Engineering Service forPower Plant Performance Improvement Program
enesG worldwide –Performance Engineering Service Group
Introduction to enesG worldwidePerformance Engineering Service Group
3
CEO
Quality Assurance Team
Financial Accounting Team Management TeamManagement Team
Monetary/Audit Accounting HR/Admin/Labor
Nuclear Maintenance and Engineering Service Group
Integrity Evaluation ServiceGroup
Hydraulic System TechnologyGroup
Performance Engineering Service Group
• A de facto unique professional engineering body for Power Plant Performance in Korea
• Exclusively conducts the thermal performance diagnostic testing program for Korean Fossil & Nuclear power plant
• Supplies hydraulic actuator for TBN valve with more enhanced durability and reliability than existing products to Fossil, Combined and Nuclear power plants.
• Supplies Integrity Service and life assessment through the In-Service inspection about the main components of power plants, which is the major requirement of the Korea Institute Nuclear Safety.
• Performing maintenance and facility improvement of core equipment for NSSS and main piping system. Also ENESG is providing comprehensive engineering services of manufacturing, developing special equipment for NSSS main facilities
Local Supply Chains & Subcontractors
Organization and Business
Project Management Division
Business ManagementDivision
R & D Center
enesG worldwide’s Performance Engineering Service Group provides total solutions relating to thermal performance of the power plant in the following area;
Technical proposal and contract review and support for performance guarantee
Performance acceptance/diagnostic testing service
- Overall plant or thermal island
- Individual equipments
- Third party performance acceptance testing support
Plant performance improvement program development
Steam Path Audit (SPA)
Customized on-line performance monitoring system
Performance test instrumentation design and supply
Flow meter calibration
Business Area of Performance Engineering Service Group
4
Recent 5 years experience – Domestic
Performance Acceptance Testing Program
• Taean #7,8 Steam Turbine (PTC 6.0)• Tangjin #7,8 Steam Turbine (PTC 6.0)• Poryoung #7,8 Steam Turbine (PTC 6.0)• Hadong #7,8 Steam Turbine (PTC 6.0)
• Yonghung #3, 4 BOP (PTC 12.1 and 12.2)• Taean #8 BOP (PTC 12.1 and 12.2)• Tangjin #7, 8 BOP (PTC 12.1 and 12.2)• Poryoung #8 BOP (PTC 12.1 and 12.2)• Hadong #7, 8 BOP (PTC 12.1 and 12.2)• Namjeju #4 BOP (PTC 12.1 and 12.2)• Namjeju #2 Diesel Power plant (ISO 3046)
Performance Diagnostic Testing Program
•Kori #1,2,3,4 Turbine Cycle (Nuclear)
•Yongkwang #1,2,3,4,5,6 Turbine Cycle (Nuclear)
•Ulchin #2 Turbine Cycle (Nuclear)
•Ulchin #3,4,5,6 Turbine Cycle (Nuclear)
•Wolsung #1, 2,3,4 Turbine Cycle (Nuclear)
•ShinKori #1,2 Turbine Cycle (Nuclear)
•ShinWolsung #1,2,3,4 Turbine Cycle (Nuclear)
•Hwasung Cogeneration Steam Turbine
• Hadong #1,2,5,6 Boiler and Turbine Cycle (Fossil)
enesG achieved long term agreement with KHNP(Korea Hydro & Nuclear Power) for periodical (6 years) performance diagnostic testing program for operating 22 units.
