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)