COMPLETE POWER PLANT, 330 MWEL LIGNITE-FIRED, LOW RUNNING HOURS
This power plant with one line 330 MWel started its commercial operation in 04/1983. The plant design was for base load with a technical useful life without higher reinvestment of 200.000 hours. Recorded yearly operating hours were up to > 5.000 mainly in wintertime, due to available excess hydro power in summertime. Steam turbine is equipped with extraction for 120 °C / 60 °C district heating. Together with an additional flue gas heat exchanger at the boiler a total of 47,5 MWth can be supplied. Efficiency of power production is 38.5 % Plant was shut down in 05/2006 based on a foreseeable run down of lignite on site. Total operating hours were 84.289 with 411 starts after a gross production of 23.876.006 MWhel. After shut down owner invested about 7.000 man hours in cleaning and preservation. Boiler is filled with water and preservation solvent, Generator and Turbine are permanently dried with hot air and are frequently turned. Coal transport system with conveyor belts from open pit mine to the coal storage area was already dismantled.
Technical data
Boiler
Manufacturer European manufacturer
Thermal cycle type forced circulation, single pass design (SULZER type)
Max. hight above ground 100 m
Max. continuous rating 980 t/h
Max. short time Overload 1.029 t/h
Heating surface size 44.746 m²
Total piping length 383.000 m
Max. pressure rating 203 bar
Live steam conditions 184 bar, 535° C
Reheat steam 920 t/h
Reheat steam temperature 535° C
Min. Boiler load 55 % operational, 40 % theoretical
Fuel Lignite, size 0 - 30 mm
Average Heating value 10.500 kJ/kg (normal 9.210 – 12.560)
Average Water content 35 % (normal 30 – 40)
Sulphur content 0,7 % (normal 0,3 – 1,05)
Firing Tangential coal dust firing
Average fuel consumption 280 t/h
Ignition 6 HFO burners
Casing Membrane walls
Slag removal Wet
Flue gas quantity 1.100.000 Nm³/h dry
Flue gas temperature 150 °C
Boiler efficiency measured 90,7 %
Coal Mills
Manufacturer German manufacturer
Type Beater Wheel
Number of Mills 6 (one in stand-by)
Rated capacity 72 t/h each
Rpm 470 - 520
Wheel diameter 3.400 mm
Coal mill motors 1.300 kWel each, 6 kV
Auxiliary steam
Steamblock Type 3000
Steam parameters 26 t/h, 14 bar, 320°C.
Fuel HFO
Dust control
System Electric Precipitator
Denitrification
System Primary measures and Selective Catalytic Reduction
Year of commissioning / retrofitting 1988 / 1990
Additive for denitrification Ammoniumwater
Average consumption 500 kg/h
Desulphurisation
System Furnace limestone injection process and wet sorption
Year of commissioning / retrofitting 1983 / 1986
Additive for desulphurisation Limestone
Number of scrubbers 2
SO2 efficiency 90 – 95 %
Average Gypsum production 17,3 t/h
Flue gas temperature into stack 80°C
Main stack
Description Concrete stack, steel flue gas duct hanging from top
Inner diameter 5.500 mm
Wall thickness 8 mm (steel)
Height of stack 180 m
Stack base outside diameter 21,8 m (concrete)
Stack crest diameter 10,2 m (concrete)
Stack wall thickness 300 mm (concrete)
Steam turbine
Manufacturer German manufacturer
Casing 1 x HP, 1 x MP, 1 x LP double flow
Max. continuous rating 330 MW
Live steam conditions 177,5 bar, 532 OC
Reheat steam conditions 37,3 bar. 534 OC
2 Bleedings for District Heating 37,5 MWth
Condenser pressure 51 mbar
Cooling surface 13.100 m²
Feed pumps
System 3 x 50 % electric driven with constant rpm pre-pumps
and variable rpm main pumps via VOITH gear box.
