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Modern Design and Upgrading of Coal Power Plants in India Conference on Clean Coal and Carbon Capture and Storage TechnologiesA TREC-STEP initiative: 'Developing a Cluster for CCT & CCS for the Indian Thermal Power Sector’
2-3 Dec 2013, Tiruchirapalli, TN, India
Doosan Power Systems India
1
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
2
HERITAGE
2011
Acquired by DPS and renamed
Doosan Lentjes
Acquired by Doosan
Acquired by Doosan to become Doosan Babcock Energy
Lentjes GmbH formed
Skoda Energoformed
Skoda daughter
companies privatised
Babcock Power Ltd formed
Ferdinand Lentjes
founded boiler manufacturing
company
Babcock & Wilcox established
Engineering workshop founded
Babcock
Škoda Power
Lentjes
20051928
2004199819931859
200619791891 2009
Doosan Power Systems (DPS) -bringing Babcockand Skoda together
2009
Company becomes Skoda Power
3
ORIGINAL TECHNOLOGY HOLDER
B&W Partnership US B&W B&W Corp.
Doosan Power
Systems India
Doosan Power
Systems
1867 1881
1891 1995
OriginCurrent
Manufacturer
Inve
stm
ent
Acquisition
Period of Investment, Mergers & Acquisitions
Market Area: USA & Cuba
Market Area:Rest of the World
2007
Calcutta office
B&W India
ACC Babcock
1904 1947 1959 1996
India
Mitsui Babcock Energy
MBEL India
Inve
stm
ent
UK B&W
Doosan Heavy
Industries
USA
UK
4
PRODUCT LINE
Boiler
• Pressure Part• Non-Pressure Part• Mill• Burner• Structural Steel• DCS / APH
AQCS
BOP
• FGD• SCR• ESP• Ash Handling
System
• Condenser• Heater• Dearator
P.P Non-P.P Pulverizer BurnerStructural
Steel
APH
Condenser Heater Dearator
FGD SCR ESP AHS
DCS
5
RECENT SUCCESS
• Mundra / Coal(800MW x 5unit)
•Sipat / Coal(660MW x 3unit)
• Raipur / Coal(685MW x 2unit)
• Kudgi & Lara/ Coal(800MW x 5 unit)
India
• Younghung #5~6(870MW x 2unit)
• Shin-Poryong #1,2(1000MW x 2unit)
South Korea• Al-Khalij / Oil (350MW x 4unit)
• Tripoli West / Oil(350MW x 4unit)
Libya
• Ain Sokhna / Gas(650MW x 2unit)
Egypt
• Rabigh PP2 / Oil(700MW x 4unit)
• Marafiq #5,6 / Oil(275MW x 2unit)
Saudi Arabia
• Hsinta #1,2 / Coal(500MW x 2unit)
Taiwan
• Nueva Ventanas / Coal(240MW x 1unit)
• Angamos / Coal(240MW x 2unit)
• Campiche / Coal(240MW x 1unit)
Chile• Cebu CFB / Coal
(100MW x 2unit)
Philippines• Cirebon / Coal
(700MW x 2unit)
Indonesia
• Gheco-one / Coal(700MW x 1unit)
• Glow CFB / Coal(115MW x 2unit)
Thailand
• Mong Duong II / Coal(600MW x 2unit)
Vietnam
USA• Trimble,2 / Coal(815MW x 1unit)
• Pecem & Itaqui / Coal(350MW x 4unit)
Brazil
6
2 x 685 MWe
• Evaporation 2,126 Ton/hr
• SH Outlet Press 256 bar
• SH Outlet Temp. 570
• RH Outlet Temp. 597
• Indian Bituminous coal 41 – 45% ash
• Client GMR Energy
• Contract Award Jan. 2010
Supercritical firing high ash coal
RECENT INDIAN PROJECTS – RAIPUR
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RECENT INDIAN PROJECTS – NTPC KUDGI & LARA
5 x 800 MWe
• Evaporation 2,550 Ton/hr
• SH Outlet Press. 253 bar
• SH Outlet Temp. 568
• RH Outlet Temp. 596
• Indian coal (High Ash) 35 ~ 45% Ash
• Client NTPC
• Contract Award Feb. 2012
Supercritical Once-thru firing high ash coal
8
RECENT KOREAN PROJECT – SHINBORYEONG
2 x 1,000 MWe
• Evaporation 3,010 Ton/hr
• SH Outlet Press. 275 bar
• SH Outlet Temp. 613
• RH Outlet Temp. 624
• Sub-bituminous coal
• Client KOMIPO
• Contract Award Mar. 2012
Ultra Supercritical Once-thru TypeInternationally traded coals
9
MANUFACTURING CAPABILITY
DPS DHIDOOSAN VINA
Changwon, Korea(Capacity : 5,500MWe /year)
Chennai, India(Capacity : 2,200MWe /year)
Vina, Vietnam(Capacity : 2,000MWe /year)
> 10 GWe / YEAR
10
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
11
CCT OPTIONS
Boiler
SteamTurbine
New installationsRunning installations
Advanced Supercritical Units:
High Cycle Efficiency
CCT: Efficiency Improvement
R&M of existing units
12
CO2 ABATEMENT FROM FOSSIL FUELS
CO2Reduction
ASC
Carbon Capture & Storage (CCS)
Possible Now
Long Term
Time
Medium Term20252015
95%
AGING FLEETS
R&M
USC
ASC – 600 ºC/600 ºC, 290 bar
USC – 700 ºC/700 ºC, 345 bar
Baseline
30%
60%
