evonik thermal analysis for mahagenco turbines

5/25/2018 Evonik Thermal Analysis for MAHAGENCO Turbines

1/56

Mrs. Remich/ Mr. Nietzschmann, Germany

Dr. Verghese, India

15.05.2008

The Importance of SoundSimulation, Analytics and

Operation Support Systemsfor the Implementation of

Efficiency Enhancement

Measures


2/56Seite | 215.05.2008 | A. Nietzschmann, C. Remich, Dr. Verghese

A sound simulation, diligent analytics andreliable operation support systems for theImplementation of Efficiency EnhancementMeasures (Retrofits) are mandatory for asustainable, economical and environment-friendly operation of power plants

Efficiency Enhancement Measures areexemplarily shown by Evoniks steam turbineretrofits

Evoniks approach and methodology will bepresented and is adaptable to other projectsand clients

Introduction


3/56Seite | 313.05.2008 | Dr. Verghese, A. Nietzschmann, C. Remich

1. Energy Enhancement Projects of ESS,

India

2. Reasons for Retrofits and Applicable

Measures

3. Evaluation Process for Retrofits

4. Sustainable Operation Management

with Operation Support Systems


4/56

Seite | 415.05.2008 | A. Nietzschmann, C. Remich, Dr. Verghese

Energy Enhancement Projects of

ESS, India

GTZ funded program

Ebsilon Mapping of 85 old units of sizes 100 to 500 MW belonging to the

Electricity Boards for CEAKfW funded program

Basic Findings for Improving Efficiency and Reliability of 200/210 MWPower Units in partnership with Vattenfall, Europe

World Bank projects:

Consultancy services for Energy Efficiency, Renovation & Modernizationof 210 MW Unit #5 at Bandel TPS - under Coal Fired Power StationRehabilitation Project

Consultancy Services to design Renovation & Modernisation scheme toimprove the Energy Efficiency, Upgrade Capacity and Residual Life ofKoradi TPS, Unit 6 (210 MW)

Review of O&M and Management Practice of MAHAGENCO & WBPDCL

for Koradi & Bandel Rehabilitation Projects


5/56


Energy Enhancement Projects of

ESS, India

PSEB

Owners Engineering Services, R & M works unit 3 &4, 110 MW, GNDTP,

Bathinda

RLA/CA/LE Studies and Performance Testing of 2 x 210MW units at Ropar

CSEB

RLA/CA/LE Studies and Performance Testing for 4 x 210 MW units of theHasdeo TPS at Korba West

R&M Consultancy Services towards preparation of techno-commercialspecification, evaluation of bids and detailed engineering of 4 x 210 MW

units at Korba West TPS

Residual Life Assessment and Steam Path Audit studies:

2 x 210 MW GGSSTPS at Ropar for PSEB

200 MW Unit #2 Ramagundam TPS of NTPC


6/56


About 130 units of LMZ/KWU turbine types

Installed between 1977 and 1982

Operation hours accumulated varies between 150,000 to 200,000hours

Plant Load Factor varying from 62 % to 90 %

Results of 26 units of 210 MW size which were mapped show awide range of performance parameters

Basic Data of old 210 MW in India


7/56


Observed Operating Capacity of

210 MW capacity units

Operating Capacity of 210 MW capacity units (MW)

170.0175.2

190.0 195.9207.8

219.0

210.8

0.5

50.5

100.5

150.5

200.5

250.5

1 2 3 4 5 6 7 8 910

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26


8/56


Observed Gross Heat Rate of

Power Plants (kcal/kWh)

Gross Heat Rate of 210 MW capacity units (kcal/kWh)

2,877

2,8392,824

2,747

2,643

3,064

2,477

2,952

2,300

2,400

2,500

2,600

2,700

2,800

2,900

3,000

3,100

Unit

#

1

Unit

#

2

Unit

#

3

Unit

#

4

Unit

#

5

Unit

#

6

Unit

#

7

Unit

#

8

Unit

#

9

Unit

#

10

Unit

#

11

Unit

#

12

Unit

#

13

Unit

#

14

Unit

#

15

Unit

#

16

Unit

#

17

Unit

#

18

Unit

#

19

Unit

#

20

Unit

#

21

Unit

#

22

Unit

#

23

Unit

#

24

Unit

#

25

Unit

#

26


9/56


Observed Boiler Efficiency (%)

Boiler Efficiency of 210 MW capacity units (%)