Manufacturer of Pumps KSB
Manufacturer of feed pump motors ASEA
Rated power 6.200 kWe each, 6 kV
Cooling
Cooling water extraction River
Cooling method 99 m concrete natural draught cooling tower
Cooling water quantity total 25.000 m³/h
Cooling water demand 720 m³/h
Synchronous Generator
Manufacturer European brand
Generator capacity 375 MVA
Voltage 21 kV
Power factor 0.88
Speed 3 000 rpm
Step-Up Transformer
Manufacturer European brand
Rated power 360.000 kVA
Voltage 21 / 116 kV
Vector group YNd 11
Start Transformer
Rated power 40.000 kVA
Voltage 116 / 6,3 kV
Consumption Transformer
Rated power 40.000 kVA
Voltage 20 / 6,3 kV
Process Control System Details on demand
Auxiliaries
All auxiliaries for safe operation of the plant are available, including turbine and generator control, fuel system, cooling water system, deionisation plant, etc. and a remarkable lot of spare parts and crane are available.
Spare Parts
Available and stored in a separate building.
Documentation
Complete documentation, including civil engineering, operation manuals, maintenance reports, log books, etc. is available.
Ref. 81262
COMPLETE POWER PLANT, APPROX. 70 MWEL HARD COAL FIRED, WELL MAINTAINED.
This power plant with one line 60 MWel started its commercial operation in 1967. The plant design was for base load with local lignite fuel. In 1985 the steam turbine was equipped with a 0 - 100 % extraction for 114 °C / 80 °C district heating for up to 20 MWth. In 1997 the power plant wasmodified and refurbished to use hard coal fuel, the power output increased from 60 to approx. 70 MWel. System efficiency of power generation was measured in 1999 with 33,39 %. Owner did a remaining life time assessment with the result of > 10 years without major investment but permanent maintenance and component control. Detailed revision reports are available. Plant was shut down on 24.04.2008 based on the commissioning of a new 400 MWel Gas Turbine Combined Cycle and is hold in cold reserve.
Total operating hours were 231.000 with OEM recommended maintenance/repair/overhaul.
Coal transport system with covered conveyor belts from rail car unloading via intermediate storage to boiler is available.
Technical data
Boiler
Manufacturer European manufacturer
(modification and refurbishment in 1997)
Thermal cycle type forced circulation, two pass design.
Desing hanging in heavy steel construction
Max. hight above ground 44 m
Max. continuous rating 240 t/h
Max. pressure rating 110 bar
Live steam conditions 90 bar, 530° C
Min. Boiler load 50 % operational
Fuel Hard Coal
Lower Heating value 25.500 to 31.500 kJ/kg
Average Water content 6 to 10 %
Sulphur content 0,4 %
Ash 5 to 14 %
Volatiles 25 to 40 %
SiO2 in ash 32 to 60 %
Hardgrove 45 to 60
Firing Tangential coal dust firing on 3 levels each 4 burners
Ignition Natural Gas and HFO burners
Casing Bricklined walls
Slag removal Wet
Air preheating 2 x LJUNGSTROEM type
Fresh air blower 2
ID fan 1
Flue gas quantity 310.000 Nm³/h dry
Flue gas temperature 95 °C
Boiler efficiency measured 92,44 %
Coal Feeding
Underground silo with chain conveyor 300 t/h
Belt conveyor to day bin 130 t/h
Chain conveyors to feed 2 x 130 t/h
Coal Mills
Manufacturing 1997
Manufacturer European manufacturer
Type Bowl Mill SM 14/9
Number of Mills 3
Rated capacity 9,2 t/h each
Coal mill motors 160 kWel each, 5 kV
Motor Rpm 985
Coal Mill Air Blower
Rated Air Volume 8,6 m³/s
Rpm 1.480
Power 132 kW
Dust control
Manufacturing 1985
System Electric Precipitator
Arrangement Double 2 Zone
Active area 5.400 m²
Filtering 99,81 %
Voltage 2 x 96 kV
Ash extraction pneumatic
Dust in flue gas < 30 mg/m³
Desulphurisation
Manufacturing 1993
System Rotating spray absorber with injection and wet sorption
Additive for desulphurisation Limestone
SO2 in raw gas design max. 4.000 mg/m³
SO2 cleaning efficiency > 90 %
Flue gas temperature into stack 85 – 90 °C
Steam turbine
Manufacturer European manufacturer
Casing 1 x HP, 1 x LP double flow
Max. continuous rating approx. 70 MW
District heating rating 57 MW
Live steam conditions 89 bar, 525 OC
Vacuum at 50 MW and 20 °C Water 0,047 bara
Condenser
Cooling surface 3.270 m²
Cooling water flow 7.500 m³/h
Tube material 70 % Cu, 29 % Zn, 1 % Sn
Number of tubes 6.400 22/24 mm
Length of tubes 6.500 mm
Feed pumps
System 2 x 50 % electric driven, 6 stages, variable RPM by
VOITH hydraulic coupling.
