reference projects power plants - your partner for water ... · pdf filecoal-fired power plant...
TRANSCRIPT
Gate Valves
BAIO®plus System
Knife Gate Valves
Penstocks
Hydrants
House Connection Valves
Non-Return Valves
Buttefly Valves
Air Valves
Control Valves
Ball Valves
Accessories
• Powerplant• Edition1.1/04-11-2014
Reference projectsPower plants
PlaceApplicationDate
KNG power plant Rostock
Rostock/GermanyCoal-firedpowerplant1996-2011
Project description
TheRostockpowerplantisahard-coal-firedcommunitypo-werplantinthenorth-eastofGermanywhoseoperatingcompany,Kraftwerks-undNetzgesellschaftmbH(KNG)wasfoundedin1990direct-lyaftertheWallcamedown.Cons-tructionworkbeganin1991,andinMarch1994thefirstcoaldeliveryarrivedattheplant.Inthefollowingmonth,thefirstpowercouldbesup-pliedfromthenewly-builtpo-werplantbeforeitofficiallytookupitscommercialoperationon1October1994.
Thepowerplant’sgrosselec-tricityoutputis553MW(netoutput509MW).Additionally,amaximumdistrictheatoutputof300MWcanbesuppliedfromcogenerationofwhich150MWhavebeenrealisedsofar.Withthisoutput,theRostockpowerplant,whichisalsoopentovisitors,iscurrentlyproducingover50%ofMecklenburgWe-sternPomerania’selectricpower,onefifthofRostock’sdistrictheatandfeedsalmost3TWhperyearintothepowergrid.Itscurrentefficiencyis42,3%andatfullheatsupplyfromcogenerationcouldbeincreasedtoamaximumof62%.
Thepowerplantfunctionsasamedium-loadandpeak-loadpowerplantandisequipped
VAG EKN® Butterfly Valves, VAG EKO®plus Gate Valves and VAG SKR slanted seat tilting disk check valves in the pumping station of the fire-fighting system
VAG CEREX® 300 Butterfly Valves and VAG SKR slanted seat tilting disk check valves in the associated intake structure
Products 10xVAGCEREX®300ButterflyValvesDN500>40xVAGEKN®ButterflyValveswithelectricactuatoruptoDN800>30xVAGBETA®/EKO®plusGateValvesuptoDN300>10xVAGSKRslantedseattiltingdiskcheckvalvesuptoDN600>10xVAGhydrantsDN100
witha141.5mhighcoolingtower(diameteratthefoot100mand60matthetop)whichisalsousedasanexhauststack.Theturbinesystemcompri-sesaone-shaft,four-cylindercondenserturbineconsis-tingofonehigh-pressure-,onemedium-pressureandtwolow-pressureturbines.
Between1996and2011VAGsuppliedover100differentval-vestotheRostockpowerplant.Thesevalvesincludedinparti-cularbutterflyvalves,gateval-ves,non-returnvalvesaswellashydrantswhichwereusedtoequipthefire-extinguishing-andcooling-watersystemoftheRostockplantandintheassociatedintakestructureatMarkgrafenheide.InsomeplacesalsoairvalvessuchastheVAGDUOJET®AutomaticAirValvewereinstalled.
AccordingtoKNG,thevalvesmadebyVAGhavebeenwor-kingtrouble-freeinthepowerplantformanyyears.
VAG BETA® 200 Gate Valve
VAG RETO-STOP Non-Return Valve, VAG BETA® 200 Gate Valve and VAG SKR Slated-Seat Tilting-Disk Check Valve in the booster station of
the fire-fighting system
PlaceApplicationDate
Project description
Intheyear2000,E.ONac-quiredastate-ownedenergycompanyintheRotterdam/TheHaguearea,thuslayingthefoundationsforE.ONBenelux.Duetothisacquisition,alsofivegas-andtwocoal-firedplantswithatotaloutputcapacityof1,052megawatts(MW)chan-gedhands.Fiveyearslater,E.ONBeneluxtakesoverano-thercompanywhichsuppliespowerto250,000consumersintheEindhovenregion.