79.10

82.00

77.25

84.20

74.00

76.00

78.00

80.00

82.00

84.00

86.00

#

1

#

2

#

3

#

4

#

5

#

6

#

7

#

8

#

9

#

10

#

11

#

12

#

13

#

14

#

15

#

16

#

17

#

18

#

19

#

20

#

21

#

22

#

23

#

24

#

25

#

26


10/56


Observed Turbine Heat rate

(kcal/kWh)

Turbine Heat Rate of 210 MW capacity units (kcal/kWh)

2407

23592337

22662234

2045

1900

2000

2100

2200

2300

2400

2500

Turbine

#

1

Turbine

#

2

Turbine

#

3

Turbine

#

4

Turbine

#

5

Turbine

#

6

Turbine

#

7

Turbine

#

8

Turbine

#

9

Turbine

#

10

Turbine

#

11

Turbine

#

12

Turbine

#

13

Turbine

#

14

Turbine

#

15

Turbine

#

16

Turbine

#

17

Turbine

#

18

Turbine

#

19

Turbine

#

20

Turbine

#

21

Turbine

#

22

Turbine

#

23

Turbine

#

24

Turbine

#

25

Turbine

#

26


11/56


Observed Auxiliary Power

Consumption (%)

Percentage of Auxilary Consumption of 210 MW capacity units (%)

8.68

11.82

8.07

8.9

9.11 9.32

11.19

6.5

7.5

8.5

9.5

10.5

11.5

12.5

Unit#

1

Unit#

2

Unit#

3

Unit#

4

Unit#

5

Unit#

6

Unit#

7

Unit#

8

Unit#

9

Unit#

10

Unit#

11

Unit#

12

Unit#

13

Unit#

14

Unit#

15

Unit#

16

Unit#

17

Unit#

18

Unit#

19

Unit#

20

Unit#

21

Unit#

22

Unit#

23

Unit#

24

Unit#

25

Unit#

26


12/56

Seite | 1213.05.2008 | Dr. Verghese, A. Nietzschmann, C. Remich

Dr. Jacob T Verghese, Managing DirectorEvonik Energy Services India Pvt Ltd15.05.2008

Analysis of Nasik Unit III-210 MW Thermal PowerPlant


13/56


Unit Capacity : 210 MW

Unit No : 3Year (age) : 1979 (29 years)

Boiler Make : BHEL

Turbine Make : BHEL

Owner : Mahagenco

Introduction to the unit


14/56


Output : 210.80 MW

Gross heat rate : 2371.8 kcal/kWhTurbine heat rate : 2040 kcal/kWh

Boiler efficiency : 86%

Unit efficiency : 33.6 %

Coal consumption : 0.47 kg/kWh

GCV of the coal : 5000 kcal/kg

Design Details


15/56


Design Model


16/56


Operating Model withActual GCV

Output : 209.7 MW Gross heat rate : 2675.8 kcal/kWhBoiler efficiency : 81.9 Unit efficiency : 32.1

Turbine heat rate : 2192.4 kcal/kWh


17/56


Operating Model withDesign GCV

Output : 209.7 MW Gross heat rate : 2650.6 kcal/kWhBoiler efficiency : 82.7 Unit efficiency : 32.4

Turbine heat rate : 2192.2 kcal/kWh


18/56


R & M Activities forBoiler Boiler water wall, superheater, economiser, safety and

critical valves

Low NOx burners and secondary air control

Ducts, expansion joints, insulation & cladding

Milling system up gradation with raw coal feeders to meetcurrent firing demand of available coal quality

Air preheaters and ESP (Electrostatic precipitator)

Fans -FD, ID and PA

Boiler soot blowers, CO monitoring, SWAS, performancemonitoring & control

Ash handling system

Coal handling system

Compressed air system


19/56


Impact of Rehabilitation onBoiler

Improvement in Boiler Efficiency (%)

81.9

86

79 80 81 82 83 84 85 86 87

Before

After R&M


20/56


R & M Activities forTurbineComponents included for R & M are:

LP Turbine and HP turbine retrofitting

Turbine gland sealings

Regenerative heaters

Condenser retubing & online cleaning system

Boiler feed pumps with energy efficient cartridges and auto

scoop controls

Turbine stress evaluator, ATRS, EHS control

Modified HP/LP bypass valves & other critical valves

Objective: To Improve the heat rate and reduce the losses

To improve the turbine controls


21/56


Impact of Rehabilitation onTurbine

Improvement in Turbine Efficiency (%)

