VASSILIKO INDEPENDENT
POWER PLANT LTD
INSTRUCTIONS / In the space provided in the right column please provide your notes, comments and if necessary data requirements. Please provide any alterations, discrepancies or alterations from the left column in BOLD letters.
COMMENT / VIPP LTD has performed a technical optimization study, to assess the concept of a Combined Cycle Power Plant (CCPP) in Cyprus
CONTACT PERSONS / MiljanRadunović
Project Manager (Belgrade office)
Energy System Integrator
m: +381 64 8731106
e: / Nikola Milutinović
Project Manager (Larnaca office)
Energy System Integrator
m:(+357) 96 475 773
e:
DESCRIPTION AND MINIMUM REQUIREMENT / NOTES/COMMENTS
1. The project will be an energy complex with the following primary components:
- Power generation system;
- High Voltage power distribution system;
- Utility systems;
- Process systems;
- Fuel oil storage tanks;
- LNG feeding system
2. The CCPP is designed to use heavy fuel oil (HFO) and to be readily convertible to natural gas when it is available in the future. HFO will be stored at the fuel storage facilities of the plant.
3. The project will provide generation capacity to the national grid by 2014, and will be an important component to the country’s power generation infrastructure. It is stressed that all solutions proposed aim at a high reliability in terms of functionality, safety and operability.
4. Plant Configuration
4.1 Combined Cycle Power Plant (CCPP) gas turbine and generator, Heat Recovery Steam Generator (HRSG) and Steam Turbine and generator.
4.2 Cogeneration Unit (CHP), to cover the needs for cold start reserve.
4.3 The units must be possitioned and integrated into the available space as defined in Drawing 1, which is an integral part of thi Tender and attached herewith. It is necessary to provide a provisonal layout of the 4.1 and 4.2 units in your submussion. PLEASE NOTE THAT SYMILAR UNIT LAYOUT HAS BEEN USED ONLY FOR REFFERENCE.
4.4 According to this plant layout, the gas turbine generator packages with the HRSG’s will be installed in open air. The steam turbine will be installed within an enclosure designed to limit noise. Water treatment plants and water storage tanks, as well as turbines and HRSG will be close together, enabling short runs for the water pipes.
For security reasons, a fence will be considered around the power plant and the Vasilikos Cement plant.
5. The electrical power output of the CCPP will be 50.92 MW (net plant output 48.009 MW) when fuelled by HFO (see Table 8.1). The heat rate will be approximately 8,246 kJ/kWh and the plant electric efficiency will be of the order of 43.66%, in full condensing mode. The plant will also have provision to supply steam to the cement works for process heat which will have the affect of increasing cycle efficiency and reducing the available electrical power.
One gas turbine, with a nominal base load power output at ISO conditions (15oC and 60% relative humidity) of approximately 39 MWe and one steam turbine with a nominal power of approximately 16.7 MWe at ISO condfitions shall generate power and supply electrical power from turbine alternators. The export voltage to the existing VCW sub-station is 11.5kV.
HFO will be supplied by tanker to a leased bulk storage tank(s) of up to 20,000 tons capacity at an existing commercial storage facility and from there to an existing on-site untreated storage tank with a total capacity of 700 tons. The untreated fuel will then be pumped by liquid fuel pumps into the HFO treatment plant and then to an existing treated HFO storage tank of 400 tons capacity.
Process and utility systems have been designed for simplicity and for ease of operation and maintenance, with simple subsystems and control loops.
6. Natural Gas fueled CCPP
The electrical power output of the CCPP will be 52.8 MW (net plant output 51.2 MW) when fuelled by NG (see Table 4.3). The heat rate will be approximately8,644 kJ/kWh, and the plant electric efficiency will be of the order of 41.65%
One gas turbine, with a nominal base load power output at ISO conditions (15oC and 60% relative humidity) of approximately 39.9 MWe and one steam turbine with a nominal power of approximately 12.9 MWe at ISO conditions shall generate power and supply electrical power from turbine alternators. The export voltage will remain 11.5 kV.
