society of thermal engineers of serbia power plants 2012

Society of Thermal Engineers of Serbia

POWER PLANTS 2012International Conference

Zlatibor, SerbiaOctober 30 – November 02, 2012

Wolfgang Apelt, Head of Project ManagementVattenfall Europe PowerConsult GmbH, Germany

New Supercritical Power Plant Projects of Vattenfall

BOXBERG unit R and MOORBURG units A and B

General Situation of Coal- fired Projects in Germany

3 | Power Plants 2012 | Wolfgang Apelt | Zlatibor 2012

Boom of Power Projects - 27 coal projects in Germany

Source: Energie Focus


Cancelling of coal projects in Germany

Source: BUND


Current Development of Power Prices

Source: Vattenfall

Power Spot Price Development Power Forward Price Development

Lignite- fired Project Boxberg, Unit R

1 x 675 MW


Air View of TPP Boxberg with Unit BoxR


Project Unit R TPP Boxberg (BoxR)

Base Load Operation

Availability > 91 %

Load Range 50 % to 103 %

High Control Level

Compliance with Transmission Code

Net Efficiency > 43,7 %

(Live Steam: t = 600 °C; p = 285 bar)

Coal Consumption: 4,5 Mio. t/a

Specific CO2-Emissions: 924 g/kWh VPC works in Owner‘s team and as

Design Engineer


+ 135 m

ESPELWORAFAKO- Horizontal ESP- Newest generation

of voltage control- HV-aggregates on

the roof

ID fanHPE

FGD PlantBabcock-Noell- Open air placement- washer protected by

rubber- Installation of tray

below spray levels

Civil Works (buildings): STRABAG

Civil Works (cooling tower): Heitkamp

Turbine HallTurbine: ALSTOM- 4 casings- Single reheater- 2 condensers in

sequence- 9 pre- heaters

BoilerHPE- Benson-boiler- Round coal

burners- Single line air and

FG system- Complex

diagnostic systems

CT with FG inletHamon- Natural ventilation- High efficiency equipment- Possible operation of

sections- Single FG-inlet,

channel-∅ 7,5 m

+ 155 m

Main Equipment BoxR


BoxR – Organisation of Site Management

Site Team

� Senior Site Manager (for erection and commissioning activities)

� Number of staff: 76

all over services: 16

technical groups: 26

(civil works, mechanical equipment, electrical

systems, I&C)

commissioning group 34


BoxR – Number of Lots

Total number of lots: 55

mechanical equipment 29

civil works 13

electrical systems 10

I&C 3

Maximum number of employees at site: app. 1,800


10/06

2005 2006 2007 20092008 2010 2011

Start of site activities


02/07

2005 2006 2007 20092008 2010 2011

Site Field ca. 100.000 m²Excavated ca. 260.000 m³

Cooling Tower (Fa. Heitkamp)Bottom Diameter 100 mHeight 155 m

Cooling Water Pipelines (Fa.Porr)Diameter 3,60 mLength ca. 600 m

Foundation (Fa. Strabag)Turbine Hall 89 x 51 m Boiler Hall 88 x 84 mSwitchgear B. 18 x 51 mmax. thickness 3,80 mConcrete ca. 40.000 m³Reinforcement ca. 10.500 t Height of Boiler Hall 135 m


01/08

2005 2006 2007 20092008 2010 2011

Start of boiler erection works


06/08

2005 2006 2007 20092008 2010 2011

Placing of feed water tank


Erection of coal bridge

08/08

2005 2006 2007 20092008 2010 2011


2005 2006 2007 20092008 2010 2011

Delivery of turbine condensers

11/08


2005 2006 2007 20092008 2010 2011

02/09

Arrival of generator stator at site


06/09

2005 2006 2007 20092008 2010 2011

Installation of evaporator panels


2005 2006 2007 20092008 2010 2011

Auxiliary steam blowingTest of transformer’s water spray system

02/10


2005 2006 2007 20092008 2010 2011

09/10

First oil fire on 20.09.10


2005 2006 2007 20092008 2010 2011

10/10First coal fire on 08.10.10

Stop of commissioning on 20.10.10 because of boiler leakages


BoxR- Location of Defects on Boiler

Defects on Evaporator

- Area from +55m to +65m (last section of evaporator as part of the membrane wall)