In2008,E.ONbeganwiththeconstructionworksforthenewplantwhichwasputintoservicein2013.Thecoal-firedpowerplantwithagrossoutputcapacityof1,100MWisknownbythenameofMaasvlaktePo-werPlant3(MPP3).Thecom-panycommissionedE.ONNewBuild&TechnolgyGmbHbasedinGelsenkirchen,Germany,withtheengineeringworksandthustheselectionofvalves.
Itisparticularlyinsea-waterconveyingwatercircuitsthatspecialcorrosionprotectionisvitalforallpartsofavalvecomingintocontactwiththemedium.AsE.ONNewBuild&TechnologyGmbHhadhadpositiveexperiencewithVAGinpreviousprojects,theyde-cidedtopurchasethesystemvalvestobeinstalledintheprimaryandsecondarycoolingwatercircuitsfromVAG.The
Maasvlakte/TheNetherlandsCoal-firedpowerplant2008-2013
Sea water valves for the Maasvlakte power plant
The coal-fired Maasvlakte Power Plant 3 (MPP3)by day and night
Employees of E.ON New Build & Technology duringthe acceptance of a VAG EKN® Butterfly Valve
Products 19xsea-waterresistantVAGEKN®ButterflyValvesDN500–DN2200withUVVsafetyinterlock2xVAGSKRSlanted-SeatTilting-DiskCheckValvesDN250
ordercomprised19sea-waterresistantVAGEKN®ButterflyValveswithnominaldiametersofDN500,700,1200,2000and2200.AsthepowerplantislocatedontheNorthSea,thepipelineshavetobeaccessibleatalltimestocleantheplantfrommolluscs.Toavoidhavingtoinstallasecondvalveaccor-dingtotheaccidentpreventi-onregulations,VAGinstalledVAGEKN®ButterflyValveswithTÜV-approvedUVVsafetyinterlock.
E.ONNewBuild&TechnologyalsodecidedtoinstallVAGSKRSlanted-SeatTilting-DiskCheckValves.TheycompliedwiththerequirementsoftheE.ONspe-cificationandreliablypreventleaks.Asneitherthelevernortheweightarelocatedonthevalve,thevalveremainscom-pletelysteadyinthevolumetricflowevenwhenitisfullyopen–andthatataminimumflowof1.5m/sec.Whenthepumpswitchesoff,ahydraulicdam-perpreventspressuresurgesandatthesametimesecuresthepumpagainstrunningback-wardatflowreversal.
Thecustomerwashighlysa-tisfiedanddescribedVAGasa“veryreliablepartner”thatensuressafetyandtrouble-freeoperationofthepowerplantwithitspremium-qualitypro-ducts.
VAG EKN® Butterfly Valve suitable for seawaterapplications (with rubber lining)
VAG SKR Slanted Seat Tilting Disk Check Valve suitable for seawaterapplications with a hydraulic damper controlled by its own medium
PlaceApplicationDate
Project description
Inpowerplants,theprimaryandsecondarycoolingwatersystemsarefrequentlycon-nectedtoeachother.Intheeventofaunitdowntime,manyofthelargepipelineshavetobeman-accessibleforinspection–althoughthepipelinesectionononesideoftheshut-offvalvesisstillpressurised.
Toensurenobodyisinjuredintheeventofafailureoftheshut-offvalves,suchsystemshavetobesafelylockedaccor-dingtotheVGBGuidelineR107:
“(32) Valves in man-accessible pipelines equipped with energy storage devices, drop weights or other quick-closing devices have to be provided with safety devices to ensure that mainte-nance staff is not exposed to any dangers. Lockable pins can serve as safety devices.”
Inthesecases,aVAGEKN®ButterflyValvecombinedwithaUVVsafetyinterlockisasui-tabledevice.IntheVattenfallpowerplantinJänschwalde,32VAGEKN®ButterflyValveswithone-sided
UVVsafetyinterlock(DN2000)andelevenbutterflyvalveswithdouble-sidedUVVsafetyinter-lock(DN2000)wereused.
