knowledge sharing session, rev 1

MY EXPERIENCES IN

THE MAINTENANCE

OF COMBINED CYCLE

POWER PLANT

knowledge sharing session

POWER PLANT

Tuanku Ja`afar Power Station, Port Dickson, Malaysia

By: Ir. Yuspikarl Adnan,

Sr. Engineer (Mechanical),

Tuanku Ja’afar Power Station

yuspikarl@gmail.com

presentation contents

• Tuanku Ja’afar Power Station: The History

• Tuanku Ja’afar Power Station: Plant Features

• Combined Cycle Power Plant: Basic Review

• Gas Turbine Technology

• Steam Turbine & HRSG

2

Tuanku Ja’afar Power Station: The History

Officially Opened in 1969...

3

• Stage I :

• 2 x 60MW Oil-Fired Conventional Steam

Power Plants

In 1973-74...

Stage II :Stage II :Stage II :Stage II :

2 x 60 MW Oil2 x 60 MW Oil--Fired Conventional Fired Conventional

Steam Power PlantsSteam Power Plants

In 1976-77...

Stage III :Stage III :Stage III :Stage III :

3 x 120 MW Oil3 x 120 MW Oil--Fired Conventional Fired Conventional

Steam Power PlantsSteam Power Plants

Total Station Capacity :Total Station Capacity :

600 MW600 MW

In 1990’s...

3 x 120 MW Oil3 x 120 MW Oil--Fired Conventional Fired Conventional 3 x 120 MW Oil3 x 120 MW Oil--Fired Conventional Fired Conventional

Steam Power Plants Converted to Steam Power Plants Converted to

DualDual--Fire, i.e. Natural Gas and Fire, i.e. Natural Gas and

Medium Fuel OilMedium Fuel Oil

Inherent Characteristics

of the old Plants

Old Technologies Old Technologies -- 1960’s1960’s

Low Efficiency Low Efficiency -- 30%30%Low Efficiency Low Efficiency -- 30%30%

Low Level of Automation Low Level of Automation --

LabourLabour IntensiveIntensive

In 2000…Stage I and II :

Decommissioned and

Demolished

In 2004…

Stage III : Decommissioned

and demolished

PD I

1 BLOCK 750 MW

COMBINED CYCLE

PD II

1 BLOCK 750 MW

COMBINED CYCLE

TJPS Rehabilitation Project

COMBINED CYCLE PLANT

COMBINED CYCLE PLANT

Tuanku Ja’afar Power Station: Plant Features

11

PD1/PD2 Plant Overview

Tuanku Ja’afar Power Station: Plant Features

PD1 PD2

2 GT – 2 HRSGs – 1 ST (750 MW) 2 GT – 2 HRSGs – 1 ST (750 MW)

COD: July 2005 COD: Jan. 2009

Fuel Type: Natural Gas/Distillate Fuel Type: Natural Gas/Distillate

AGC Operation Mode Available AGC Operation Mode Available

12

AGC Operation Mode Available AGC Operation Mode Available

GT Maker: MHI GT Maker: General Electric

HRSG Maker: MHI HRSG Maker: Nooter Eriksson

ST Maker: MHI ST Maker: Toshiba

Black Start Operation N/A

CCP Net Efficiency: 48% (HHV) CCP Net Efficiency: 49.5% (HHV)

Availability of Bypass Damper N/A

Combined Cycle Power Plant: Basic Review

• Combination of Brayton cycle (topping cycle) and Rankinecycle (bottoming cycle)

• Utilizes the advantages of both thermodynamic cycles in improving the overall efficiencies

• Typically the Brayton cycle is a high temperature heat addition cycle while the Rankine cycle is a low temperature heat rejection cycle

13

Combined Cycle Power Plant: Basic Review

T-S diagram of combined cycle power plants

effective effective effective effective

outputoutputoutputoutput

heat lost in heat lost in heat lost in heat lost in

T-S diagram of combined cycle power plantsBasic composition of Combined Cycle Power Plants

fuelfuelfuelfuel

heat recovery

steam generator

effective effective effective effective

outputoutputoutputoutput

heat lost in heat lost in heat lost in heat lost in gas turbine

effective effective effective effective

outputoutputoutputoutput

14

heat lost in heat lost in heat lost in heat lost in

exhaust gasexhaust gasexhaust gasexhaust gas

2

entropy

gas turbine

exhaust gas

generator

steam generator

effective effective effective effective

outputoutputoutputoutput

heat exhaust heat exhaust heat exhaust heat exhaust

to condenserto condenserto condenserto condenser

heat lost in heat lost in heat lost in heat lost in

exhaust gasexhaust gasexhaust gasexhaust gas

steam turbine

effective effective effective effective

outputoutputoutputoutputsteam turbine

Gas Turbine Technology at TJPS

PD1 Gas Turbine PD2 Gas Turbine

Model M701 F PG 9351 FA

Type of Combustor Can Annular – DLN Can Annular – DLN

Turbine Inlet Temp.: 1400 C 1327 C

Exhaust Temp 586 C 630 C

GT Output Efficiency 30.97 % 30.78 %

15

GT Output Efficiency 30.97 % 30.78 %

No Of Stages Compressor – 17 stages

Turbine – 4 stages

Compressor – 18 stages

Turbine – 3 stages

No of Combustor 20 18

NOx emmision 25 ppm 25 ppm (at full load)