Third Party Performance Acceptance Testing Support
• GS EPS Bukok CCPP Block 2 (PTC 46) • Poryoung #1,2 Steam Turbine Retrofit (PTC 6.0)• Poryoung #1,2 Boiler Retrofit (PTC 4.0)• Busan Junggwan Cogeneration (PTC 46)• Song-Do Cogeneration (PTC 46)• Gwangju Suwan Cogeneration (PTC 46)• Busan Junggwan Cogeneration (PTC 46)• Hundai Green Power Gas Thermal Power Plant
(PTC46, PTC4.0, PTC6.0)
On-line Performance Monitoring System
• GS EPS Bukok CCPP Unit 1 and 2• KHNP’s operating 22 Units (Completed in 2012)
5
Recent 5 years experience – Overseas
More than 10 Units of CCPPin Middle East
Cabras Low Speed Diesel Power Plantin Guam
Kanudi Low Speed Diesel Power Plant in PNG
Glow 115MW CFB Fossil Power Plant
Chilca CCPPin Peru
Kallpa CCPPin Peru
Kos Low Speed Diesel Power Plantin Greece
OPC Rotem CCPPin ISRAEL
Shoaiba CCPPin Saudi Arabia
SLP CGPPin Mexico(on-gong)
Takoradi CCPPin Ghana(on-going)
GHECO-ONE 660MW CFPP ProjectIn Thailand
Qurayya CCPPin Saudi Arabia
Marafiq 300MW TPPin Saudi Arabia
6
Performance Acceptance Testing • Glow CFB 115MW FPP Project in Thailand
(PTC 46, PTC 4.0, PTC 6.0)• Gheco PCB 660MW FPP Project in Thailand
(PTC 46, PTC 4.0, PTC 6.0)• Kallpa CCPP Add-on Project in Peru
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Chilka CCPP Add-on Project in Peru
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Rotem CCPP Project in Israel
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Qurayya IPP CCPP Project in Saudi Arabia
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Maragiq 300MW TPP Project in Saudi Araba
(PTC 46, PTC 4.0, PTC 6.0, PTC 12.1, PTC 12.2)• Shoaiba II CCPP Project in Saudi Arabia (on-going)
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Tacoradi II CCPP Add-on in Ghana (on-going)
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Ciproel CCPP Add-on in Cote D’Ivoire (on-going)
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• SLP II CCPP Add-on in Chile (on-going)
(PTC 46, PTC 22, PTC 4.4, PTC 6.2)• Tufanbeyli CFB 150MW FPP Project in Thailand
(on-going) (PTC 46, PTC 4.0, PTC 6.0)
Diesel Power Plant Testing in Greece (ISO 3046)
• Kos Diesel Power Plant #5, 6• Chios Diesel Power Plant #3, 4 • Paros Diesel Power Plant #2, 3
More than 20 units of HRSG Testing (PTC 4.4)in the Middle East Area
Performance Diagnostic Testing • Cabras Diesel Power Plant #3,4 in Guam• Kanudi Diesel Power Plant #1,2 in PNG
ENESG has been conducting periodical performance diagnostic testing program for the Cabras and Kanudi Diesel Power Plants for last 5 year in annual basis.
Performance Test Instruments Supply• Full set of HRSG testing instrument (MAPNA)• Full set of HRSG testing instrument (Benghazi)
Process and Engineering Activities forPlant Performance Improvement Program
Population of the Power Plants over 15 years Operation
8
83.92 GW
83.92 gigawatts located in south-east Asian 6 countries have been operated more than 10 years and need performance improvement programs, such as recapture of performance losses in short term plan and facility retrofit in mid/long term plan.
23.09
19.20
0.42 10.19
23.99
7.03
INDONESIA MALAYSIA MYANMAR
PHILIPPINES THAILAND VIETNAM
8.88
10.70
0.22
3.34
10.82
3.33
14.21
8.50
0.19
6.85
13.17
3.70
0
2
4
6
8
10
12
14
16
INDONESIA MALAYSIA MYANMAR PHILIPPINES THAILAND VIETNAM
GW
GT/CCPP FOSSIL
Source : UDI Annual Report
Plant Performance Improvement Program
Engineering Activities that enesG worldwide provides for Plant Performance Improvement Program
① Field performance diagnostic testing service
③ AS-IS basis plant performance model
Purpose
• Determine performance degradation from new & clean condition
• Achieve Inputs for AS-IS Plant Performance Modeling
• Conduct thermo-economic analysis to select items to be repaired, improved or replaced from simulation of AS-IS basis plant performance model (needs input from equipment manufactures)
• Confirm TO-BE basis plant performance model
Find AS-IS
Process 1
Expect TO-BE
Process 2
⑤ Field performance acceptance testingservice
• Verify performance improvement and compare with contractual performance guarantee
Verify TO-BE
② Energy losses recapture program • Recapture energy losses caused by valve or steam trap malfunction, non-ideal operation method and etc.
Activities
• Contract and execution of RetrofitRetrofit
Process 3
Process 4
9
• Ranking of components based on their contribution to plant performance degradation (sensitivity analysis)
④ Feasibility study for Retrofit
The process begins with the collection of data for the new and clean and current operational plant conditions. These data are used performance optimization and cost benefit analysis.