Jänschwalde/GermanyThermalpowerplant1992-2013
Power plant Jänschwalde
VAG EKN® Butterfly Valve with double-sided UVV safety interlock as unit isolation valve DN 2000
VAG EKN® Butterfly Valve with one-sided UVV safety interlock
Products 32xVAGEKN®ButterflyValvesDN2000withUVVsafetyinterlockononeside11xVAGEKN®ButterflyValvesDN2000withUVVinterlockonbothsides
Intheyear2008thepowerplantoperatorconfirmedthattheyweresatisfiedwiththeVAGvalvesinstalled:
“Inourcompany,hydrants,checkvalves,gatevalvesandairvalvesmadebyyourcom-panyareinusebesidesthenumerousVAGEKN®ButterflyValves,andallofthemperformtheirtaskscompletelytrouble-free.TheVAGbutterflyvalveshavebeeninoperationinourplantsuccessfullyformanyyears.Wedecidedinfavourofyourproductduetoitsexcel-lentquality.(…)Particularlyinourpowerplants(…)VAGEKN®ButterflyValvesmeetalltherequirements.Inthepastfewyears,wehavepurchasedvariousvalvesfromyouwhichperformessentialfunctionsintheoperationofourplants.Sin-ce1992,youhavesupplied(…)EKN®ButterflyValveswithUVVsafetyinterlockforourplants.”
VAG EKN® Butterfly Valve with double-sided UVV safety interlock ready for installation into the pipeline system
VAG EKN® Butterfly Valve with double-sided UVV safety interlock as unit isolation valve DN 2000
PlaceApplicationDate
Project description
InBoxberg,acommunityinGermany’sstateofSaxony,thelignite-firedUnitRofthepowerplantwithanelectricpoweroutputof675MWwascommissionedinOctober2012.
ForthisnewlybuiltunitVAGsuppliedanumberofvalvesincludingVAGEKN®andVAGCEREX®ButterflyValves,VAGRIKO®PlungerValves,VAGSKRSlantedSeatTiltingDiskCheckValvesaswellasVAGEKO®plusGateValves.
Toprotectthemaincoolingwaterpumpfromcoolingwaterpressuresurgesduringcontrolledshut-downbutalsointheeventofaquickshutdown,twoVAGEKN®ButterflyValvesDN2000withahydraulicbrake-and-liftunitwereinstalleddownstreamofthispump.
Thedesignofthebutterflyvalvehasbeenadaptedtothepressuresurgecalculationsofthemaincoolingwatersystemtobeabletoresistallcondi-tionspresentinthesystem.
TheVAGEKN®ButterflyValvemustbeabletoshutoffmassflowratesof10.28m³/sduringacontrolledclosingprocedure.
Bywayofatwo-stepclosingcharacteristic,thediskofthe
Boxberg/GermanyCoal-firedpowerplant2009-2012
Boxberg power plant
Construction site of the lignite-fired Unit R
VAG EKN® Butterfly Valve with hydraulic brake-and-lift unit during customer acceptance for the pressure test in the year 2009
Products 2xVAGEKN®ButterflyValvesDN2000PN61xVAGhydraulicbrake-and-liftunit(aspumpprotectiondeviceinthemaincoolingwatersystem)+safetyinterlockaccordingtoUVV
butterflyvalveismovedfroma90°openingtoa20°openinginnineseconds.Ittakesanother30secondsuntilthevalveisfullyclosed.Theopeningtimeforthisunitis45seconds.
Thekineticenergyneededtoclosethebutterflyvalveisstoredinthethree-tonnedropweight.
