CFAS Enterprises Inc.
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GTG_1572TGD_MS6001FA_50Hz.doc
1 x 1997 GE FM 6FA 87.5MW 50Hz Combined Cycle Cogeneration Plant
The asking price is US $7.55 MM as is where is.
Plants are still operating and will be in shutdown mode in about 2-6 months
Download 6FA Maintenance Summary
They are coordinating a plant visitation in about 60 days so potential buyers can meet
with GE representatives about LTSA and maintenance issues.
The 90MW GE Frame 6FA plant is still under GE LTSA (Long Term Service Agreement),
it’s a complete combine cycle plant.
1 SCOPE OF THE DOCUMENT....................................................... 4
2 DEFINITIONS AND ABBREVIATIONS ......................................... 4
3 POWER PLANT GENERAL DESCRIPTION ................................ 5
4 PERMANCES AND EMISSIONS .................................................. 9
4.1 HV GRID FEATURES ................................................................ 9
5 MAIN EQUIPMENT LIST ..............................................................10
6 GAS TURBINE ............................................................................. 11
6.1 MAIN FIGURES .........................................................................11
6.2 AUXILIARIES ...........................................................................,.14
6.3 MAINTENANCE ACTIVITIES .....................................................18
6.4 GAS TURBINE CONTROL SYSTEM .........................................18
7 HEAT RECOVERY STEAM GENERATOR ...................................19
7.1 WATER - STEAMCYCLE EQUIPMENT .....................................20
8 STEAM TURBINE ..........................................................................23
8.1 MAIN FIGURES ..........................................................................23
8.2 AUXILIARIES ..............................................................................24
8.3 MAINTENANCE ACTIVITIES .....................................................25
9 GENERATOR ................................................................................26
9.1 MAIN FIGURES ..........................................................................26
9.2 MAIN MAINTENANCE ACTIVITIES: ..........................................29
10 GAS COMPRESSION STATION .................................................30
11 STEP – UP TRANSFORMER ......................................................32
11.1 MAINTENANCE ACTIVITIES ...................................................34
12 OTHER MECHANICAL EQUIPMENT .........................................35
12.1 AUXILIARY STEAM GENERATOR ..........................................35
12.2 STEAM CONDENSER (WATER-TYPE) ...................................35
12.3 CONDENSATE SYSTEM .........................................................36
12.4 VACUUM SYSTEM ...................................................................37
12.5 BY-PASS VALVE ......................................................................38
12.6 DEMIWATER PLANT ................................................................38
12.7 COOLING SYSTEM ..................................................................38
12.8 COMPRESSED AIR SYSTEM ..................................................40
12.9 FIRE FIGHTING SYSTEM ........................................................ 41
12.9.1 Water system for external areas ............................................ 41
12.9.2 Deluge system on HV/MV and MV/MV transformers ............. 42
12.9.3 Powder system on gas compressors ..................................... 43
12.9.4 CO2 system ........................................................................... 43
12.10 CHEMICAL DOSING .............................................................. 43
13 OTHER ELECTRICAL EQUIPMENT ........................................... 44
13.1 UNIT TRANSFORMERS 11,5/6,3 KV ....................................... 44
13.1.1 Maintenance Activities ............................................................ 45
13.2 AUXILIARY TRANSFORMERS 6/0,4 KV .................................. 45
13.2.1 Maintenance Activities ............................................................ 46
13.3 EMERGENCY TRANSFORMER 15/0,38 KV ............................ 46
13.4 DISTRIBUTED CONTROL SYSTEM (DCS) .............................. 46
13.5 GENERATOR CIRCUIT BREAKER ........................................... 47
13.5.1 Maintenance Activities ............................................................. 47
13.6 HV &MVPROTECTION, CONTROL/ PANEL ............................. 49
13.7 MVPANEL 6KV ........................................................................... 49
13.8 LV PANEL 0.4KV, DC SYSTEM, UPS ........................................ 50
13.9 LIGHTING AND EARTHING SYSTEMS ..................................... 51
13.10 MEASUREMENT PANELS ....................................................... 51
14 ANNEXES ...................................................................................... 52
1 SCOPE OF THE DOCUMENT
Scope of present document is the supply of technical information about the main figures
of the Power Plant and its main equipment, including operation and
maintenance data, to be handed over to potential purchasers.
2 DEFINITIONS AND ABBREVIATIONS
Utilities Partner Means the local Company (paper mill), whose industrial settlement –
nearby the subject Power Plant – purchases the steam from the Plant and returns well
water, demi water, steam from aux boiler and condensate to the Plant.
3 POWER PLANT GENERAL DESCRIPTION
The combined cycle power plant is able to produce electric power
(exported to the National Grid) and steam (exported to local Partner’s industrial
facilities).