Manufacturer of Pumps KSB
Rating 276 t/h
Pressure 128 bar
Manufacturer of feed pump motors ABB
Rated power 1.500 kWe each, 5 kV
Synchronous Generator
Manufacturer European manufacturer
Generator capacity 75 MVA
Voltage 10,6 kV +/- 5 %
Power factor 0.8
Speed 3 000 rpm
Exciter 250 V, 1.450 A
Cooling H2
Step-Up Transformer
Manufacturer European manufacturer
Rated power 75.000 kVA
Voltage 10,5 / 117 kV
Consumption Transformer
Manufacturer European manufacturer
Rated power 8.000 kVA
Voltage 10,5 / 5 kV
Process Control System
Installed in steps 1993 – 1997
Manufacturer SIEMENS
Type Teleperm M
Operating System
Installed 2003
Manufacturer ETM
Type PVSS
Auxiliaries
All auxiliaries for safe operation of the plant are available, including turbine and generator control, fuel system, cooling water system, deionisation plant, etc. and a remarkable lot of spare parts are available.
Documentation
Complete documentation, operation manuals, maintenance reports, log books. etc. is available in the plant.
Ref. 81263
TRIVENI ENGINEERING & INDUSTRIES LTD. - FR13E-56, 7,1 MW, STEAM TURBINE GENSET
( 1 ) Steam Turbine Genset, 7,1 MW,
Extraction-, Condensing - Type
Make Triveni Engineering & industries Ltd.
Tpe FR13E-56
Power Rating 7100 KW
Year of Manufacture 2009
Year of installation 2009
Steam Inlet Flow 39.5 TPH
Steam Inlet Pressure 41.5 BAR
Steam inlet Temperature 490 Deg. C
Extraction Pressure (Controlled) 13 ATA
Extraction Steam Flow (Controlled) 13.05 TPH
No of hours since Installation 5000 hours
Generator Make T D Power Systems Pvt. Ltd.
Year of Manufacture 2009
Rating 8000Kw
Voltage 11000 V
Frequency 50 Hz
Scope of supply
All equipment and auxiliaries for operation as in the existing plant
Condition of the equipment
They are still installed at the moment in running Condition
Ref. 81264
SIEMENS GK 32/45, 6,5 MW STEAM TURBINE GENSET
Multistage- condensing unit, oil tank as base frame.
Turbine Type Siemens GK 32/45
Year built 1997
Design capacity 6 030 kW
Rated 6 500 kW
Rotation speed 9 635 rpm
Steam pressure design / max. 20 / 26 bar
Wheel chamber pressure max 16,5 bar
Exhaust pressure design / max 0,1 / 0,25 bar
Steam temperature design / max. 375 / 400
Reduction gear Type Tacke TS 560
Rotation speed 9635 / 1 500 rpm
Condenser Siemens TUG
Cooling surface 420 m2
Cooling water flow 412 kg/s
Piping material CuZn20A12
Generator Siemens
Voltage
Rating
Scope of supply
All equipment and auxiliaries for operation as in the existing plant
Condition of the equipment
Plant was shut down and maintained regularly according to manufacturers requirements, so all
equipment is in very good condition.
Ref. 81265