Installation of a VAG EKN® Butterfly Valve with double-sided UVV safety interlock, ready for
installation into the pipeline system
PlaceApplicationDate
Project description
Whatisgeothermalenergy?ThetermoriginatesfromGreek“geo”,meaningEarth,and“thermos”,whichtranslatesashot,i.e.thermalenergygene-ratedandstoredintheEarth.GeothermalenergyisreferredtoasarenewablesourceofenergywhichcanbegainedfromtheEarth’scrustthathasathicknessofabout40km.ThisenergyisconductedbyacontinuousflowofheatfromtheEarth’sliquidcore,whosetemperatureisestimatedtobe5,000to9,000°C,intotheEarth’scrust.Insomecases,thisheatevenreachesthesurface–intheformofvolca-noesorgeysers.Icelandhasanunusuallyhighnumberofactivevolcanicsystemsandisknownforitsgeysersandhotsprings.ItthereforecomesasnosurprisethatgeothermalenergyisIceland’smostim-portantsourceofenergy.TheaveragetemperatureclosetotheEarth’ssurfaceisabout10°Candincreasestowardsthecorebyabout3°Cper100mofdepth.Inadepthof3,000m,thisamountstoabout85°C–whichisenoughtouseitforheating.
UseofgeothermalenergyinPullachButalsoinGermany–ormorepreciselyinSouthernBava-ria–thegeologicalconditionsareoptimalfortheextraction
Pullach/GermanyThermalpowerplant2011
Geothermal energy in Pullach
Each valve installed in the pipeline as a fully isolated VAG RIKO® Plunger Valve
Products 2xVAGRIKO®PlungerValvesDN150PN25
ofheatfromtheEarth.Since2005,thecommunityofPullachimIsartal,locatedinthesouthoftheadministrativedistrictofMunich,hasbeenoperatingageothermalCHPplantrunbyInnovativeEnergiefürPullachGmbH(IEPGmbH).Twobore-holesareneeded,aso-calleddoublet.Throughthefirstbore-hole,theextractionborehole,hotwaterwithatemperatureof102°Cto107°Cisconductedtothesurfacefromadepthofabout3,500mandfedintoaheatexchanger.Afterrunningthroughtheheatexchanger,theheatedwaterissupplieddirect-lytotheconsumers,andthecooledthermalwaterextractedbeforeisreinjectedintotheearthviathesecondborehole(=principleofsustainability).
VAGequippedthegeothermalenergyplantwithtwoVAGRIKO®PlungerValvesDN150PN25.ThesetwovalveswereinstalledbetweenthewellheadsandtheheatexchangerandanotherVAGRIKO®PlungerValveDN200PN25wasin-stalledupstreamoftherein-jectionborehole.Thecontrolvalvesarecustom-madeplun-gervalves,madecompletelyofspecialsteelcasting,andareresistanttotemperaturesofupto150°C.Themediumtobecontrolledbythevalvescon-tainshighconcentrationsofso-lublegasessuchasmethane,nitrogenorcarbondioxideandhasanoperatingtemperature
of107°C.Thevalves’taskistokeepthesystempressureataconstantlevelsothatalldissolvedgasesremaindissolvedtopreventdeposits.
Duetothespecialconditionsoftheplant,specialsteelcas-tingwaschosen.Thismaterialfeatureslong-termresistancetothedifficultconditionsofthermalwater.In2009,PullachwasgivenanawardasclimateprotectionprojectbyDeutscheUmwelthilfe,anenvironmentalprotectionorganisation,andasearlyas2011Pullach’sdistrictheatingnetworkhadgrownto25km.
Almostallpublicbuildingssuchasthetownhall,municipalhall,swimmingpoolandschools,butalsochurchinstitutions,commercialenterprisesandofcoursemanyprivatecustomersaresuppliedwithheatgeneratedintheplant.Sincetheirinitialset-up,theplungervalveshavebeenperformingtheircontroltasksreliablyandtrouble-free.
PlaceApplicationDate
Project description
Thecontinuouscoolingofthecondenserwithinaverynar-rowtemperaturerangeisoneoftheessentialprerequisitesforkeepingthepressureintheturbineataconstantlevelandisthusdecisivefortheeffici-encyofapowerplant.Inregi-onswherewaterisabundant,once-throughcoolingorawetcoolingtowerisnormallyused.
Inareaswithecologicallysen-sitivebodiesofwaterorlimitedwateravailability,watercon-sumptionmustberestricted.Thisiswhyindirectdrycoolingtowersareusedintheseregi-onsasarule.