Fuel to the CCPP is to be supplied as pressurised natural gas as and when it is available in Cyprus.
Again, as it was mentioned before process and utility systems have been designed for simplicity and for ease of operation and maintenance, with simple subsystems and control loops.
7. Design Basis
The design of the unit has been based on the general requirements listed below:
- HFO tank storage capacity : 1 x 3,000 m3 and 1 X 500 m3
- Design life: 25 years
- CCPP power plant capacity: 50 MW natural gas/HFO fuelled
- CCPP power plant nominal voltage / frequency: 11 kV / 50 Hz
8. Systems description
In the following paragraphs the CCPP systems description will be presented.
The CCPP shall be consisted of the following systems:
- Power generation system;
- High Voltage power distribution system;
- Utility systems
- Process systems;
- Fuel oil storage tanks;
- NG feeding system
9. Power generation system
Combined Cycle Process Description
The combined cycle process is in general the most efficient fossil-fuelled power generation process of today.
The core part of the process is one or more gas turbine(s) that are operating on HFO or compressed natural gas. Power is generated from an alternator coupled to the gas turbine shaft. The hot exhaust gases (at typically 537oC for natural gas and 551oC for HFO for the present case) from the gas turbine is then used to generate steam in a heat recovery steam generator (HRSG). The steam produced here is in turn used for generating more electricity by steam expansion in one or more steam turbines connected to alternators. The output from both the gas turbine and the steam turbine electrical alternators is combined to produce electricity in a very efficient matter.
10. Overall efficiency
The proposed combined cycle process MINIMYM performance data are tabulated in (HFO TABLE) and (NG TABLE).ATTACHED
NG TABLE shows an overall efficiency before taking power used for all auxiliary electrical consumption into account. Depending on which of the auxiliary systems are in use, the net electric efficiency of the complete CCPP will vary between roughly 43 and 45 percent.
NG TABLE shows an overall efficiency before taking power used for all auxiliary electrical consumption into account. Depending on which of the auxiliary systems are in use, the net electric efficiency of the complete CCPP will vary between roughly 41 and 43 percent. The quoted efficiency on natural gas is reduced in part because the HRSG is designed for higher stack temperatures that are needed because of sulphur content in the HFO. Investigations are taking place to design a HRSG that will be capable of simple cost effective conversion to natural gas operation at efficiency levels in the 43% to 44% range
Please provide your notes on the Tables a separate page
11. Gas Turbine
The VIPP CCPP will be based on the gas turbine which is a single shaft, annular combustor, heavy-duty gas turbine with hot end drive. It can burn both gaseous and liquid fuels and can be used both in open cycle and combined cycle operation.
Firing heat duty, HFOLHV (MWth)112.907t/h 9.798
Firing heat duty, NGLHV (MWth)122.925
The Turbine will be equipped with a ten-chamber combustion system (burners) for burning HFO and will be readily convertible to natural gas. With steam injection into the combustion chambers, the NOX concentration in the exhaust gas will be reduced, resulting also in higher power output but slightly lower efficiency.
Generally, the gas turbine unit including generator and auxiliaries will be based on the manufacturer’s standard design to secure the advantages of a standardized packaged product. The control equipment will be located in an air-conditioned building. The GT generator packages will be installed in a separate gas turbine container.
The starting system for the GT will be an electric motor and a torque convertor.
The main MINIMMUM REQUIRENENTS data for the gas turbine are listed below.
