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Mechanical equipment and operation and maintenance
Session VI
Elín Hallgrímsdóttir and Lilja Tryggvadóttir
Mannvit Strasbourg, Nov. 8th, 2012
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Presentation overview
• Features of mechanical equipment used in geothermal power plants
• Example showing methods used for choosing a gas extraction system
• O&M with photographs of extreme conditions shown
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Power Plant Preliminary P&ID
Two phase flow
Steam separators
Geothermal
water
Steam
Re-injection wells
Pressure
regulation
Geothermal water
emergency
exhaust
Turbines
Generators
Mist separators
Cooling
towers
Condenser
s
Condenser
s
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Power Plant - Turbine
• Axial turbines
• Single flow
• Double flow
• Turbo expander
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Single and double flow turbines
single flow 20 - 70 MW Double flow 40 - 140 MW
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Double pressure 6,3/1,4 bara -> 0,1 bara
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Power Plant – Turbine / generator
• Rotor
• Turbine blade size is over 30”
• Corrosion protection on the last stages
• Turbine drain
• Double steam inlet – Stem free test
• Generator
• Overpressure in generator housing
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Power Plant - Heat Exchangers
• Evaporators/recuperators
• Conventional shell and tube or plate heat exchangers
• Hybrid
• Condensers
• Direct contact
• Indirect contact • Shell and tube
• Special cooling section for gas
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Power Plant - Gas extraction system
• Type
• Compressors
• Vacuum pumps
• Ejectors
• Selection
• Gas content
• Condenser pressure
• Cost evaluation • Price of electricity/steam
2 stage hybrid system
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Power Plant - Cooling Tower
25. 02. 2008
Wet CT Hybrid CT
• Type
• Wet
• Hybrid
• Dry
• Selection
• Cost efficiency
• Availability of water
• Visual impact
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Power Plant - Layout
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Layout – 45 MW unit at Hellisheiði
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Power Plant – Building
• Turbine hall
• Conventional steel structure
• Connecting buildings
• Housing electrical rooms
• Concrete building to achieve higher tightness
• Earthquake requirements
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Layout – 133 MW hot water plant at Hellisheiði
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Example
• Selection of gas extraction system
• Assumptions
– Gas content 1% gas
– Steam consumption 83 kg/s
– Price of steam 500.000 EUR/kg/s
– Price of electricity 300.000 EUR/100 kW
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Example, continued
• Vacuum pumps – Electrical consumption 1200 kW – Capital cost 400.000 EUR
• Ejectors – Steam consumption 5 kg/s – Capital cost 100.000 EUR
• Hybrid system – Electrical consumption 300 kW – Steam consumption 2 kg/s – Capital cost 200.000 EUR
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Example, continued
• Evaluation formula
– CC+EC*PE+SC*PS
• Capital Cost (CC)
• Electrical Consumption (EC)
• Price of Electricity (PE)
• Steam Consumption (SC)
• Price of Steam (PS)
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• Vacuum pumps: – 400.000 + 1200*300.000/100 = 4.000.000 EUR
• Ejectors – 100.000 + 5*500.000=2.600.000 EUR
• Hybrid system – 200.000+2*500.000+300*300.000/100=2.100.000 EUR
• Hybrid system would be selected.
Please note that numbers are fictive.
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Operation and maintenance
• In this session operation and maintenance of geothermal power plants with emphasis on the geothermal part of the plant is introduced. Photographs of extreme conditions will be shown.
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Geothermal Power Plants
• Central operation centers
• Observation of machinery
• Security
• Operation supplies (chemical for cooling water, inhibitors, oil, filters for air cleaning, cleaning products, binary fluid)
Included in Operation & Maintenance
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Geothermal Power Plants
• Maintenance – work (rotor and generator every 15 years)
• Maintenance – supplies
• Monitoring of the reservoir and area
• Drilling for maintaining steam
Operation & Maintenance
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Operating Console
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Turbine Monitoring
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Wellhead
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Enclosure Wellheads
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Leakage in Wellhead
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Leakage in Wellhead
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Leakage in Wellhead
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Leakage in Wellhead
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Leakage in Wellhead
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Well Discharge in Winter
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Well Discharge in Winter
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Wellhead Master Valve
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Well Cleaning during Discharging
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Steam Separator for 60 kg/sek
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Cooling Tower in Winter
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Turbine Rotor
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Cleaning of Rotor
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Scaling on Rotor
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Scaling in Stationary Diaphragms
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Erosion in Stationary Diaphragms
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Erosion in Stationary Diaphragms
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Erosion in Stationary Diaphragms
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Diaphragm Repaired by Welding
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Diaphragms Repaired by Welding
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Erosion of Rotor
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Damages Caused by Drainage
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Improvement of Drains in Turbine
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Drains in Turbine
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Shut Down Valve Axle
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Shut Down Valve End Bearing
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Turbine and Generator Bearings
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Oil filter
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Oil System
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Broken turbine blades
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Damaged turbine housing
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Generator broken
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