
Power GenerationEnergy Efficient Design of Auxiliary Systems in Fossil Fuel Power Plants