New and Clean Performance
Current Performance
thru. Diagnostic Testing
Diagnostics for Performance Optimization
Hardware Inspections
Recommendations
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① Find AS-IS : Field Performance Diagnostic Testing Service
1 2 4
3
5
11
Field Performance Diagnostic Testing Service - Coal Fired Power Plant
① Find AS-IS : Field Performance Diagnostic Testing Service
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Field Performance Diagnostic Testing Service - Combined Cycle Power Plant
① Find AS-IS : Field Performance Diagnostic Testing Service
Cycle Isolation Testing
As a part of performance diagnostic testing program, the valves and steam traps which are important to cycleisolation are tested. The result is an effective ranking of each test item based on its impact on a plant’sperformance.
Valve leakage detection
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Steam trap malfunction check
② Find AS-IS : Energy Losses Recapture Program
Plant Operation Method for Performance Optimization
Optimization of the Condenser Vacuum Pressure
• Compressor efficiency management- Fouling, erosion & foreign object damage
monitoring- Timing of online washes(minor cleaning)- Timing of offline washes(major cleaning)
• Inlet temperature optimization(via spray cooling)
258 315 377 462 566 699 874
1,116 1,427
1,775 2,130
2,487 2,878
3,313
3,822
4,346
4,890
5,406
5,918
6,407
6,891
7,344
7,766
8,192 8,583
8,938
-54 -1 120 283 420 534 672 902
1,198 1,485
1,753 2,027
2,284 2,531
2,771 3,007
3,232
-1,000
1,000
3,000
5,000
7,000
9,000
11,000
0.00 ℃ 5.00 ℃ 10.00 ℃ 15.00 ℃ 20.00 ℃ 25.00 ℃ 30.00 ℃ 35.00 ℃
Chan
ge in
Gen
erat
or Po
wer O
utpu
t, kW
해수온도
100% NR ≒ 500,000kW ≒ 91.92% Heat Duty
2 Pumps to 3 Pumps Operation
3 Pumps to 4 Pumps Operation
29.7 30.2 30.7 31.3 32.0 32.9 33.8 34.7 35.8 37.0
38.3 39.6
41.0 42.5
44.2 46.1
48.2 50.4
52.7 55.2
57.8 60.6
63.5
66.6
69.9
73.3
18.5 19.1 19.7 20.4 21.2 22.0 22.9 23.8 24.8 25.8 27.0
28.2 29.4
30.8 32.3
33.8 35.6
37.4 39.3
41.3 43.5
45.7 48.1
50.6 53.3
56.1
14.8 15.4 16.0 16.7 17.4 18.2 19.1 20.0 20.9 21.9 23.0 24.1
25.3 26.5
27.9 29.3
30.9 32.6
34.3 36.2
38.1 40.2
42.4 44.6
47.0 49.6
0.000
10.000
20.000
30.000
40.000
50.000
60.000
70.000
80.000
0.00 ℃ 5.00 ℃ 10.00 ℃ 15.00 ℃ 20.00 ℃ 25.00 ℃ 30.00 ℃ 35.00 ℃
Cond
ense
r Pre
ssur
e, m
mHg
해수온도
100% NR ≒ 500,000kW ≒ 91.92% Heat Duty
48,339 m3/hr
72,508 m3/hr
93,470 m3/hr
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• Main Steam Temperature• Main Steam Pressure• Reheat Steam Temperature• Condenser Vacuum Pressure• Superheat Spray Flow• Reheat Spray Flow• Boiler Exit Flue Gas - Excess O2
Fossil Power Plant
Combined Cycle Power Plant
② Find AS-IS : Energy Losses Recapture Program
No Troubles Actions Power Loss Recapture
Effective Period
1Main steam drain line shot-off valve is not fully closed.
Tightly close the valve 1.2 MW continuous
2Defective primary flow element (over estimation of reactor thermal power)
Change of flow measurement channel (Average Mode→ X Channel Mode)
3.0 MW continuous
3Restriction of condenser pressure during winter season
Change the operation procedure 1.0 MW 1 month/year
4MSR heating steam supply line shutoff valve not fully open (interference)
Machine the valve disc guide during outage 0.9 MW continuous
5 MSR HP reheater partition plate leak Change the gasket during outage 0.4 MW continuous
6Excessive feedwater heater continuous vent in many units
Optimizes the continuous ventMore than
7.5 MWcontinuous
7Drift of differential pressure transmitters in the primary flow element
Adjust the DP transmitter baes on the precision test instrument
2.5 MW continuous
8Defective primary flow element (over estimation of reactor thermal power)
Change of flow measurement channel and change the COLSS constant
2.4 MW continuous
9Wrong calculation of nuclear reactor thermal power
Change the thermal power calculation software logic
2.0 MW continuous
Experience of enesG worldwide in the Nuclear Power Plants
more than 25 MW power losses were recaptured in the field performance diagnostic testing of the 22 nuclear units.
