engineering service for power plant performance...

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

10

① Find AS-IS : Field Performance Diagnostic Testing Service

1 2 4

3

5

11

Field Performance Diagnostic Testing Service - Coal Fired Power Plant


12

Field Performance Diagnostic Testing Service - Combined Cycle Power Plant


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

13

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

14

• 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


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.

15


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

16


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

18

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.


Current Performance


Diagnostics for Performance Improvement


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


AbradablesS1S

S3N PurgeReduction

Low dP Combustor Case TemperatureManagement

Bellows crossfire tubes

Ejectors: ExtractionOptimization

MkV >> MkVIe Upgrade

DLN 2.6 Combustion SystemFA+e Flared Compressor

21

• Sample Case : Gas Turbine Upgrades in a Combined Cycle Power Plant


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)



Current Performance


Diagnostics for Performance Improvement


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


24

• TO-BE Basis Plant Performance Model (with new equipment)


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


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;

engineering service for power plant performance...

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