It was first synchronized in October 1997 and entered commercial operation in February
1998.
As a single-shaft line, it is mainly composed by:
One General Electric MS6001FA gas turbine (Frame 6FA)
One Heat Recovery Steam Generator (HRSG) producing steam at two different
pressure levels (80 and 3 bar)
One General Electric steam turbine, with steam extractions
One General Electric generator, connected both to gas turbine and to steam turbine
Power plant is now in stand-by and turning operation, last full load operation was in
March, 8th, 2011.
Original design foresees the predispositions to add a second Steam Turbine with its own
Generator; for this reason, Step Up transformer is designed with three windings.
EPC contractor for the original installation was Italian company Turbotecnica, based in
Florence.
General layout and single line diagrams are available in Annexes.
Additional information about present site conditions:
Figure 1-Single Line Diagram
Figure 2- Power Plant general layout
4 PERFORMANCES AND EMISSIONS
Nominal power plant total output:
Power Plant nominal Gross Output:
Gas Turbine nominal power:
Steam Turbine nominal power:
93 MW
93 MW
70 Mw
23 Mw
On 7th June, 2011 a Witnessed Test Run of the combined cycle was performed under
the attendance of an independent inspector from ‘no load’ conditions up to ‘base load’
conditions, main parameters have been recorded.
At the base load condition, power of 67.1MW has been recorded for the Gas Turbine;
with Steam Turbine connected to the Turbine train, the performance was 78.2MW.
Full test report can be found in Annex.
With reference to 15% O2, Power Plant complies with the following limits:
NOx local limit value:
50 mg/Nm3
CO local limit value:
mg/Nm3
4.1 HV GRID FEATURES
Following table summarizes the main features for present HV grid, for reference only:
Electric Power costumer:
ENEL
Rated voltage, frequency:
132kV ; 50
Plant is also connected to the Grid via a secondary emergency line, available 363
days/year (2 maintenance days are scheduled with a 15days advance).
Electric Power provider:
ENEL
Rated voltage, frequency:
15kV ; 50
5 MAIN EQUIPMENT LIST
Following table summarizes the key data for main equipment:
Equipment OEM Model Running hours (Aug 2010)
Gas Turbine
OEM:
Model:
Running Hours:
General Electric
Frame 6FA (MS6001FA)
85097
Steam Turbine:
OEM:
Model:
Running Hours:
G.E./Nuovo Pignone
HNK 50/90-3
N/A
Generator
OEM:
Model:
Running Hours:
General Electric
7AG
85097
Gas Compressors (n.2x100%):
OEM;
Models:
Running Hours:
Nuovo Pignone (motors: ABB)
2HM/1 560 kW
37795; 48791(Dec 2010)
Heat Recovery Steam Generator:
OEM:
Model:
Running Hours:
Henry Vogt
49
85097
Step-up transformer 11,5 – 11,5 - 132 kV
OEM:
Model:
ABB
112 MVA + 29 MVA
MV Transformer (A) 11,5 - 6 kV
OEM:
Model:
ABB
8 MVA
MV Transformer (B) 11,5 - 6 kV
OEM:
Model:
ABB
8 MVA
MV/LV Transformer (A)
OEM:
Model:
VENETA TRASFORMATORI
2 MVA
MV/LV Transformer (B)
OEM:
Model:
VENETA TRASFORMATORI
2 MVA
Emergency Transformer 15 – 0,4 KV
Model:
1,25 MVA
Auxiliary steam generator and Demi water production plant are owned by the local
industrial partner, hence they are excluded from the sale.
6 GAS TURBINE
Gas Turbine is a General Electric MS 6001FA (Frame 6FA).