Activities

- Comprehensive inspections and assessment of defects till February 2011

- Conservation of plant during the break time of commissioning activities

- Investigation of two different technical solutions in parallel:

* repair of the damaged part of evaporator

* replacement of the damaged part of evaporator

- Decision was made in April 2011 to replace the damaged parts of evaporator

Area of evaporatordefects (leakages)


BoxR - Boiler – Replacement of evaporator panels

Boiler front wall after replacement of T 24 parts of e vaporator (09.11.2011)

880 m²

9.218 weld seams


BoxR - Boiler – Flushing and Heat Treatment of SH 1

Compressors for air injection during high velocity flushing and for temperature controlduring heat treatment of superheater 1 (25.11.2011)

Provisional flue gas exhaust on boilerhouse roof during heat treatment process(28.11.2011)

Flushing

Heat treatment

Protection layerestablishment


BoxR - Boiler – Heat Treatment of SH 1

Process monitoring and control during heattreatment process(05.12.2011)

The heat treatment process was accomplished after a 72 h hold phase on temperature level of 520 °C.


BoxR – Sequence of Re- start Activities

29.10.2011 Completion of pressure test

10.11. – 13.11.2011 High velocity flushing

28.11. – 07.12.2011 Heat treatment of superheater 1

21.12.2011 Start of bypass operation

27.12.11 – 01.01.12 Operation with oil burners only to establishproper protection layer inside of boiler tubes

(measurement of H2 concentration)

07.02.2012 1st steam to turbine

16.02.2012 1st synchronization

17.02.2012 start of test operation/ optimisation of plant operation

30.03.2012 1st full load operation of the plant


BoxR- Time Schedule for Commissioning and Hand- Over

OktSepAugJulJunMaiAprMrzFebJanDez

Test run of the plant / Optimisation

17.02.2012 – 30.06.2012

Trial run (for all lots)

01.07.2012 – 08.10.2012

Take over by Employer TPP Boxberg / Start of trial run

by Employer

on 09.10.2012, 00:00 Uhr

1. Synchronization

16.02.2012

Bypass operation

21.12.2011 – 16.02.2012

Nov

Hard Coal-fired Project Moorburg, Unit A + B

2 x 820 MW


Moorburg TPS - 2 x 820 MW

• Site at the Baltic Sea

• World-wide hard coal with up to 1,5 % S, supply by oceanvessels

• 600 MW district heating

• Boiler design: 276 bar, 604/620°C

• 46 % efficiency with once-through cooling

• Single flue gas train

• Package-wise tendering

VPC works in Owner‘s team and as Design Engineer


Moorburg TPS - Aerial view

3D Model as of October 2011 including hybrid cooling tow er


2006 2007 2008 20102009 2011 2012

08/08


2006 2007 2008 20102009 2011 2012

02/09


2006 2007 2008 20102009 2011 2012

09/09


2006 2007 2008 20102009 2011 2012

10/10


2006 2007 2008 20102009 2011 2012

10/11


2006 2007 2008 20102009 2011 2012

04/12


2006 2007 2008 20102009 2011 2012

06/12


Moorburg TPS - HSE


Moorburg TPS – Time Schedule Unit A


Moorburg TPS – Time Schedule Unit B


Determination of activities for building decisionApplication for total budgetDecision of overall conceptConfirmation of project progressConfirmation of major project changesConfirmation of project organisationBusiness and measures with substantial relevance for operationProperty issuesConfirmation of communication concept

Decision of substantial technical conceptsEffecting and amendment of the project manualFinal appraisal of layout and architecture of the plantFinal appraisal for selection of major componentsConfirmation of and monitoring of master scheduleSetting of binding project defaults for the Project ManagementBudget monitoring and controlControl of project deviationsCo-opting of divisions Power Plant Operation and Technical ServicePreparation of decisions for the Project Council

Total Process Responsibility

Project Council

Project Management

Steering Committee

Employer‘s Project Organisation I


Design & Engineering

(VPC)

Project service

Budget/ChangesDocumentationQuality AssuranceSite PreparationSecretary

Project

Management

Employer‘s Project Organisation II

Procurement

Department

Line Organisation

of Employer (VE)

Site Management incl.

Commissioning

Project

Controlling


Lessons learned


Thank you for your attention!

POWER PLANTS 2012 – International Conference

society of thermal engineers of serbia power plants 2012

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