75

89

60

85

90

80

50 60 70 80 90 100

HP

IP

LP

After R & MBefore R & M


22/56


Installation of smart transmitters and prime measuring elements,localized cabinets meeting IP 56 protection standards, thermo coupleswith compensating cables

New DCS system including monitoring, diagnosis, boiler protection Replacement of cables-on need basis and wirings, dampers and actuators

Replacement of flow elements, scanners, igniters, level transmitters

Partial retrofit of electrical system

Modern O&M organisation & procedures to reduce cost

LAN system and local server with firewalls to transmit and receive data toexpert centres

Objective:

To improve reliability and achieve smooth & efficient operation

Improved control for load change in response to load demand.

Adaptable for on line efficiency monitoring and optimization

R & M Activities ofI & C and Electrical Systems


23/56


Improvement in power generation

Increase overall efficiency

Improve the unit availability

Increase the period between overhaul

Reduce the O & M costs

Extension of equipment life time up to 20-25years

Reduction in auxiliary power consumption

Summary of benefitsof R & M activities


24/56


Options for R & M

Option A1 Option B Option C

Essential R & M Include

Option A and

Include

Option B and

DCS system withPrime measuring

elements

LP turbine retrofit Generatormodification

Total APHmodification

HP and IP turbineretrofit

Parameter Option A1 Option B Option C

Load, MW 210 215 220

Heat rate,kcal/kWh

2543 2456 2402

Capital RsMillion 3625 4630 5099

Features of options


25/56


Salient features of financial options

Par ticulars Units Option A 1 O ption B O ption CCapacity MW 210 215 220

Capital Costs Rs Million 3625 4630 5099

Capital Cost/MW Rs Million 17.26 21.54 23.18

Shut Down Duration Months 5 6 7

Plant Load Factor (Zeroth Year) % 45.21 42.50 35.42

Plant Load Factor (First Year) % 77.5 85 85

Heat Rate kcal/kWh 2543 2456 2402

Gross calorific value of coal kcal/kg 3800 3800 3800

Aux consumption in zeroth Year % 8.75 8.5 8.5

Specific Consumption of Oil ml/kWh 2.00 1.00 1.00

19.81 21.85 21.25IRR


26/56


Sensitivity Analysis of options Financial cost

Particulars Option A1 Option B Option C

FIRR - Base Case19 81 21 85 21 25

FIRR 21.42% 23.66% 23.03%

Change in FIRR in absolute terms 1.60% 1.81% 1.78%

Change in FIRR in relative terms (%) 7.48% 7.66% 7.73%

FIRR 18.41% 20.28% 19.70%

Change in FIRR in absolute terms -1.40% -1.57% -1.55%

Change in FIRR in relative terms (%) -7.60% -7.75% -7.84%(-ve is adverse)

A. Impact of changes in Capital Cost - Reduction by 10%

B Impact of changes in Capital Cost - Increase by 10%


27/56


Sensitivity Analysis of Options Power Tariff


FIRR - Base Case 19.81 21.85 21.25

FIRR 16.63% 18.81% 18.37%


Change in FIRR in relative terms (%) -19.15% -16.14% -15.66%

FIRR 22.45% 24.45% 23.72%


Change in FIRR in relative terms (%)11.75% 10.64% 10.41%

A. Impact of changes in Power tariff - Reduction by 10%

B.Impact of changes in power tariff-Increaseby 10%

Sensitivity Analysis of Options


28/56


Power Tariff


FIRR - Base Case 19.81 21.85 21.25

FIRR 16.63% 18.81% 18.37%



FIRR 22.45% 24.45% 23.72%


Change in FIRR in relative terms (%)11.75% 10.64% 10.41%

A. Impact of changes in Power tariff - Reduction by 10%

B.Impact of changes in power tariff-Increaseby 10%

Sensitivity Analysis of Options


29/56


Shut Down Period


FIRR - Base Case 19.81% 21.85% 21.25%

FIRR 19.62% 21.60% 20.98%Change in FIRR in absolute terms -0.19% -0.25% -0.27%


(-ve is adverse)

Impact of increase in Shut Down Duration by 10%


30/56


Sensitivity Analysis of OptionsFIRR Sensitivity to 10% Adverse Variation in Selected Factors