6.1 MAIN FIGURES
Gas Turbine
Manufacturer:
Model:
Serial:
1st synchronizing:
Operating Fire Hours:
Fuel:
Power @ base load, ISO conditions:
Heat rate @ base load, ISO conditions:
Speed:
Control system:
General Electric / Nuovo Pignone
MS 6001FA (Frame 6FA)
296828
October 1997
85097 at August 2010
Natural gas
75.9 Mw
9760 kJ/kWh
5231 rpm
Speedtronic Mark V
Design temperature:
Inlet air:
Exhaust flow:
Starting device:
Mounting:
15°C
600°C
Generator driven
Skid base
Compressor section details:
Compressor
Type:
Number of stages:
Inlet guide vanes:
Axial
18
Regulating I.G.V., hydraulically actuated
Turbine section details:
Turbine
Number of stages:
3
Figure 3 - Combustor Figure 4 - Fuel nozzles (during 2008 inspection)
Combustion section
Combustion section details:
Combustors
Number of combustion chamber:
Number of spark-plugs:
Flame detectors:
Conventional / DLN:
NOx reduction system
Type:
Injection stages:
Inlet gas pressure:
Valves type:
Valves manufacturer:
Fuel:
Type:
Pressure:
6
2, electrode type
4
DLN 2
DLN 2
4
26-29 bar
Hydraulically actuated
EECC SA Mezzovico (CH)
Fuel gas
26 ÷ 29
35 ÷ 100 (no heating devices,
compression heating only)
Figure 5 - External view of the power block enclosures
6.2 AUXILIARIES
Air intake system:
Air intake
Manufacturer:
Flow rate (ISO conditions):
Pressure loss (filter room):
Anti-icing:
Donaldson - Inso
772.000 kg/h
330 Pa
Steam coil fed by LP steam,
activated <7°C. Original design:
heated by premixing with hot air
from GT compressor (73000kg/h
@310°C)
Filtering section
Prefilter:
High efficiency filter class:
coalescer
n. 224 cylindrical + n.224 conical
Self cleaning
Compressed air flow:
Compressed air pressure:
Start / stop thresholds:
Silencer:
Evaporative cooler:
77 m3/h
Min 5,5 – Max 6,7 bar
450 / 750 Pa
Yes
No
Fogging:
Entering direction of air into GT compressor:
No
From top
Gearbox
Manufacturer:
Manufacturer:
Model:
Year:
Number of units:
Type:
RENK TA
SICME
P200NL4-CNV/VI
1997
1 x 100%
DC motor driven
Lube oil tank includes heaters to grant a minimum oil temperature; oil cooling is provided
by oil – water exchangers (2x100%) with dewatering PALL system, model HNP021-GYF12 .
An additional lube oil tank , 1m3 sized, in installed in high location and acts as an
emergency reservoir.
Vapour extraction system is PALL make, 26mm H20 drop, with an additional oil
eliminator (installed later).
Rotor cooling system:
Rotor cooling
Type:
Coolers:
Regulation:
Compressor washing system:
Compressor washing
Manufacturer:
Operation frequency
Online:
Offline:
Cleaner:
Model:
Speeds
GT side:
Generator side:
Cooling:
Air
Water to Air exchangers
2 valves, for blades and combustors
PROGECO
Never
Every 2/3 months
ROCHEM MARINE F1CKE
TA73XT
5500
3000
Oil
Figure 6 – Reducer gearbox – turning gear group
Lube oil system
An unique system provides oil lubrication to the whole Power Plant (Gas Turbine,
Generator, Gear box, Steam Turbine, Clutch).
Lube oil pump (main)
Manufacturer:
Model:
Year:
Number of units:
Type:
Aris Chiappa
CVTG 100/250
1997
1 x 100%
AC motor driven (ABB)
Lube oil pump (auxiliary)
Manufacturer:
Model:
Year:
Number of units:
Type:
Aris Chiappa
CVTG 100/315A
1997
1 x 100%
AC motor driven
Lube oil pump (emergency)
Manufacturer:
Model:
SICME
P200NL4-CNV/VI
Year:
Number Of Units:
Type:
1997
1 x 100%
DC motor driven
Lube oil tank includes heaters to grant a minimum oil temperature; oil cooling is provided
by oil – water exchangers (2x100%) with dewatering PALL system, model HNP021 GYF12 .
An additional lube oil tank , 1m3 sized, in installed in high location and acts as an
emergency reservoir.
Vapour extraction system is PALL make, 26mmH20 drop, with an additional oil
eliminator (installed later).
Rotor cooling system:
Rotor cooling
Type:
Coolers:
Regulation:
Air
Water to Air exchangers
2 valves, for blades and combustors
Compressor washing system:
Compressor washing
Manufacturer:
Operation frequency
Online:
Offline:
Cleaner:
Never
Every 2/3 months
ROCHEM MARINE F1
Tank capacity
Water:
Cleaner:
Cleaning mix (water + cleaner):
3m3
n/a
1m3
PROGECO
Figure 7 - Fuel gas skid valves Figure 8 - Fuel gas skid panel
Gas turbine is started by the Generator, which acts as a motor during start-up phase.
6.3 MAINTENANCE ACTIVITIES
Gas Turbine is covered by Long Term Service Agreement (LTSA) by OEM up to 2012.
Major Inspection was performed at 48.000 OH , in 2003; next Major Inspection is
planned at 96.000 OH.
After a load coupling failure in September 2003, a three months outage was necessary
to inspect and replace damaged components of compressor, turbine, gearbox and
clutch.
Main maintenance interventions are summarized in the relevant table in Annexes.
6.4 GAS TURBINE CONTROL SYSTEM
Gas turbine control system is GE SPEEDTRONIC™ Mark V , with two (2) operator
stations.
Some features of the system follow:
Triple-redundant microprocessor controllers, two-out-of-three voting
Control of liquid, gas or both fuels in accordance with the requirements of the speed,
load
control under part-load conditions
Temperature control under maximum capability conditions or during startup conditions.