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② Find AS-IS : Energy Losses Recapture Program
No Troubles Actions Eff. Loss Recapture
Effective Period
1Drift of SH outlet temp. measurement for set point control (2 units)
Recalibrate and loop check during outage More than 0.30% continuous
2Loss of credit from combustion air caused by additional intake for PA & FD fan (3 units)
Check the intake duct gasket to prevent entrance of the cold air
More than 0.60% continuous
3Excessive clearance of HP turbine diaphragm packing ring
Develop a guideline for optimization of packing clearance
0.11% continuous
4Malfunction of variable clearance packing (HP/IP mid-span packing)
To be determined 0.19% continuous
5 Poor turbine back pressure controlDevelop the CW pump operation profile for performance optimization
unaccountable
6Leakage of LP cleanup recirculation line shut-off valve
Optimizes the continuous vent 0.17% continuous
7Leakage of BFPT HP stop valve before and after seat drain line MOV
Inspect and repair during outage 0.45% continuous
8Valve leakage during normal operation in all units
Inspect and repair during outage unaccountable continuous
9Steam trap malfunction during normal operation in all units
Inspect and repair during outageunaccountable
continuous
more than 1.75% plant efficiency losses were recaptured in the field performance diagnostic testing of the 4 fossil units
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② Find AS-IS : Energy Losses Recapture Program
Experience of enesG worldwide in the Fossil Power Plants
17
③ Find AS-IS : AS-IS Basis Plant Performance Model
The thermal performance modeling is customized to the power plant hardware characteristics and tuned to current performance data and plant capabilities resulted from the field performance diagnostic testing.
KOSPO Block #11Estimated Combined Cycle Output Degradation Distribution
-7.0%
-6.0%
-5.0%
-4.0%
-3.0%
-2.0%
-1.0%
0.0%
CC
Out
put D
egra
datio
n %
Del
ta
Start 0.0% 0.0% -1.8% -2.0% -2.3% -3.1% -3.5% -3.1% -4.7% -5.0% -4.9% -5.1% -5.6% -5.8% -6.2%
End 0.0% -1.8% -2.0% -2.3% -3.1% -3.5% -3.1% -4.7% -5.0% -4.9% -5.1% -5.6% -5.8% -6.2% -6.6%
New & Clean
GT13 Comp
GT13 Turbine
GT14 Comp
GT14 Turbine
HP Steam Turbine
IP Steam Turbine
LP Steam Turbine
HRSG13 HP
HRSG13 IP
HRSG13 LP
HRSG14 HP
HRSG14 IP
HRSG14 LP
Condenser
Performance Degradation Analysis (Sample for Combined Cycle Power Plant)
Determine overall plant degradation and recovery potential in Power Output and Efficiency through simulation of the AS-IS Basis Performance Model.
KOSPO Block #11Esimated Combined Cycle Efficiency Degradation Distribution
-2.0
-1.8
-1.6
-1.4
-1.2
-1.0
-0.8
-0.6
-0.4
-0.2
0.0
CC
Effi
cien
cy D
egra
datio
n %
p (H
HV)
Start 0.00 0.00 -0.15 -0.23 -0.24 -0.48 -0.61 -0.47 -1.08 -1.19 -1.18 -1.25 -1.43 -1.50 -1.66
End 0.00 -0.15 -0.23 -0.24 -0.48 -0.61 -0.47 -1.08 -1.19 -1.18 -1.25 -1.43 -1.50 -1.66 -1.84
New & Clean
GT13 Comp
GT13 Turbine
GT14 Comp
GT14 Turbine
HP Steam Turbine
IP Steam Turbine
LP Steam Turbine
HRSG13 HP
HRSG13 IP
HRSG13 LP
HRSG14 HP
HRSG14 IP
HRSG14 LP
Condenser
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③ Find AS-IS : AS-IS Basis Plant Performance Model
Hardware inspections of major plant components are carried out. Information collected is used in conjunction with operational and design data to determine recommendation for the performance improvement.