19.8%

21.8%21.2%

18.4%

19.7%

18.4%

19.6%

21.6%21.0%

20.3%

16.6%

18.8%

0%

5%

10%

15%

20%

25%

Option A1 Option B Option C

FinancialIRR

FIRR Increase in Capital Cost Reduction in Power Tariff Increase in Shut Down Duration

1 Energy Enhancement Projects of ESS


31/56



India


Measures




Reasons for Retrofits and


32/56


Applicable Measures

Steam Turbine Retrofit

Measures:

Objectives:

Improvement of TurbineEfficiency due to new parts aswell as new design

improvement of unit efficiency increase of power output at constant

fuel input with low specific costs reduction of specific CO2-emissions reduction of maintenance costs

Requirements

for Evoniks Retrofit: short schedule of project realization during a normal long-time

shut-down (maintenance) of the unit short payback-time success of measure

State of Turbine: old design, means effficiency

is not state of the art, but remaining life time sufficient

for further operation or life time extension of parts

possible by overhaul



33/56


Potential Measures on Steam Turbines

HP- and IP-cylinders

further use of outer casing mostly possible

replacement of inner casing and modification to state-of-the-art 3D-blading

- i,HP 88% ; i,IP 92% (150 MW / 300 MW)- if necessary upgrade of process-parameters (residual life time!)

- sliding-instead of constant-pressure operation(only HP; depending on boiler)

replacement of shaft

drop-in or complete module replacement

Applicable Measures



34/56


Potential Measures on Steam-Turbines

LP-cylinder modification to state-of-the-art 3D-blading

lowering of condenser vacuum by condenser optimization

duration of measures

from order approx. 16-24 months (depending on type and manufacturer)

Applicable Measures



35/56



India


Measures





36/56


Evaluation Process for Retrofits

Decades of experience

and strik ing new grounds in the energy field

Kln-Godorf

211 MW

2004

Termopaipa

165 MW

1999

Infracor

600 MW

Iskenderun

1.320 MW

2003

Mindanao

232 MW.

2006

Walsum

750 MW

COD 2010

Walsum

600 MW

Weiher

724 MW

Fenne

502 MW

Lnen

500 MW

Voerde

2.234 MW

Bergkamen

747 MW

Herne

950 MW

Bexbach

773 MW

Leuna

158 MW

1996

COD = Commercial Operation Date


37/56



Evaluation Process for Steam Turbine Retrofits

Measurement of the units

characteristics like turbine

and plant efficiency on a

time to time basis

(report / units history)


38/56



Evaluation Process for Steam Turbine Retrofits

Simulation of a reference

heat and mass balance of

the units actual state of

the water-steam cycle by

utilization of Evoniks

simulation software

EbsilonProfessional

real model of the unit

compiled with Evonik ES Programme EbsilonProfessional


39/56



Evaluation process for steam turbine retrof its

increased power output = improved plant efficiency

Calculate the improvement of

the cycle with state-of-the-artturbine efficiencies(manufacturers figures)

Calculate the improved plant

efficiency

150 MW

157 MW

increaseturbineefficie

ncy

E l ti P f R t fit


40/56



Wrap up: Evaluation process for steam

turbine retrofits

Measurement of the unit on a time

to time basis reports

Economic evaluation on basis of

expected costs, schedule of power

plant and remaining operating

hours

Realization of Retrofit during

planned outage

Acceptance test after Retrofit toconfirm guarantee values

(mostly turbine efficiency)

executed by EES/supplier

What is necessary to carry out Retrof its

successfully :

large amount of experience in retrofit-projects(very different engineered units)

good knowledge of necessary scope ofmeasures, used materials and worked outconcepts

reliable planning / scheduling

wide-spread expertise of thermodynamic

simulation, engineering and testing services



41/56


India


Measures




Performance Analysis Diagnostics

d O ti i ti P k


42/56


and Optimization Package

In 2002, BHEL placed its first order for a complete

Diagnostic and Optimisation System(PADO) basedon STEAG/KETEK SR Systems for the 2 x 500MW units of NTPC at Simhadri

After the successful installation and trial use, BHELhave placed a further order for 14 units of 500 MWunit size at:

Ramagundam, Sipat, Vindhyachal, Rihand,Kahalgaon and Talcher Power Stations

Main Feat res


43/56


Main Features

Complete Plant Optimisation based onvalidated 5-minute calculations

Controllable losses identified and highlightedin terms of Rs/hour

Soot Blowing Optimisation

Set Point Optimization

Root Cause Diagnosis

Boiler Life Time Monitoring

Overview


44/56


Overview

Boiler


45/56


Boiler


46/56


Turbine


47/56


Turbine

Condenser


48/56


Trending


49/56


Signing of Framework

Agreement for PADO


50/56


Agreement for PADO

PADO

Performance, Analysis, Diagnost ic, Optimization

Summary Sheet


51/56


Summary Sheet

Particulars Units Option A1 Option B Option C

Capacity MW 210 215 220

Capital Costs Rs Million 3625.24 4630.06 5099.23

Capital Cost/MW Rs Million 17.26 21.54 23.18

Residual Plant Life Years 15 15 15

Project Duration Months 24 24 24Shut Down Duration Months 5 6 7

Plant Load Factor (Zeroth Year) % 45.21 42.50 35.42

Plant Load Factor (First Year) % 77.5 85 85

Plant Load Factor (annual reduction of PLF) 0.2 0.1 0.1

Heat Rate kcal/kWh 2543 2456 2402

Heat Rate after first major overhaul after 5 years kcal/kWh 2555.72 2468.28 2414.01

Heat Rate after second major overhaul after 10 years kcal/kWh 2568.49 2480.62 2426.08

Heat Rate Escalation Factor % 0.3 0.2 0.2

Gross calorific Value of coal kcal/kg 3800 3800 3800

Aux Consumption Zeroth Year % 8.75 8.5 8.5

Aux consumption after first major overhaul after 5 years % 8.78 8.53 8.53

Aux consumption after second major overhaul after 10 years % 8.81 8.56 8.56

Annual increase in Aux Consumption 0.2 0.15 0.15

Specific Consumption of Oil ml/kWh 2 1 1

Specific Consumption of Oil annual Escalation factor % 1 1 1

Dismantling, erection and commissioning %age of Equipment cost % 18.5 18.5 18.5

Option A 1 Summary


52/56


Option A 1 -Summary

Boiler

Renovation of essential pressure parts replacement

depending up on equipment history & analysisRectification and retrofitting milling system

Installation of CO monitoring and combustion control

Renovation of ducts & insulation systemsAir preheater rectification

Dry ash handling system & Systems required forenvironmental compliance

Rectification of boiler auxiliaries and water system

Option A 1 Summary


53/56


Option A 1 -Summary

Turbine

Renovation of HP, LP and IP turbine of old technology

Retrofitting of modified regenerative heaters

Improvement in HP, LP bypass system

Retrofitting of TSI and EHS system

Rectification of hangers and supports

Rectification of critical valves

Rectification of turbine auxiliaries

Condenser retubing and on-line cleaning system

Rectification of cooling towers and CW system

Option A 1 -Summary


54/56


p 1 y

Electrical and I & C System

Renovation of control and instrumentation system

Replacement of transmitters and prime measuringinstruments

Online monitoring and optimization system

Retrofitting of switchgears,isolators and LT and HT

panels Modification of switchyard

Retrofitting new protection system

Retrofitting of seal oil system, generator rotor,hydrogen dryer

Implementation of energy management system

Retrofitting of electrical system for auxiliaries

Summary Sheet


55/56


y

Option A1 Option B Option CFIRR 19.81% 21.85% 21.25%

Sensitivity Analysis basis FIRR (above)

A. Impact of changes in Capital Cost

Reduction in Capital Cost % 10% 10% 10%

FIRR 21.42% 23.66% 23.03%

Change in FIRR in absolute terms (-ve is adverse) 1.60% 1.81% 1.78%


Increase in Capital Cost % 10% 10% 10%

FIRR 18.41% 20.28% 19.70%

Change in FIRR in absolute terms (-ve is adverse) -1.40% -1.57% -1.55%


B. Impact of changes in Power Tariff

Reduction in Power Tariff % 10% 10% 10%

FIRR 16.63% 18.81% 18.37%



Increase in Power Tariff % 10% 10% 10%

FIRR 22.45% 24.45% 23.72%Change in FIRR in absolute terms (-ve is adverse) 2.64% 2.60% 2.47%


C. Impact of increase in Shut Down Duration

Increase in Shut Down Duration % 10% 10% 10%

FIRR 19.62% 21.60% 20.98%



56/56

evonik thermal analysis for mahagenco turbines

Documents

mahagenco turbines

mw size

mw ggsstps

mw units of thehasdeo

energy efficiency

mw review of om

mwpower units

bandel tps