Sequencing of the auxiliaries
Fully automated startup, shutdown and cool down
Turbine protection against adverse operating situations and annunciation of abnormal
conditions
Operator interface consists of a color graphic monitor, keyboard, cursor positioning
device to provide feedback regarding current operating conditions.
In the first period, Gas turbine was online monitored by General Electric for several
months.
OSM hardware (owner: General Electric) in installed in Control Room and provides
remote online monitoring of the fuel gas pressure fluctuations after each start-up, by GE
headquarters.
Mark V Specialist (by G.E.) tunes the settings on the control systems using the
parameters set by G.E.
Vibration monitoring system BENTLY NEVADA 3300 controls vibrations on main
equipment.
7 HEAT RECOVERY STEAM GENERATOR
Heat Recovery Steam Generator is HENRY VOGT make; installed downstream of the
exhaust duct of the Gas Turbine, it receives the hot flue gas from the Gas Turbine itself
and produces steam at two different pressure levels.
HRSG
Manufacturer:
Designer:
Manufacturer:
Serial:
Year:
Type:
License: HENRY VOGT (USA)
MIR
COMEF
49
1997
Water tubes type horizontal gas flow
natural circulation
Sections
HP:
LP:
Economizer/Evaporator/Superheater
Economizer/Deareator/Evaporator/Superheater
High Pressure (HP) Steam:
Steam pressure:
Steam temperature:
Steam flow:
83 barg
523°C
106,7 ton/h
Low Pressure (LP) Steam
Steam pressure:
3 barg
Steam temperature:
Steam flow:
191°C
18,6 ton/h
Postfiring
Manufacturer:
Fuel:
Fresh air intake:
Steel Stack:
De Jong – Coen
Natural gas (3bar)
No
dia 3,5 - h 50m
BMS
Manufacturer:
Model:
Hartmann & Braun
Contronic S
Figure 9 - Heat recovery steam generator
7.1 WATER - STEAM CYCLE EQUIPMENT
Condensate is pumped by Condensate Extraction Pumps to a 250 m3 storage tank
where it is mixed with condensate coming from paper mill (Condensate Extraction
pumps data sheet is shown in section “Condensate system”).
From storage tank, condensate is pumped by LP feedwater pumps to HRSG Low
Pressure system (LP Economizer, LP Evaporator, LP drum with deareator).
LP Feedwater pumps:
Manufacturer:
Model:
Year:
Number of units:
Water flow:
Pressure (inlet ; outlet):
Temperature:
Speed:
P930 A/B/C
Nuovo Pignone
F-4x13 DSTHF/2STG
1996
3 x 50%
87 m3/h
0,7 ; 27,1 bar g
90°C
2980rpm
Electrical motor
Manufacturer:
Adsorbed power:
Feeder:
Marelli
119Kw
380V / 3ph / 50Hz
Steam in LP drum is sent to the LP superheater and then to LP section of the ST.
From the LP drum, bottom side, water is sucted by HP Feedwater Pumps and sent to
HP section (HP Economizer, HP Evaporator, HP Superheater). HP Feedwater pumps
Manufacturer:
Model:
Year:
Number of units:
Water flow:
Pressure (inlet ; outlet):
Temperature:
Speed:
Nuovo Pignone
4x12 MSND/9ST
1996
2 x 100%
163 m3/h
6,5 ; 122,6 bar g
150°C
2950rpm
Electrical motor
Manufacturer:
Adsorbed power:
Feeder:
Storch
706kW
6000v/ 3ph / 50Hz
During winter season, it is often necessary to recirculate water in LP economizer section
to overcome low ambient temperatures effect. The purpose is satisfied by Economizer
Recirculation Pumps.
Economizer recirculation pumps
Manufacturer:
Model:
Year:
Number of units:
Water flow:
Head:
Speed:
Nuovo Pignone
F- 4x13 – DSTHF / 2 ST
1997
2 x 100%
87 m3/h
27,6 bar
2980 rpm
Electrical motor
Manufacturer:
Model:
Adsorbed power:
Marelli
A4 315 MC / 2
112vKw
Voltage lever:
380v
8 STEAM TURBINE
8.1 MAIN FIGURES
Steam Turbine
Manufacturer:
Model:
Power:
1st synchronizing:
Condenser fluid:
General Electric / Nuovo Pignone
HNK 50/90-3
23,05 Mw
1997
Water
Weights (approx.)
Total:
Rotor:
Max for maintenance:
Skid:
Speed [rpm]:
85000 kg
10000kg
41000kg
16000 kg
3000
Inlet Steam Conditions
Pressure (HP/LP):
Temperature (HP/LP):
Condensing pressure:
82 / 2.2 [bar a]
515 / 191 [°C]
0,06 bar
Figure 10-Steam turbine Nuovo Pignone NK-HNK
8.2 AUXILIARIES
Clutch allows connection / disconnection between Gas Turbine and Steam Turbine.