12. Compressor
The compressor will be a multistage axial flow design with modulating inlet guide vanes. Interstage extraction will be used for cooling and sealing. High strength stainless steel blading material will be provided. The blading material in the compressor will have high corrosion resistance
13. Combustion System
The combustion system—which contains fuel nozzles, liners, transition pieces, X-fire tubes, flame detectors and spark plugs—consists of 10 reverse-flow combustion chambers arranged concentrically around the periphery of the compressor discharge casing
Steam is injected into the compressor discharge air stream around each of the fuel nozzles to reduce flame temperature, which leads to a reduction in NOx emissions. The quality of steam for injection must comply with GEK101944: Requirements for Water/Steam Purity in Gas Turbines; typical supply conditions of the steam would be 325 psig with a minimum of 50°F superheat. Steam injection will increase the gas turbine output and reduce heat rate (improved heat rate) The quantity of steam required will depend on the desired NOx level required, the fuel used, and the ambient conditions. The steam injection provides NOx emission control by modulating the steam injection rate proportional to fuel consumption. The steam injection system consists of steam flow control and regulating valves and control plus monitoring devices located off base in the operator’s steam piping. The steam from this off-base source is supplied in a controlled flow to the turbine’s steam injection manifold. The steam is then injected directly into the combustion can, serving to lower combustion temperatures thereby reducing NOx production
14. Turbine Section
The turbine section will have three stages The rotor will be a single shaft, with high torque capability incorporating internal air-cooling for the turbine section. The turbine buckets (rotating blades) will be changeable in sets or individually without any field balancing of the rotor.
Turbine materials, coating and cooling systems enable reliable operation at high firing temperatures. This achieves high gas turbine specific power and high efficiency for combined-cycle systems.
15. Generator
The generator will be designed and constructed for continuous GT drive, and will withstand without harm all normal conditions of operation, as well as transient conditions such as system faults, load rejection and mal-synchronization. Temperature detectors will be installed in the generator to permit the measurement of the stator winding, gas temperatures, etc
16. Gas Turbine Control System (MK V)
The turbine control must be considered here. It is also a suitable platform for integrating all power island and balance of plant controls.
17. Gas turbine generator unit
Gas turbine generator unit includes the gas turbine package consisting of:
The gas turbine compartment:
- multi-stage (17 stages), axial flow compressor;
- modulated inlet guide vanes;
- three-stages turbine;
- multi-chambers combustion system;
- ignition system with spark plugs and UV flame detectors;
- borescope openings for maintenance inspection;
- seismic type vibration sensors on bearing caps for protection;
- proximity type sensors for shaft line displacement monitoring;
- thermocouples for measuring exhaust temperature;
- thermocouples on bearing drains;
- thermocouples on bearing metal;
- inlet plenum and exhaust diffuser;
- exhaust frame blowers;
- on/off line compressor wet washing system;
- water injection system for NOx control
- lubricating oil system;
- hydraulic oil system;
- liquid fuel system;
- gas fuel system;
- atomizing air system;
- water injection for NOx level reduction
- gas turbine dry flexible diaphragm type load coupling;
- connected to generator with solid coupling;
- load gear box mounted between the gas turbine and the generator;
- lubrication system integral with the gas turbine
- GT rotor turning gear with electrical motor
- enlarged acoustic enclosure around gas turbine compartment;
- compartment ventilation and heating;
- hazardous area classification;
- gas detection system;
- fire detection and protection system with thermal detectors
- totally enclosed water-to-air cooled (TEWAC) generator;
- 50 Hz generator frequency;
- generator voltage approx. 11 kV;
- 0.85 power factor (lagging);
- SCR approximately: 0.45 to 0.5;
- Xd’’ approximately 14%;
- class “F” armature and rotor insulation;
- Cylindrical forged steel rotor with Class F insulation;
- “B” temperature rise, armature and rotor winding;
- temperature monitoring device for windings, cooling air path, bearings, cooling water, etc.
