Society of Thermal Engineers of Serbia POWER PLANTS 2012 ...
Transcript of Society of Thermal Engineers of Serbia POWER PLANTS 2012 ...
Society of Thermal Engineers of Serbia
POWER PLANTS 2012International Conference
Zlatibor, SerbiaOctober 30 – November 02, 2012
Wolfgang Apelt, Head of Project ManagementVattenfall Europe PowerConsult GmbH, Germany
New Supercritical Power Plant Projects of Vattenfall
BOXBERG unit R and MOORBURG units A and B
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Boom of Power Projects - 27 coal projects in Germany
Source: Energie Focus
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Cancelling of coal projects in Germany
Source: BUND
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Current Development of Power Prices
Source: Vattenfall
Power Spot Price Development Power Forward Price Development
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Project Unit R TPP Boxberg (BoxR)
Base Load Operation
Availability > 91 %
Load Range 50 % to 103 %
High Control Level
Compliance with Transmission Code
Net Efficiency > 43,7 %
(Live Steam: t = 600 °C; p = 285 bar)
Coal Consumption: 4,5 Mio. t/a
Specific CO2-Emissions: 924 g/kWh VPC works in Owner‘s team and as
Design Engineer
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+ 135 m
ESPELWORAFAKO- Horizontal ESP- Newest generation
of voltage control- HV-aggregates on
the roof
ID fanHPE
FGD PlantBabcock-Noell- Open air placement- washer protected by
rubber- Installation of tray
below spray levels
Civil Works (buildings): STRABAG
Civil Works (cooling tower): Heitkamp
Turbine HallTurbine: ALSTOM- 4 casings- Single reheater- 2 condensers in
sequence- 9 pre- heaters
BoilerHPE- Benson-boiler- Round coal
burners- Single line air and
FG system- Complex
diagnostic systems
CT with FG inletHamon- Natural ventilation- High efficiency equipment- Possible operation of
sections- Single FG-inlet,
channel-∅ 7,5 m
+ 155 m
Main Equipment BoxR
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BoxR – Organisation of Site Management
Site Team
� Senior Site Manager (for erection and commissioning activities)
� Number of staff: 76
all over services: 16
technical groups: 26
(civil works, mechanical equipment, electrical
systems, I&C)
commissioning group 34
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BoxR – Number of Lots
Total number of lots: 55
mechanical equipment 29
civil works 13
electrical systems 10
I&C 3
Maximum number of employees at site: app. 1,800
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10/06
2005 2006 2007 20092008 2010 2011
Start of site activities
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02/07
2005 2006 2007 20092008 2010 2011
Site Field ca. 100.000 m²Excavated ca. 260.000 m³
Cooling Tower (Fa. Heitkamp)Bottom Diameter 100 mHeight 155 m
Cooling Water Pipelines (Fa.Porr)Diameter 3,60 mLength ca. 600 m
Foundation (Fa. Strabag)Turbine Hall 89 x 51 m Boiler Hall 88 x 84 mSwitchgear B. 18 x 51 mmax. thickness 3,80 mConcrete ca. 40.000 m³Reinforcement ca. 10.500 t Height of Boiler Hall 135 m
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01/08
2005 2006 2007 20092008 2010 2011
Start of boiler erection works
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06/08
2005 2006 2007 20092008 2010 2011
Placing of feed water tank
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Erection of coal bridge
08/08
2005 2006 2007 20092008 2010 2011
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2005 2006 2007 20092008 2010 2011
Delivery of turbine condensers
11/08
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2005 2006 2007 20092008 2010 2011
02/09
Arrival of generator stator at site
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06/09
2005 2006 2007 20092008 2010 2011
Installation of evaporator panels
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2005 2006 2007 20092008 2010 2011
Auxiliary steam blowingTest of transformer’s water spray system
02/10
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2005 2006 2007 20092008 2010 2011
09/10
First oil fire on 20.09.10
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2005 2006 2007 20092008 2010 2011
10/10First coal fire on 08.10.10
Stop of commissioning on 20.10.10 because of boiler leakages