Clutch
Manufacturer:
Model:
SSS Gears
200FT
Turning Gear System:
Turning gear Manufacturer:
Motor Type:
Max torque (at 50kg/cm2):
NUOVO PIGNONE
Electrohydraulic + manual
575 kg
Figure 11 - Steam Turbine main valve
8.3 MAINTENANCE ACTIVITIES
In August – October 2009 a Major Inspection was performed by Ansaldo EGS, together
with some additional repairs and replacements. Report is available in Annexes.
9 GENERATOR
9.1 MAIN FIGURES
Generator
Manufacturer:
Model:
Date:
Power output:
Operating hours:
Cooling system:
General Electric
7AG
1997
110 MVA
85.097
Air cooled by air/water coolers
Speed:
Frequency:
Insulation class:
Power factor:
Rated Voltage:
Rated Current:
Total Mas:
Excitation system
Manufacturer:
Model:
Type:
Rated Power:
Rated voltage levels:
Output:
Input:
3.000 rpm – 2 poles
50Hz
F
0.85
11500v
5522 Amps
150.000kg
General Electric
EX2000
Static
293Kw
305v DC
360v 3-phases
Rated current:
Output:
Input:
Rated frequency
962A DC
699A 3-phases
60Hz
Static starter
Manufacturer:
Model:
Type:
Rated Power:
Rated output voltage:
Rated output current:
Installation:
General Electric
DIRECTO-MATIC 2000
Static
2075Kw
4160v
320A
Indoor, inside enclosure
No jacking pumps for rotor lifting.
Generator is provided with:
1 control panel 1PG-1 with synchronizing system (ABB Synchrotac 4) and electric
measurements (ABB Muratori)
1 protection panel 1PG-2 (ABB Muratori)
1 excitation panel (GE EX2000)
1 static starter panel (GE DIRECTO-MATIC 2000)
Figure 12- General Capability Diagram
9.2 MAIN MAINTENANCE ACTIVITIES:
A generator inspection, consisting on visual inspection to core, stator and winding, was
performed In August 2007.
On 19/05/2008 a rotor earth fault occurred, requiring a three month-long recovery activity
during which rotor was completely rewound
A deep inspection of the stator windings and frame was performed and the following
maintenance activities were carried out:
Stator winding cleaning;
Measurement of stator winding resistance;
Measurement of polarization index;
Insulating resistance test;
DC windings leakage test;
Tan delta test and partial discharge test;
Bearing inspection;
Air/water heat exchanger rust removal;
Gaskets change.
In September 2009 the last inspection was performed, including: visual and boroscope
inspection, polarization index, insulating resistance test and stator winding resistance.
Figure 13- Generator Polarization Index
Figure 14 - generator polarization index
10 GAS COMPRESSION STATION
Natural gas is supplied by national network (SNAM Rete Gas) via underground network.
Gas compressors
Manufacturer:
Nuovo Pignone
Model:
Number of units:
Type:
Flow rate:
Pressure, Temperature
Suction:
Delivery:
Mechanical power:
Rotating speed:
Regulation steps:
2HM/1
2 (1 duty, 1 stand-by)
Reciprocating
22.750 Nm3/h
16 , 20 bar g, °C
29 , 65 bar g, °C
500Kw
740rpm
-50-75-100% +continuous regulation via
bypass valve
Electric motor
Manufacturer:
Electric data:
Adsorbed power:
Cooling:
ABB
3 ph – 8 poles – 50 Hz – 6300V
560Kw
IC411
Cooling system:
Lubrication system:
Water 35.5m3/h]
Upgraded to oil-free
Gas compressors went under revision in 2010.
Figure 14 - Gas compressor
It is available a gas chromatograph, DANIEL make, now out of service (to be refurbished).
11 STEP – UP TRANSFORMER
Generator is connected, via an air-insulated bus duct, to a three windings Step-Up
transformer, ABB make.
Third winding (MV2) is available for a future expansion, to be connected to the generator
of a second steam turbine.
