Components of Cycling - CCPP - Siemens
Components of Cycling - CCPP - Siemens
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of emissions can support these efforts. The gas turbine and the plant concepts with high
flexibility will be the backbone of all these business trends.
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Starting point of the analysis was the current design of the 50Hz single-shaft (Fig. 5). The
Siemens PG single-shaft concept has been introduced to market in 1994 (Kings Lynn, UK)
and accumulated a big pool of operational data for different load regimes which allowed to
start the analysis not just on theoretical data but on real operational data.
Kings Lynn (United Kingdom)
Concept: Single Shaft 1S.V94.3
350 MW
Output (nat. gas, site) :
Efficiency (nat. gas, site):
55.3 %
COD:
August 1996
Fuels: Natural Gas (Fuel oil Back up)
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8-16h
16-64h
>64h
200 starts/a
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50 starts/a
2 starts/a
The description and considerations of the cycling capability improvements in the following
sections follow the chronological sequence of a combined cycle start-up. A typical start-up
curve for a start of a single-shaft unit after a weekend shutdown is shown in figure 7. Startups after a overnight or a extended standstill follow the same logical sequence. The
improvements and considerations are highlighted for each phase of the start-up.
Start-up preparations
As per definition the preparation for start-up is not included in the start-up time which starts
with ignition of the gas turbine. However, the single-shaft BOP design includes design
features which enables the operator to get systems ready for operation before the gas turbine
start is initiated and simplifies the start-up procedure. The use of water ring pumps and an
auxiliary boiler for seal steam supply to the steam turbine allows to pull vacuum and have the
condenser ready for operation. The first steam produced after gas turbine start can therefore
be dumped into the condenser via the steam bypasses and steam vents are not required (1).
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Prior to gas turbine (GT) start the HRSG is purged as required by code by accelerating the gas
turbine from turning speed using the start-up frequency converter (SFC) (2). The turbine
speed is then reduced to ignition speed and the ignition procedure is initiated.
HRSG
At rated speed the generator is synchronized and connected to the grid and the GT is loaded to
minimum output. A further increase of the GT exhaust gas temperature and the GT ramp rate
is limited by the allowable temperature and pressure transients of the HRSG. These transients
are determined by the thermal stresses and fatigue damage of the thick-walled HRSG
components like the HP-drum and the HP-superheater headers as well as tube connections.
The investigations of the team therefore were focused on evaluations to:
Include measures to keep the HRSG warm before start-up. This will be achieved by
using steam sparging into the evaporator and closing of the stack damper.
Optimize the superheater and reheater outlet header designs with smallest possible
inner diameters and wall thicknesses in order to maximize the allowable temperature
gradients during start-up.
Once the HP-steam temperature approaches the GT exhaust gas temperature and the drum
levels stabilized at operating level, the gas turbine output and hence the exhaust gas
temperature is increased further with the target to reach a GT load to operate completely in
the low NOx premix mode (3).
All these measures support a reduced start-up time for a conventional drum boiler. For
conventional drum boiler design the sizing criteria of the HP-drum with regard to level
control during transient load conditions and carryover impedes to fulfill the requirements of a
cycling plant.
Reducing the start-up times further leads to considerations to overcome limitations by the
HP-drum by eliminating the HP-drum completely which leads to a once-through design of
the HRSG (fig. 8), as already demonstrated in the power plant Cottam, UK.
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Steam Turbine
In parallel to that the warm-up of the steam lines is initiated as soon as the HRSG generates
steam. Up to a certain pressure the piping systems as well as the combined steam turbine
stop/control valve casings are warmed up by opening the drain valves and the emergency
stop valves.
Prior to opening of the governor valves and rolling on of the steam turbine, the criterias for
the required steam purity, allowable temperature differences between steam and steam
turbine components and adequate temperature margins to run up the steam turbine are
checked (4).
Improvements to reduce the start-up time during this phase focused on:
a changed start-up sequence in order to ramp the ST power output oriented with
almost constant HP/HRH steam temperatures from roll on to full load. The feasibility
of an increased attemperator capacity until the GT is at full load has been checked.
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Benefits
A plant designed for increased cycling capability offers operational benefits that will
positively affect the life-cycle costs, due to:
Increased flexibility
Fuel savings
Since this plant can be operated in a fast-start, intermediate-load or a base-load mode, there is
a high degree of flexibility for the owner also with changing market conditions. The ability to
rapidly reach dispatchable load allows the owner to participate in more revenue generation
opportunities and allows additional profit depending on its specific contractual conditions.
An advantage that can be quantified are the fuel savings. Due to accelerated start-up, the
improvements significantly reduce start-up fuel. For the economic calculation on NPV-basis a
set of assumption with regard to input data was required such as fuel prices, electrical
revenues and interest rates. Furthermore a load regime and a fixed relation between expected
and unexpected starts has been fixed. This results in savings in NPV of approx. 3.5 million
over 20 years in case of a conventional water-/steam cycle using a drum boiler with cycling
features and are almost doubled for a once-through design (fig. 10).
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Conclusions
The single-shaft concept with enhanced cycling capabilities represents an approach for the
market that targets the needs of combined cycle power plants in intermediate duty with
frequent start-up and shutdown cycles, without sacrificing base-load operability.
Special detail in system integration using expertise and experience of a full EPC contractor is
key to the success of the plant design. Controlled steam temperatures and an advanced ST
start-up mode are considered to mitigate ST induced start-up restrictions.
Its improvement in operating flexibility helps power plant owners to be prepared for a
deregulated market to maintain their revenue stream over the uncertainty of the dispatch
requirements.
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References
[1]
The real cost of cycling powerplants: What you dont know will hurt you by S A
Lefton, P M Besuner, G P Grimsrud, Aptech Engineering, POWER, Nov/December
2002
[2]
Design of High Load Cycling Operation for Combined Cycle Power Plants by
Andrew Chrusciel, Justin Zachary, Sam Keith: Bechtel Power Corp., Published for
PowerGen International 2001, Las Vegas, NV
[3]
Successful Combined Cycle Debut for Novel Horizontal-Flow Vertical-Tube BensonHRSG by Joachim Franke, Uwe Lenk, Robert Taud: Siemens Power Generation,
Erlangen, Germany; Friedrich Klauke: Babcock Borsig Power, Oberhausen, Germany.
Published in Modern Power Systems, July 2000
[4]
[5]
Combined Cycle Steam Turbine Operation by Leo Bize, Harry Martin: Siemens
Westinghouse Power Corporation, Orlando FL; Norbert Henkel, Edwin Gobrecht:
Siemens Power Generation, Muelheim, Germany. Published for 2001 International Joint
Power Conference, June 4-7, New Orleans, LO. JPGC2001/PWR-19127
[6]
An Integrated Combined-Cycle Plant Design that Provides Fast Start and Cycling
Capability at Base-Load Efficiency by Raymond Baumgartner, Christian Engelbert,
Mathias Groepner, Michael McManus, Erich Schmid: Siemens Westinghouse Power
Corporation, Orlando FL. Published for Electric Power 2003 Conference, March 4-6,
Houston, Texas, USA