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ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
14
R&M OF BOILERS AND AUXILIARIES
R&M - A Global perspective based on DPS’s Expertise and Experience
1. Renovation & Maintenance through Framework Alliances
2. R&M methodologyBoiler Life ManagementEngineering ApproachModern ToolsTesting
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R&M THROUGH FRAMEWORK ALLIANCES
The Alliance
Customer benefits
Long Term (7-10 years) agreements for fleet wide maintenance
For Ex. DPS is engaged in Framework alliances with major utilities such as British Energy, Scottish Power and RWE
Access to staff & labour resources to meet known long term requirements & response to events
Preferred access to OEM competence and Technology & Engineering resource focused on plant life extension and reliability
Incentive for high performance via agreed KPI
Agreed mechanism for rate increases
Reduced risk through gain / pain share and capped price works packages
Continuous improvement plan with incentive to deliver
16
R&M METHODOLOGY
Phase I:Plant Condition Assessment
Phase II:Post Assessment Analysis & Boiler redesign
Phase III:Refurbishment
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BOILER PRESSURE PART DAMAGE MECHANISMComponents Creep Fatigue Erosion Corrosion Over heat Wear
Drum/SeparatorSH/RH Header WW Header Eco. Inlet Header Downcomer/Integral Piping Main Steam Piping Hot Reheat Piping SH/RH Tubing WW Tubing
BOILER LIFE MANAGEMENT
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THE ENGINEERING APPROACH
Require to assess the impact of the past …
… and predict the effects of the future
Explore and understand original design margins
Understand previous operational history
Develop time histories of temperature behaviour
Enable assessment of operational drift from design intent and available margins
Operation < Design Operation > Design
Operational history
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THE ENGINEERING APPROACH
Assess damage due to creep – knowledge of materials creep strain behaviour across a range of temperatures
Assess fatigue damage and likely accumulation
Assess ongoing damage due to creep
Assess fatigue damage from future operating regime
From past history:
From future projection:
Assessment of remnant life:
Use cumulative damage techniques and creep/fatigue interaction diagram to assess current and future path
Enables a standard methodology to be used for the formulation of remnant life – recognised by designers and regulatory authorities
20
Specialized NDT and In-Service Inspection Technology
TESTING AND MODERN TOOLS
Visualization Technology
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Software and Tools group (SWAT) undertake continuous development of a range of in- house tools, which are used for both design and analysis
HAMBE
Calculates the flow, temperature, pressure and composition for the fuel, air and flue gas streams in a utility boiler system for the design load and part loads
BWHOT
System of 13 programs for modeling radiation and heat transfer in a furnace
Recently been extended beyond the furnace exit plane to include the high temperature convective pass
SteamGen
Calculations involve the heat transfer between the gas side and the steam side
Stress Analysis
TESTING AND MODERN TOOLS
Computational Fluid Dynamics
Fluent Computational Fluid Dynamics (CFD) code is used in the development and optimization of burner and furnace design
22
MULTI FUEL BURNER TEST FACILITY
Full-scale testing and demonstration, contract or third party burners on the 90 MWtMulti-fuel Burner Test Facility (MBTF) in Renfrew, Scotland
Capability to Fire a Wide Range of Fuels
Coals, Bituminous and Low Volatiles8% to 40% Volatiles, Dry Ash FreeUp to 35% Ash, as firedUp to 20% Inherent Moisture, as fired
Heavy Fuel OilNatural Gas
Two Stage Combustion
Oxyfuel Conversion
Biomass firing capability
Combustion Chamber : 17m Long, 5.5m Wide, 5.5m High Horizontal, Water-Jacketed
23
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
24
CASE STUDY