Step-up transformer:
Manufacturer:
Year:
Serial:
Number of units”
Type (indoor/outdoor):
Windings:
Frequency:
Volt levels (HV/MV1/MV2):
Rating Power (HV/MV/MV2):
Current (HV/MV1/MV2):
Connection groups:
Insulation levels :
Cooling type:
Tap-changer:
Short circuit v at 75°C HV/LV1 [%]:
Short circuit v at 75°C HV/LV2 [%]
Weight (oil; with drawable part; total:
1ETM
ABB
1996
5I6110
1
Outdoor
3 phases (1 primary HV and 2 secondary MV)
50HZ
139.8±8x1.25% / 11,5 /11,5[kV]
141.5 / 112 / 29.5 [MVA]
584.4 / 5623 / 1481[A]
YN-d11-d11
IA 750 FI 325 [kV]
IA 125 FI 50325 [kV]
IA 125 FI 50325 [kV]
ONAF
Yes, on-load
n/a
n/a
48000; 112000; 196000kg
Figure 15 - Step Up transformer
Step-up transformer is provided with the following main protections:
Max. current
Differential protection
Residual overvoltage protection
Restricted earth fault protection
Tank Buchholtz relay
OLTC Buchholtz relay
Tank Pressure relief relay
Min. oil transformer tank level alarm
Min. oil transformer OLTC level alarm
Oil temperature relay
11.1 MAINTENANCE ACTIVITIES
In August 2009 the tap changer was checked by ABB, in detail a visual inspection was
performed, the transmission system was lubricated and insulating oil replaced.
In August 2009 a visual inspection was performed by ABB, some electrical test and a
specific one called “Frequency Response Analysis” on the windings were performed. In
the same year ABB removed some leak by re-welding.
On August 2010 oil selective depolarization was performed by Sea Marconi specialists.
On 24/03/2011 oil inspection was latest performed by Sea Marconi specialists.
12 OTHER MECHANICAL EQUIPMENT
12.1 AUXILIARY STEAM GENERATOR
Auxiliary steam generator is owned by the local Utility Partner and is not located inside
the Power Plant boundary; it is not included in the present sale.
Starting procedure does not require auxiliary steam generator.
12.2 STEAM CONDENSER (WATER-TYPE)
Downside the steam turbine, steam is condensed by a water-cooled steam condenser.
Steam condenser:
Type:
Manufacturer:
Model”
E 500
Surface condenser
Wellman Graham Ltd (GB)
E-500
Design data
Code:
Temp (tubes; for shell): 80 ;
ASME VII div. 1 (1994)
200°C
Water tubes
Number:
Material:
5864
Stainless steel ASME A249 TP 304L
Condensing system is provided with a vacuum system.
Figure 16 - Steam condenser
Figure 17 - Condensate extraction pumps
12.3 CONDENSATE SYSTEM
After Steam Turbine, exhaust steam and condensate from Utility Partner are sent to
Condenser, from which it is drained by the Condensate Extraction pumps and forwarded
to HRSG.
On the suction of the CEPs, an idrazine injection is provided.
Condensate Extraction pumps:
Manufacturer:
Model:
Year:
Number of units:
Number of stages:
Flow rate:
Head:
NPSH:
Speed:
P500 A/B
NUOVO PIGNONE
6” – VDA / 3ST
1996
2 x 100%
3
161 m3/h
6,7bar
0,1bar
1480rpm
Electric motor
Manufacturer:
Model:
Adsorbed / rated power:
Voltage level:
Marelli
A4C 280 S437
3 ; 55Ks
380v
12.4 VACUUM SYSTEM
Vacuum level in the condenser is granted by a dedicated redundant system, ejectorstype.
Main vacuum system:
Type:
Manufacturer:
Number of stages:
Steam for ejectors
Supply:
Pressure (min ; max);
Temperature:
EJ-501B / EJ502B
Ejectors-type
AB PROGETTI
2, with intercooler and aftercooler
From HRSG
3,5 ; 4Bar a
190°C
Ejectors
Number of ejectors, first stage:
Number of ejectors, second stage:
Cond. pressure (min; max):
Condensate temp. (min; max):
Extracted flow (air; steam):
2 x 100%
2 x 100%
0,034 to 0,4 Bara a
22 to 72°C
15,5 ; 34 kg/h
Intercooler condensing fluid
Number:
Fluid:
Design flow:
2 (inter- & after-cooler)
Water
100.000 Kg//h
During start-up, when steam from HRSG is not available, vacuum system is on stand-by
and vacuum is granted by a separate system, using liquid-ring pump.
Start-up vacuum system:
Type:
Manufacturer:
Model of pumps:
Number of pumps:
Pressure:
Electric motor size:
P502A/B
Liquid-ring pump
ROBUSCHI
RPA-40
2
0,300 bar
45Kw
12.5 BY-PASS VALVE
By-pass valves
Manufacturer:
Number:
BTG
1 for HP, 1 for LP
12.6 DEMI WATER PLANT
Demi water for the thermal cycle reintegration is supplied by the local Utility Partner, so
Demi Water Production Plant is not included in the Power Plant assets.
12.7 COOLING SYSTEM
Heat from Power Plant main equipment (GT, gas compressors, HRSG auxiliaries, …) is
removed by a water cooling system and finally dissipated by Evaporative towers, which
discharge the water into a collection pit, from which it is then drained and sent back to
users.
