Claus C Project 1300 MWe CCGTDynaflow lecture 6-12-2012
Repowering of Unit B into Claus CE- power extension (640 MWe to 1300 MWe)
Maximum of re-used equipment (saving investment)
Cycling plant (daily start –stop)
Fully automated operation
Project Claus CNew;• 3 x Alstom GT26 gas turbine (3 x 270 MWe)> 380 KV Grid
• 3 Triple Pressure Reheat HRSG's (3x380 t/h steam)
• Retrofitted HP, IP, LP Steam turbine unit B (480 MWe) > 150 KV Grid
• Common Main Condensate system;
- 4 x 33% Main Condensate Pumps
- 1 Deaerator
- 4 x 33% HP/IP/LP Boiler Feed Water Pumps
- 3 x 33% Re-circulation Pumps
• Secondary Cooling water system:
• Closed Cooling Water System;
- 3 x 50% Coolers (shell and tube)
- 3 x 50% Circulation Pumps
• Demin Water Installation
• Natural Gas Reducing System.
RE-use;
• ST Generator (partly) + Auxiliaries (H2, Seal Oil)
• Connection to 150 KV Grid
• Condenser (retubed)
• Vacuum system
• Step up trafo Steam Turbine Generator
• Main Cooling water system (incl. cooling tower)
• Lube Oil System Steam Turbine
• Existing Buildings and Infra Structure
Process Data:
2804325LP steam
56529302IP steam
565140265HP steam
T [°C]P [bar]m [kg/s]Full load (100% capacity)
%59.51(gross) Efficiency
MWe1300Total (3x GT + ST)
MWe490Steam Turbine
MWe270Gas turbine
Gross Power at full load
Scoping
LOT's Non Alstom scope
NON Alstom scope Packages:
.
ST generator, busduct, transformer& aux.
Contracted SiemensLOT 8
Cooling TowerContracted E&S Planbau
LOT 7
Contracted NEM-SFL
Contracted Gruenbeck
Cancelled
Contracted / Tenderingin coop with Stork
Contracted StorkThermeq
Contracted StorkThermeq
Aux BoilerLOT 6
WTULOT 5
Chemical unit MCW systemLOT 4
Main Cooling Water pumps - KSBLOT 3
Main Cooling Water Intake, outlet& recirculation
LOT 2
In house Main Cooling Water system incl Aux.
LOT 1
Remaining M & E & C&I worksContractedCofely
LOT 16
Remaining civil worksTenderingBallast Nedam
LOT 15
Contracted
Ballast Nedam
Contracted
Hofstede
ContractedGasunie
ContractedTennet
Contracted NKT
ContractedAriva
Site preperationLOT 14
Dismantling unit BLOT 13
Gas Reducing Station by GTSLOT 12
Tennet Grid connectionLOT 11
380 KV cablingLOT 10
ST Generator Bus Circuit BreakerLOT 9
Time Schedule
• Pre-engineering started; 2006
• Contracting; June 2008
• Start at Site January 2009
• Start Commissioning; July 2011
• PAC; December 2011
• AC; September 2012
Project Team
Gas Turbine
HRSG’s
Steam Turbine
Main Cooling Water (LOT 1,2,3)
Auxiliary Boiler (LOT 6)
Water Treatment Unit (LOT 5)
Proces Control;
Operating Phylosophy;• Fully automated installation (one/two operators)• Design Cock pit philosophy
Distributed Control System (DCS);• Integrated system for analogue and binary control and
protection of the combined cycle process.• Interfacing of GT and ST control system (ST integrated)• Interfacing of package control systems (minimalized for CCC)• Maintaining operation within safe operating limits• Ergonomic Human Machine Interface• Software structure and HMI according VGB guidelines
FeldgeräteFeldgeräte Feldgeräte
Recurrent issues
Piping systems
Supporting
No U-bolts for hot lines
Stop blocks
Use no “Upside down rigid struts”
Installed stop blocks
Agreement on stop blocks and U-boltsColdMax operating temp < 100 degr C
HotMax. operating temp >= 100 degr CPipe size <= DN25
HotOperating temp >= 100 degr CPipe size> DN25 and <= DN50
HotOperating temp >= 100 degr CPipe size > DN50
Stop blocks welded to pipe
No No
Yes (for displacements >= 40 mm) *
Yes (for displacements >= 40 mm)
" Cleats "Welded to secondary steel No No
Yes (for displacements >= 40 mm) *
Yes (for displacements < 40 mm)
Remark *) Preferred are stop blocks (due to constructability cleats can be installed)
General 1) No U-bolted pipe supports allowed , except for the HRSG scope U-bolts are allowed for fixed points of small bore lines and cold lines (operating temp. < 80 degr C). For STG, WSC and BOP U-
bolts will not be used except for external certified systems i.e. fire fighting.2) Stop blocks/cleats not applicable for rigid hangers, spring hangers, constant load hangers and
rigid struts
Unstable supports
Cold and Hot settings
Unacceptable support constructions in GRP
Specify GRP piping in full compliance to ISO 14691including1000 h test and perform dynamic calculation
Power Island Construction (webcam)
Lessons Learned
How the customerexplained it
How the project leader understood it
How the analystdesigned it
What the eventualowner expected
Pipe supports;
Spring loaded supports (also constant spring loaded) , and sliding supports to be checked in cold (in advance of HC and after 1st shut down) and hot condition (during HC and after start-up first shit down) .
These so called Cold and Hot settings shall be indicated in a separate list indicating all applicable values (kks code support, kks branch, date of check, PED category, support type, preload, theoretical travel, actual travel, operating temperature, deviation between theoretical value and actual value (deviation of maximum +/- 10% is allowed))
• Dynamic calculation shall be performed for those piping systems where water hammer can occur
• Pipe supports with travel; Cold offset (50% of max travel) shall be installed
• Overthrow devices to be installed to prevent damage due to waterhammer
• Pipe supports; Upside down rigid struts are not allowedPipe
Pipe stress Calculations;
• Pipe stress calculation report shall at least contain;• Short description of the piping system and conclusion• Allowable stresses• Description of simulated cases• Line list• PID• Equipment drawings• Table with allowable nozzle loads• Stress Isometric• Pipe support drawings• Input pipe stress calculation program• Pipe support loads (output stress calculation)• Spring data (out put stress calculation)• Verification of nozzle loads• Maximum pipe stresses (output stress calculation)