BANDEL THERMAL POWER STATIONUNIT 5 EER&M
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CASE STUDY - BANDEL PJT : BOILER BASIC PARAMETERS(OEM)
Plant BTPS – Unit 5
Year of installation 1982
OEM ACC Babcock
Capacity 1 x 210 MWe
Design Parameters 700 TPH Steam at Final Superheater outletof steam generator 135 kg/cm2 (g) at SH outlet
540 oC at SH outlet540 oC at RH outlet252 oC feed water at Economiser inlet60% MCR to 100% MCR SH control range132 oC flue gas leaving airheater4000 kCal/Kg design coal GCV6 nos Babcock E mills
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CASE STUDY - BANDEL PJT : SCENARIO PRIOR TO R&M
Deterioration of seals, casings
From 4111 to 3300 kCal/Kg
2092 to 2298 kCal/KWh
From 86.3 to 81.8%
Up by 12%
From 210 to ~185 MWe
Availability down to 71% and PLF
down to 60%
SPM levels are high
Baseline
Increase
Decrease
27
To enhance operating life by further 15 to 20 years
Replacement of various deteriorated pressure parts
Up gradation of coal mill capacity
Reduction in NOx level (fitting of latest design PF burners)
Changing/Replacement of critical components in FD, ID and PA Fans
Improve boiler efficiency (lowering backend temperature)
Reduction in outlet dust burden
Modernize steam turbine to achieve 215 MWe
Reduce Auxiliary power consumption.
Improve plant heat rate
On the whole the project aims at Energy Efficiency R & M of Unit – 5 (210 MW)
CASE STUDY - BANDEL PJT : R&M OBJECTIVES
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Item Client requirements Guarantee by Doosan
Unit Capacity Increase from 210 MWe to 215 MWe
215 MWe
PLF 80% from present level of approx. 60% avg.
PLF as per grid requirement
Gross Unit Heat Rate
2456 kCal/KWh from present levels of ~3000 kCal/KWh
2345 kCal/KWh
Auxiliary Power Consumption
13.5 MW for key auxiliaries 13 MW for key auxiliaries
Fuel diet Designed for worst coal with Calorific Value of 3300 kCal/kg
Designed for worst coal with Calorific Value of 3300
kCal/kgParticulate Emission
90 mg/Nm3 90 mg/Nm3
Life Extension Minimum 15 years Minimum 15 years
CASE STUDY - BANDEL PJT : CONTRACTUAL GUARANTEES
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• Platen superheater upgrade
• Additional reheater surface
• Economiser modification
• Burner panel modification
• Final SH and Pendant RH
replacement
HEATING SURFACES
Before After
Before After
CASE STUDY - BANDEL PJT : MODIFICATIONS
30
CASE STUDY - BANDEL PJT : PPA, PRE & POST R&M
31
• Low NOx Axial Swirl Burner
• Developed in 1980s• Over 2700 burners installed• 40 - 70% NOx reductions
BURNER
• Enhanced mill throughput• Dynamic classifiers• PF piping & VARBs
MILLING SYSTEM
CASE STUDY - BANDEL PJT : TECHNOLOGY UPGRADES
32
• New ID and PA fans• FD fan refurbishment• New lube oil skids• Replacement of control
dampers
FANS
• Additional field• SPM level within 90mg/Nm3• Automatic rapping system• New TR sets
ESP
CASE STUDY - BANDEL PJT : MODIFICATIONS
33
• Additional block• Modular construction• Inlet ferrulesAIRHEATER
CASE STUDY - BANDEL PJT : OTHER MODS
34
• Seals• Expansion joints• Refractory & insulation• Aerofoils & Venturi• Ash handling system• Electricals• Fire fighting system• Dosing and sampling system• Misc civil works
MISC. SCOPE
CASE STUDY - BANDEL PJT : MISCELLANEOUS
35
BANDEL : BOILER PROJECT SCOPE SUMMARY
Lower SPM / NOx Emission &Boiler Performance Improvement;
Enhanced life from modern replaced equipment.
Typical Drum-type Boiler
Major Pressure PartsReplacement for Life extension, reliability and performance improvement
DCS Modernization Renewal of Field Instruments
Environment Equip. RetrofitESP
Low-NOx Burner
New sootblowers, replacement/refurbishment of valves and actuators
Milling Plant upgrade, New PA Fans, PF Piping and Gravimetric Feeders
New ID Fan, Seal Air and Core Air Fans, refurbished FD
Fans, Flues and Ducts & Dampers
Airheater refurbishment and surface addition for reduced flue gas losses
36
BANDEL: TURBO GENERATOR PROJECT SCOPE SUMMARY
Improved Heat Rate and capacities allowing for quick pay-back of project and reduction in carbon footprint.