Circuit is fed by well / raw water, filtered, softened and injected with corrosion inhibitors
and biocides.
Data sheets of main equipment follow:
Evaporative towers:
Manufacturer:
Type:
Number of units (cells):
Design Air Temperature (Wet / Dry):
Water temperature (Cold / Hot):
Flow rate (design, max):
EH900/901/902
HAMON CIFA
Wet dry, forced draft, counterflow
3 x 50%
22,8 / 35,0°C
27,0 / 35,2°C
5450 m3/h
Electrical motor
Number, each unit:
Power:
1x100%
110Lw
Condenser cooling water pumps:
Manufacturer:
Model:
Year:
Number of units:
Flow rate:
Head:
Speed:
Adsorbed power:
P900 A/B/C
Nuovo Pignone
20” H VSA/1ST
1996
3 x 50%
2500 m3/h
2,6 bar
985rpm
215Kw
Circulating cooling water pumps for aux;
Number of units:
Design flow rate:
Head:
P901 A/B
2 x 100%
430 m3/h] (each pump)
5.1bar
Figure 18 - Condenser cooling water pumps
12.8 COMPRESSED AIR SYSTEM
Compression station provides compressed air to service air users and instrumental air users.
Air compressors:
Manufacturer:
Model:
Number of units:
Type:
Motor speed:
Adsorbed power:
Flow rate:
Pressure:
Temperature:
Cooling system:
K 870 A/B
ATLAS COPCO
ZT 75
2 x 100%
Screw – double stage
2970rpm
81,7Kw
600 m3/h
5 - 8 barg
28°C
Air
Service air and Fire fighting lines are taken directly from the accumulator (3 m3 / 12 bar).
Instrument air is filtered, dried (double-column type), final filtered and accumulated in a
second vessel (3 m3 / 12 bar).
12.9 FIRE FIGHTING SYSTEM
Fire fighting system provides protection to the CCPP , its equipment and personnel in
case of fire event.
12.9.1 Water system for external areas
An underground water system serves hydrants and hoses all around the plant.
Pressurization of the water network is granted by an electric jockey pump; in case of fire
event, with the activation of protection devices, main electric pump is called to start.
A diesel pump acts as a backup in case of main pump failure.
Main FF electric pump:
Manufacturer:
Model:
Number of units:
Flow rate:
Head:
NPSHR:
Design temperature:
P886
NUOVO PIGNONE
2000X500DVE
1 x 100%
300 m3/h
7 bar g
0,24 bar g
35°C
Electric motor
Manufacturer:
Model:
Power:
Marelli
B4C-315 MA479,1
79.1Kw
Jockey FF electric pump:
Manufacturer:
Model:
Number of units:
Flow rate:
Head:
NPSHR:
Design temperature:
Electric motor
P887
NUOVO PIGNONE
C-2 X 11-VP
1 x 100%
15 m3/h
7,7 bar g
0,55 bar g
30°C
Manufacturer:
Model:
Power:
Marelli
A4C-160 MB2
8,7Kw
Backup FF diesel pump:
Manufacturer:
Model:
Number of units:
Flow rate:
Head:
NPSHR:
Design temperature:
P885
NUOVO PIGNONE
2000X500DVE
1 x 100%
300 m3/h
7 bar g
0,55 bar g
35°C
Diesel motor
Manufacturer:
Model:
Type:
Capacity:
DEUTZ
BF6M 1013E
4 strokes, 6 cylinders, direct injection
7146 cm3
12.9.2 Deluge system on HV/MV and MV/MV transformers
As per original installation (by SANCO), n.1 HV/MV electrical transformer and n.2
MV/MV electrical transformers are protected by
Fire detection system (cable detector)
Water deluge system (dry type)
Additional similar systems have been installed later (by CIODUE SUD) also on the
MV/LV transformers.
12.9.3 Powder system on gas compressors
Two independent fire detection (cable detectors) and powder systems provide fire
protection and extinguishing on the gas compressors.
12.9.4 CO2 system
Smoke detection system and automatic CO2 extinguishing system in
steam turbine and auxiliaries enclosure
Gas turbine enclosure - bearing n.2
Electrical & control room building, rooms and under floor for MV room, LV room, control
room, technical room
Smoke detection system in warehouse.
12.10 CHEMICAL DOSING
A chemical dosing system provides the injections of chemicals to cooling water and
steam circuits
13 OTHER ELECTRICAL EQUIPMENT
Figure 19 - Unit transformer Generator-side
Figure 20 - Unit transformer Step-up
transformer-side
13.1 UNIT TRANSFORMERS 11,5/6,3 KV
Unit transformers:
Manufacturer:
Number of units:
Rated voltage;
Rating:
Cooling:
Tap-changer :
Connection groups:
Short circuit voltage at 75°C:
Weight (oil; withdrawable part; total):
1ETU-2ETU
ABB
2 (1 upstream GCB 1 downstream GCB)
11,5±5% / 6,3Kv
8 MVA
ONAN
Yes, off-load
Dyn11
4,9%
2950; 9100; 16500kg
13.1.1 Maintenance Activities
In August 2009 was performed by ABB visual inspection and some electrical test.