New and Clean Performance
Current Performance
thru. Diagnostic Testing
Diagnostics for Performance Improvement
Hardware Inspections
Recommendations
1 2 4
3
5
19
④ Expect TO-BE : Feasibility Study for Retrofit
20
• Sample Case : Steam Turbine Upgrade in a Fossil Power Plant
① Rotor & Bucket② Diaphragm③ Packing Casing④ Journal Bearing⑤ HP/IP Turbine
Integral cover buckets(ICB's)
High Efficiency Stage Design
Root Sealing : Brush seals
Tip Sealing : Advanced Seals
Advanced VortexHP Nozzle & Bucket
Advanced VortexIP Nozzle & Bucket
1
2
4
3
HP IP
Tip Seal
5
5
④ Expect TO-BE : Feasibility Study for Retrofit
AbradablesS1S
S3N PurgeReduction
Low dP Combustor Case TemperatureManagement
Bellows crossfire tubes
Ejectors: ExtractionOptimization
MkV >> MkVIe Upgrade
DLN 2.6 Combustion SystemFA+e Flared Compressor
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• Sample Case : Gas Turbine Upgrades in a Combined Cycle Power Plant
④ Expect TO-BE : Feasibility Study for Retrofit
① Combined Cycle Configuration (Preliminary)
CCPP Extension Modeling
Upgraded Gas Turbine Modeling
1
3
Performance Optimization based on Thermo Economic Analysis
G
G
② HRSGs and STG configuration (Preliminary)• Dual Pressures (HP/LP)
• Triple Pressures (HP/IP/LP)
③ Condenser configuration• Steam Surface Condenser• Air Cooled Condenser
2
• 2 x GTG + 2 x HRSG + 1 x STG • 3 x GTG + 3 x HRSG + 1 x STG• 4 x GTG + 4 x HRSG + 1 x STG
New Equipment Modeling
5
CCPP Extension Modeling Test4
22
• Sampling Case : Gas Turbine Upgrade and Steam Cycle Add-On
① Combined Cycle Configuration (Preliminary)
④ Expect TO-BE : Feasibility Study for Retrofit
New and Clean Performance
Current Performance
thru. Diagnostic Testing
Diagnostics for Performance Improvement
Hardware Inspections
Recommendations
23
Recommendations for performance improvement are issued based on current plant condition, existent equipment capabilities, and cost-benefit analysis.
1 2 4
3
5
④ Expect TO-BE : Feasibility Study for Retrofit
24
• TO-BE Basis Plant Performance Model (with new equipment)
④ Expect TO-BE : Feasibility Study for Retrofit
25
Optimization process for Total Capital (investment) CostsSelecting optimal combination of equipment or components to minimize theInvestment Costs.
Supporting the Investment DecisionEvaluating the economic considerations by several possible methods e.g. theCumulative Cash Flow Diagram, Payback Period, Average Rate of Return, Int-ernal Rate of Return (IRR) according to Client’s requirements.
Thermo Economic Analyses data requirement from ClientSeveral financial data are needed e.g. Fuel Price, Electricity Price, DesiredRate of Return on Investment, planned Project Lifetime etc.
• Performance Optimization based on Thermo-Economic Analysis
④ Expect TO-BE : Feasibility Study for Retrofit
26
⑤ Verify TO-BE : Field Performance Acceptance Testing Service
Design and execution of performance acceptance testing for overall power plant or thermal islandand individual equipment with a highest level of accuracy consistent with the best engineeringknowledge and practice in the power industry.
Conclusion
• Improved plant efficiency – fuel cost savings • Improved plant output – additional revenue• Performance degradation recovery
• Short payback period• Maximize use of original capital investment• State of the art technology - increased Asset Value
• Lower Emissions (NOx, tonnes CO2/MWh)
28
Conclusion
② The basis and very beginning activity of Plant Performance Improvement Program isto periodical Field Performance Diagnostic Testing which supports;
③ Retrofit is cost-effective way to meet the increasing electric power demand in Asiancountries, minimize environmental pollutions.For successful retrofit project, “Find AS-IS” and “Expect of TO-BE” is very importantprocesses and should be executed by specialized engineering group.
• monitoring of plant performance degradation and effective ranking of components for plant performance recovery
• recapturing energy losses • ideal plant operation for performance optimization
① Benefits of Plant Performance Improvement Program to the Owners are;
Q & A