IntheYangchengpowerplant(2x600MW),theworld’stwolargestdrycoolingtowersareoperated.Throughtheuseofthesetowers,waterconsump-tioncouldbereducedtothreecubicmetresperday.ThesecoolingtowerswereerectedbyGEAEGIin2007.
Toensurethesafeoperationofthisplantovermanyyears,itisessentialtousemodernandpremium-qualityvalves.Thefailureofevenasmallcoolingwatervalvemayhavedisastrousconsequencesfortheentiresystemandhaveanadverseeffectontheoutputofthepowerplant.
Yangcheng/ChinaCoal-firedpowerplant2007-2009
Yangcheng Coal-Fired Power Plant
Dry cooling towers at the Yangcheng coal-fired power plant
Machinery room; Hydraulics area
Products VAGDUOJET®AutomaticAirValveVAGEKO®plusGateValveVAGSKRSlantedSeatTiltingDiskCheckValveVAGEKN®ButterflyValvewithVAGHYsecHydraulicBrakeandLiftUnit
Thisiswhy,besideshighquali-tystandards,modernsolutionsfordemandingtasksareaskedfor.Whentheambienttempe-raturedrops,thesystemmustbequicklydrainedtopreventdamagecausedbyfreezingcoolingwater.Ithastobedonefast,reliablyand,ifnecessary,evenwithoutelectricalenergy.Toensurethis,GEAEGIdeci-dedinfavourofVAGbutterflyvalvescombinedwithhydraulicbrakeandliftunits.
EGI’sconstructionsitemana-ger,MrBorosJeno,hasbeenattheYangchengpowerplantsiteforalmosttwoyearsnow.Tohimthefailureofevenasmallvalvemeansadisasterfortheentiresystem.HeishighlysatisfiedwithVAG’svalvesastheyareoftopquality,easytocontrolandpracticallymainte-nance-free,allofwhichsetshisheartatrest.
VAG EKN® Butterfly Valve with VAG HYsec Hydraulic Brake and Lift Unit in open position
VAG EKO®plus Gate Valve
PlaceApplicationDate
Project description
TheSchwarzePumpepowerplantoperatedbyVattenfallwasbuiltbetween1993and1998,and,inJune1998,officiallytookupcommercialoperationafterunitAhadcomeonlineinMay1997andunitBinOctober1997.Thedoubleunitplanthasatotalgrosselectricityoutputof1600MWwitheachunithavinganoutputof800MW.Thebrown-coalfiredpowerplantislocatedonthesiteoftheSchwarzePumpeindustrialestatewhichhasservedasapowerplantlocationsincethe1950s.Beforethat,thepowerplantsSchwarzePumpeWest,MitteandOstwerelocatedthe-rewhichhavemeanwhilebeendecommissionedandpulleddown.Withanoutputbetween25and100MW,theygenera-tedbothelectricalenergyandprocesssteam.Thenewpo-werplantfollowsthistraditionandbesideselectricalenergyitalsogeneratesprocesssteamforthecompanieslocatedinthenearbyindustrialestateSchwarzePumpe.Additionally,oneofthemostimportanttasksofthispowerplantisthesupplyofdistrictheattothevillageofSchwarzePumpeandthecitiesofSprembergandHoyerswer-da.