Advanced Seals
Entropy/Velocity Distribution
Generator & Aux. Replacement
Efficiency & hence turbine heat rate improvement is the key to the EER&M:Approx. 5% improvement over original LMZ turbine design
State-of-art Turbine Technologies
Advanced Blade Technology
Integral Covered Bucket Design
HP, IP, LP Turbine ReplacementTG Lube oil system upgradeElectro hydraulic governors
New ESVs, IVs and CVsDrains & extraction system
refurbishmentCondenser retubing, New CEPs,Energy Efficient BFP cartridges
Drip Pump Refurbishment,HP/LP heater tube nest replacement,
Deaerator tower replacement,Renew HP/LP Bypass Valves
Misc. Valves, actuatorsRenewal of Hangers and supports of
critical piping + InsulationTurbo-visory system, Field Instruments
37
BANDEL: PROJECT MILESTONES OF BANDEL R&M PROJECT
2012 2013 20143 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 10 111 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 27 28 32 32
Detailed Engineering(~12M)
Completion of Material Order
(~10M)
Shut-down(19M~24M)
Warranty
Reliability Test(25M)Manufacturing
(~17M)
Delivery(12~18M)
Opening of site office, Pre-Shut down works (13~18M) (Installation)
Commissioning
PG Test(~27M)
38
BANDEL - UPDATE
Project is more or less on-time, with boiler presently is shutdown for erection.
Relationship with the customer is excellent
39
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
40
AMGEN TORRENT POWER LIMITEDE & F STATION UPRATING
RECENT PROJECT
41
TORRENT - BOILER BASIC PARAMETERS
Plant Torrent Thermal Power station – E & F Stations
Year of commissioning 1984 & 1988
OEM M/s BHEL
Capacity 2 x 110 MWe
Design Parameters 375 TPH Steam at Final Superheater outletof steam generator 138 kg/cm2 (a) at SH outlet(original design) 540 oC at SH outlet
540 oC at RH outlet241 oC feed water at Economiser inlet60% TMCR to 100% BMCR SH control range152 oC flue gas leaving airheater4450 KCal/Kg Coal GCV
42
TORRENT PROJECT - OBJECTIVES
Retrofitting existing turbine components with state-of-art efficient turbine components
Modification in boiler reheater surface including replacement of reheater headers to suit requirements of retrofitted turbine
Replacement of existing turbine hydraulic governing system with electro hydraulic turbine control (EHTC)
Overhauling and servicing of turbine valves
RLA and refurbishment of turbine oil system, regenerative system and cooling water system
RLA study of piping valves and castings
Replacement of existing C&I system with state-of-the art DCS
110 MWe 121 MWeUp-rating and modernization
43
TORRENT - BOILER R&M CHALLENGES
R&M on non-OEM designAdditional heating surface shall be supported from roof tubes, local supports to be checked, modified and suitably reinforced
Existing Sootblowersand access openings retained
Enhanced surface addition shall be within original overall RH pressure drop
Entire reheater elements replaced with new elements having extra heating surface (~30% increase) to meet requirement of HBD, within the existing layout
44
ABOUT DOOSAN POWER SYSTEMS
WHY R&M
R&M MODALITY
CASE STUDY
RECENT R&M PROJECT
CONCLUSION
PROGRAM
45
R&M INCREASES LIFE AND ENERGY EFFICIENCYPlant Cycle Efficiency Enhancement
Enhance Efficiency
Increase Capacity
Improve Reliability
Life Extension
Old Plants get a lease of life of at least 15 - 20 yearsHigher cycle efficiency results in lower generation costsLower fuel consumption and hence lower carbon footprintLower emissions
Capacity
Efficiency
Reliability
46
ENERGY EFFICIENT R&M IS ECONOMICALLY VIABLE
New Build
Project Cost(land cost excluded)
EE R&M
(X) INR / MW (0.6 – 0.65 X) INR / MW
Outage More than 50 months project cycle 6 - 8 months
Design Life 20 years 20 years(extended)
Cycle Efficiency(compared with new plant of similar cycle)
100% 100%
Project Risk High Low
Coal Linkage & otherclearances Difficult None
EE R&M is the best available solution for quick increase of reliable power capacity and technically can enhance plant capability as much as a new-build plant in energy efficiency and in design life with optimized CAPEX
47
THANKS FOR YOUR ATTENTION!