On 24/03/2011 oil inspection was latest performed by Sea Marconi specialists.
13.2 AUXILIARY TRANSFORMERS 6/0,4KV
Auxiliary transformer:
1ETD – 2ETD
Manufacturer:
VENETA
TRASFORMATORI
Number of units:
Voltage levels:
Rating:
Cooling:
2
6±2x2.5% / 0,4Kv
2MVA
ONAN
Tap-changer:
Connection groups:
Short circuit voltage:
Weight (oil; withdrawable part; total):
Yes, off-load
Dyn11
6,47%
930; 3100; 4800kg
Figure 21 - Auxiliary MV/LV transformer
13.2.1 Maintenance Activities
In August 2009 a visual inspection and some electrical test were performed by ABB.
On 24/03/2011 oil inspection was latest performed by Sea Marconi specialists.
13.3 EMERGENCY TRANSFORMER 15/0,38KV
Emergency transformer
Number of units:
Voltage levels
1
15 / 0,380Kv
13.4 DISTRIBUTED CONTROL SYSTEM (DCS)
Distributed Control System (DCS), manufactured by HARTMANN & BRAUN, collects
information from dedicated control systems for main equipment and allows an overall
overview of the main data of the power plant as well as the possibility to control and
manage its operation.
Main dedicate control systems:
Gas Turbine control system (GE, Mark V)
Steam Turbine and Generator control system
Boiler Monitoring System (HARTMANN & BRAUN)
Continuous Emission control system (HARTMANN & BRAUN)
Figure 22 - Control system monitors
13.5 GENERATOR CIRCUIT BREAKER
Generator (MV) Circuit breaker
Manufacturer:
Model:
Year:
Number of units:
Type:
Rated current, voltage:
Aux voltage for operating device:
SIEMENS
8FG10
1996
1
Vacuum
6300A ; 17,5
110 dc V
13.5.1 Maintenance Activities
In August 2009 a revision to the earthing switch, a minor inspection to the components
and a synchronization test on the tree poles of the breaker during opening and closing
operations was performed by Siemens.
Figure 23 - Generator Circuit breaker
Figure 24 - Unit transformers, GCB, bus duct
13.6 HV & MVPROTECTION, CONTROL ANDMEASUREMENT PANEL
Control & Protection panel
Manufacturer:
ABB Muratori
Protection devices manufacturer :
ABB
Protection devices type:
Some “REG” type
Figure 25 - Electric Control & Protection panels
1PT-1 Transformer Measurement and Control Panel
1PT-2 Transformer Protection Panel (HV-MV)
1PG-1 Generator Measurement, Control and Synchronizing Panel
1PG-2 Generator Protection Panel (MV)
PH Change Over Panel
13.7 MVPANEL 6KV
Figure 26 - MV switchboard
Figure 27 - LV switchboard
MV Panel is provided with 2 separate sections connected by a bus tie and automatic
change-over.
Manufacturer: ABB.
13.8 LV PANEL 0.4KV, DC SYSTEM, UPS
LV Panel is provided with 2 separate bus bars, fed by the two auxiliary transformers,
connected by a bus tie with automatic change-over device.
Manufacturer:
General Electric
UPS system is manufactured by BORRI and refurbished in 2010.
Batteries have been replaced on December 2010.
13.9 LIGHTING AND EARTHING SYSTEMS
External lighting system is made up by:
Fluorescent lamps installed on the buildings;
Lighting columns around the motorized roads.
The earthing system of the power station is connected with the one of Steam Client’s
facilities. Maximum current of earth fault is 16000A; step max voltage permitted is 639V
and the contact max permitted voltage is 213V.
13.10 MEASUREMENT PANELS
One panel for gas fiscal measures
One panel for electrical fiscal measures.
14 ANNEXES
Annex 01 - Witnessed Test Run report
Annex 02 – Power Plant Layouts
Annex 03 – Single line diagrams
Annex 04 – Balance of Plant P&IDs
Annex 05 – Gas Turbine maintenance reports (2004-2010)
Annex 06 – Steam Turbine maintenance reports
Annex 07 – Generator data and maintenance reports (2007-2009)
Annex 08 – Transformers maintenance reports
Annex 09 – Generator Circuit Breaker maintenance reports
Annex 10 – Operation data (daily operation data 2010; monthly gas consumption and
energy production 1999-2006; design H&M balance; Steam Turbine design operating
conditions)