The172mhighexhauststackoftheauxiliaryboilerplantandtwonaturaldraughtwetcoolingtowersriseabovethepower
Spremberg/GermanyCoal-firedpowerplant1996-2011
The Schwarze Pumpe power plant
VAGSKRSchrägsitz-Kipp-RückschlagklappeDN600PN10inderWasseraufbereitung
VAG EKN® Butterfly Valves DN 800 PN 10 in the condenser section
VAG SKR slanted seat tilting disk check valveDN 600 PN 10 in water treatment
Products 4xVAGEKN®ButterflyValvesDN2000withelectricactuatorandUVVsafetyinterlockononeside>50xVAGEKN®ButterflyValveswithelectricactuatoruptoDN1000>50xVAGBETA®GateValvesuptoDN300>10xVAGSKRSlantedSeatTiltingDiskCheckValvesuptoDN600>10xVAGhydrantsDN100variousaccessories
plant.Aglazedobservationdeckcanbefoundoneachofthetwostairtowersofthesteamgenerationbuilding.Theeasterndeckisopentovisitors.ThepowerplantusedtocoverbaseloadpowerdemandissuppliedwithrawbrowncoalbythenearbyWelzow-Südstripmineandconsumesabout36,000tonnesofcoalperday.Likeallmodernpowerplants,theSchwarzePumpepowerplant,whichhasanefficiencyofalmost40%,isequippedwithamultistagefluegasclea-ningsystem.AspecialtyofthispowerplantisitspilotplantforCO2sepa-rationwhichofficiallywentintooperationinSeptember2008afterateststage.Thecarbondioxidegeneratedbycombu-stioniscompressedandlique-fiedintheplant.Inthepast15years,VAGhassuppliedover50VAGEKN®ButterflyValvestotheSchwar-zePumpepowerplant,inclu-dingfourVAGEKN®ButterflyValveswithsafetyinterlockwhichserveassafetyvalves.Additionally,agreatnumberofVAGBETA®GateValves,VAGSKRslantedseattiltingdiskcheckvalvesandVAGhydrantswereinstalledintheprimaryandauxiliarycoolingcircuitsand/orthefire-fightingsystemofthepowerplant. VAG EKO®plus Gate Valve DN 100 PN 16
Installed in the ash settling pond
VAG EKN® Butterfly Valve DN 2000 PN 6 as pump safety valve with hydraulic brake-and-lift unit installed in the pump-house
downstream of the main cooling water pump
PlaceApplicationDate
Project description
InOctober1986,theownersatthattime,PreussenElektraandHEW,starteduptheBrokdorfNuclearPowerStation(KBR)inSchleswig-Holsteinforthefirsttime.TodaytheenergygroupE.ONowns80%ofthepowerplantandtheSwedishcompa-nyVattenfall20%.
Inthe1980s,VAGinstalled,amongotherthings,VAGEKN®GateValveswithnominaldiametersofuptoDN2000,VAGSKRSlantedSeatTiltingDiskCheckValvesuptoDN700,VAGHydrantsandVAGBETA®GateValves.Thevalves,someofthemseawaterresistant,arelocatedinthemaincoolingwatersystem,inthenuclearandtheconventionalinterimcoolingsystem,inthesecuredancillarycoolingwatersystem,andinthefirefightingsystemandinvariousaidandancillarysystems.
Morethan20yearslater,themaincoolingwaterbutterflyvalvesaretobereplaced.VAGisreplacingtheringsfromitsheadquartersinMannheim.TheVAGdesignersareusingtheolddrawingstoproduceacentrallymountedsealingvalve.VAGisalsorubberliningthebodiesanddisksofsixothersealingvalvesandreplacingthesensitivehydraulicbrakeandliftcylindersoftheolder
Brokdorf/GermanyNuclearpowerplant2008-2010
E.ON Nuclear Power Station in Brokdorf
The centrally mounted disk is dismantledat the headquarters in Mannheim
Installation of a VAG AKL Butterfly Valve in a seawaterdesign for the nuclear power station in Brokdorf
Products 115xVAGAKLButterflyValves/EKN®ButterflyValvesuptoDN200013xVAGSKRSlantedSeatTiltingDiskCheckValvesuptoDN700294xVAGBETA®GateValves45xVAGHydrants
100generationwiththemodern200actuatorseries.VAGEKN®ButterflyValvesDN2000PN10withaVAGHYsechydraulicbrakeandliftunithavebeendesignedforuseinthebrackishElbewateratapressureof6barsandtemperaturesof70°C.
An extract from a reference letter from the customer shows that the VAG valves are still reliable, even after 25 years.
BETA® 136 Gate Valve
Oldhydraulicbrakeandliftcylinder
Modifiedhydraulicbrakeandliftcylinder
Notes
Notes