- turbine control panel;
- Triple modular redundant (TMR);
- Local (I) processor (computer);
- Single remote (I) processor;
- One (1) Mark V per stage link;
- RS232 serial link (modbus);
- Mark V to (I) connection <15 m (50 ft);
- Demand display;
- Extended I/O;
- Customer input contacts;
- Customer output contacts;
- Normal start/normal load;
- Normal start/fast load;
- Speed matching, synchronization and check;
- Generator manual synchronization;
- Generator synchronizing module;
- Isochronous control;
- Droop control;
- Constant adjustable droop;
- Power factor calculation and display;
- Load limiter;
- Base load only;
- Preselected load – manual set point;
- Trip signal display;
- Bearing metal temperature readout and alarm
- Fire protection discharge – time delay;
- Vibration alarm readout and trip (seismic only);
- Redundant sensors for critical measurements;
- Combustion monitor;
- Wheelspace temperature readout and alarm;
- Generator stator over-temperature protection;
- Generator coolant and stator temperature indicator
- Turbine Inlet Air System
- Up and over configuration
- Inlet air compartment with:
- Three stage
- Coalescer + pre-filters + high efficiency
- Support structure
- Instrumentation
- Inlet system pressure differential indicator
- Inlet system pressure differential alarm
- Inlet silencing 2.4 m
- Perforated stainless steel construction
- Inlet duct section
- Inlet elbow
- Inlet expansion joint
- Inlet transition piece from duct to plenum
- Structural support
- Zinc rich paint on outside and inside of inlet plenum
- shut off and vent valve skid;
- gas piloting system
- Fully lagged enclosure for outdoor installation
- Located at fuel tank
- Dual inlet liquid fuel strainers
- Single unit, one (1) ac motor-driven pump and one (1) black start dc pump
- Pressure regulating valve
- Liquid fuel heater
- Flow meter
- one (1) HP CO2 bottle rack inside a air-conditioned storage container;
- unit fire detection and protection panel;
- unit fire protection panel
- Compressor on- and off-line washing skid
- air filter;
- ducting and inlet silencer;
- supporting steel structure
Compressor
Number of stages17
Type of rotor constructionMulti-disk with Hirt serration and central tie rod
Number of stages of variable inlet guide vanes1
Combustion system
Combustion chamber typeAnnular
Number of combustion chamber1
Number of burners10
Burners typeHybrid (diffusion / premix)
Type of ignitersSpark plugs
Number of igniters1 per burner
Type of flame supervisory elementsFlame sensors
Number of flame supervisory elements2
Type of NOx reduction method for fuel gasSteam injection
Type of NOx reduction method for fuel oilSteam injection
Turbine
Number of stages3
Type of rotor constructionMulti-disk with hirth serration and central tie rod
Turbine temperature
Inlet ISO temperature at base load1,094 oC +/- 10 oC
Gas turbine speed
Nominal speed5,413 rpm
Range of allowed speed5,142 – 5,575 rpm
Over-speed protection threshold5,846 rpm
Duration of start-up and loading (in open cycle at ISO condition)
Time to reach full speed no load condition
from standstill5 min
Time to reach base load from synchronisation17 min
Turning gear
TypeHydraulic ratchet
Speed in turning operationna
Operating period required after shutdown24 hours
Starting system
TypeElectric motor plus torque converter system
Nominal power1,400 kW
Speed5,413 rpm
Allowed number of start-up4 (2 hours interval required after fourth start)
. Performance characteristics
FUEL NG (5) HFO (6)
Amb. Temp. (oC) 15 15
Amb. Press. (mbar)1,013 1,013
Amb. Rel. Hum. (%)60 60
Load (%)100 100
Exh. Press. Drop (mbar)0 0
Power Output (kW) (4)52,801 54,203
Efficiency (%)(1,4)35.38 34.83
Exhaust gas mass flow (kg/s) (2)141142
Exhaust gas temp. (oC) (3)537 538
Exhaust gas composition
O2 (%vol)13.52 13.42
N2 (%vol)73.21 71.77
Ar (%vol)0.8817 0.8642
CO2 (%vol)3.09 4.207
H20 (%vol)9.289 9.703
SO2 (%vol)9.289 0.0365
18. Co-generation Unit
Please provide the data for the specified engine:
- Number of cylinders
- Bore/Stroke
- Engine speed
- Frequency
- Mechanical output
- Electrical output, cosø = 0.8
- Mean effective pressure
- Specific fuel consumption
- Fuel consumption
- Charge air cooler
- Lube oil cooler
- Jacket water cooler
- Exhaust mass
- Exhaust gas temperature
- Lube oil consumption
- Nom el efficiency, cosø = 0.8
19. Gas Turbine driven Alternator Sets
The power production system of the power plant comprises of one gas turbine, accompanied by two-pole air-cooled turbo-generator.