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BoxR- Location of Defects on Boiler
Defects on Evaporator
- Area from +55m to +65m (last section of evaporator as part of the membrane wall)
Activities
- Comprehensive inspections and assessment of defects till February 2011
- Conservation of plant during the break time of commissioning activities
- Investigation of two different technical solutions in parallel:
* repair of the damaged part of evaporator
* replacement of the damaged part of evaporator
- Decision was made in April 2011 to replace the damaged parts of evaporator
Area of evaporatordefects (leakages)
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BoxR - Boiler – Replacement of evaporator panels
Boiler front wall after replacement of T 24 parts of e vaporator (09.11.2011)
880 m²
9.218 weld seams
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BoxR - Boiler – Flushing and Heat Treatment of SH 1
Compressors for air injection during high velocity flushing and for temperature controlduring heat treatment of superheater 1 (25.11.2011)
Provisional flue gas exhaust on boilerhouse roof during heat treatment process(28.11.2011)
Flushing
Heat treatment
Protection layerestablishment
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BoxR - Boiler – Heat Treatment of SH 1
Process monitoring and control during heattreatment process(05.12.2011)
The heat treatment process was accomplished after a 72 h hold phase on temperature level of 520 °C.
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BoxR – Sequence of Re- start Activities
29.10.2011 Completion of pressure test
10.11. – 13.11.2011 High velocity flushing
28.11. – 07.12.2011 Heat treatment of superheater 1
21.12.2011 Start of bypass operation
27.12.11 – 01.01.12 Operation with oil burners only to establishproper protection layer inside of boiler tubes
(measurement of H2 concentration)
07.02.2012 1st steam to turbine
16.02.2012 1st synchronization
17.02.2012 start of test operation/ optimisation of plant operation
30.03.2012 1st full load operation of the plant
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BoxR- Time Schedule for Commissioning and Hand- Over
OktSepAugJulJunMaiAprMrzFebJanDez
Test run of the plant / Optimisation
17.02.2012 – 30.06.2012
Trial run (for all lots)
01.07.2012 – 08.10.2012
Take over by Employer TPP Boxberg / Start of trial run
by Employer
on 09.10.2012, 00:00 Uhr
1. Synchronization
16.02.2012
Bypass operation
21.12.2011 – 16.02.2012
Nov
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Moorburg TPS - 2 x 820 MW
• Site at the Baltic Sea
• World-wide hard coal with up to 1,5 % S, supply by oceanvessels
• 600 MW district heating
• Boiler design: 276 bar, 604/620°C
• 46 % efficiency with once-through cooling
• Single flue gas train
• Package-wise tendering
VPC works in Owner‘s team and as Design Engineer
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Moorburg TPS - Aerial view
3D Model as of October 2011 including hybrid cooling tow er
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Determination of activities for building decisionApplication for total budgetDecision of overall conceptConfirmation of project progressConfirmation of major project changesConfirmation of project organisationBusiness and measures with substantial relevance for operationProperty issuesConfirmation of communication concept
Decision of substantial technical conceptsEffecting and amendment of the project manualFinal appraisal of layout and architecture of the plantFinal appraisal for selection of major componentsConfirmation of and monitoring of master scheduleSetting of binding project defaults for the Project ManagementBudget monitoring and controlControl of project deviationsCo-opting of divisions Power Plant Operation and Technical ServicePreparation of decisions for the Project Council
Total Process Responsibility
Project Council
Project Management
Steering Committee
Employer‘s Project Organisation I
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Design & Engineering
(VPC)
Project service
Budget/ChangesDocumentationQuality AssuranceSite PreparationSecretary
Project
Management
Employer‘s Project Organisation II
Procurement
Department
Line Organisation
of Employer (VE)
Site Management incl.
Commissioning
Project
Controlling