Net Output 236.06 MW @32oC 255.6 MW @ 32oC

Gas Turbine Technology at TJPS

• MHI M701F3 Gas Turbine

16

Gas Turbine Technology at TJPS

• GE 9FA+e Gas Turbine

17

• M701F3 Gas Turbine

Gas Turbine Technology at TJPS

18

• GE 9FA+e Gas Turbine

Gas Turbine Technology at TJPS

19

Turbine Inlet Temperature

Gas Turbine Technology at TJPS

20

1000

1200

1400

1600

Turbine Inlet Temp.

1150℃

1350℃

1500℃Turbine Inlet Temp.Turbine Inlet Temp.

D seriesD series

F seriesF series

G seriesG series H seriesH series

℃Evolution of Gas Turbine TIT

Gas Turbine Technology at TJPS

21

0

200

400

600

800

1980 1985 1990 1995 2000/year

Turbine Inlet Temp.

Exh. Gas Temp.Exh. Gas Temp.

540℃540℃605℃605℃ 600℃600℃

Main SteamMain Steam

Non-ReheatNon-Reheat ReheatReheat

500℃500℃ 538～566℃538～566℃

Gas Turbine Technology at TJPS

22

Gas Turbine Technology at TJPS

• Trend of high temperature resistance material development

23

• Technology for high temperature turbine

Gas Turbine Technology at TJPS

24

• GT Advance Cooling System (M701F3)

Gas Turbine Technology at TJPS

25

• GT Advance Cooling System (GE 9FA+e)

Gas Turbine Technology at TJPS

Gas Turbine Maintenance Policy

• M701F3:

• Use Equivalent Operating Hours (EOH) as milestone indicator.

• Inspection is done on every 8,000 EOH

• EOH = (∑Hi + So X A) X FFHi = Actual Operating Hours

So=Number of Equivalent Start and Stop

A = Correction Factor for Number of Equivalent Start

FF = Fuel Factor (Gas:1.0 , Distilate:1.25)

• GE 9FA+e

• Use Operating Hour (OH) as a milestone indicator

• Inspection is done on every 8,000 OH

• OH is affected by type of fuel, use of water injection and start factor Distillate - 1.5 hours factor, Gas – 1 hour factor

Use of wet control water injection – 1.9 hour sfactor

Trip from full load – 8 hours factor

Fast Load – 2 hours factor

Emergency starts – 20 hours factor

Gas Turbine Maintenance Policy

Gas Turbine Maintenance Policy

• M701F3 schedule inspection:

Year (Estimated EOH) Inspection TypeExpected Duration

(Mech. Work)*

1st (8,000) Combustor Inspection (CI) 10 days

2nd (16,000) Turbine Inspection (TI) 16 days

3rd (24,000) Combustor Inspection (CI) 10 days

4th (32,000) Turbine Inspection (TI) 16 days4th (32,000) Turbine Inspection (TI) 16 days

5th (40,000) Combustor Inspection (CI) 10 days

6th (48,000) Major Overhaul Inspection (MI) 35 days

8,000 16,000 24,000 32,000 40,000 48,000

CI TI CI TI CI MI

0

Cumulative EOH for One Maintenance Cycle of GT

* Based on 2 shifts per day

Gas Turbine Maintenance Policy

• 9FA+e schedule inspection:

Year (Estimated OH) Inspection TypeExpected Duration

(Mech. Work)***

1st (8,000) Combustor Inspection (CI) 8 days

2nd (16,000) Combustor Inspection (CI) 8 days

3rd (24,000) Hot Gas Path Inspection (HGPI)* 13 days

4th (32,000) Combustor Inspection (CI) 8 days4th (32,000) Combustor Inspection (CI) 8 days

5th (40,000) Combustor Inspection (CI) 8 days

6th (48,000) Major Overhaul Inspection (MI)** 38 days

8,000 16,000 24,000 32,000 40,000 48,000

CI CI HGPI CI CI MI

0

Cumulative OH for One Maintenance Cycle of GT

* 1200 starts, which ever come first

**2400 starts, which ever come first

* **Based on 2 shifts per day

Gas Turbine Maintenance Policy

• 9FA+e schedule inspection:

Year (Estimated OH) Inspection TypeExpected Duration

(Mech. Work)***

1st (8,000) Combustor Inspection (CI) 8 days

2nd (16,000) Combustor Inspection (CI) 8 days

3rd (24,000) Hot Gas Path Inspection (HGPI)* 13 days

4th (32,000) Combustor Inspection (CI) 8 days4th (32,000) Combustor Inspection (CI) 8 days

5th (40,000) Combustor Inspection (CI) 8 days

6th (48,000) Major Overhaul Inspection (MI)** 38 days

8,000 16,000 24,000 32,000 40,000 48,000

CI CI HGPI CI CI MI

0

Cumulative OH for One Maintenance Cycle of GT

* 1200 starts, which ever come first

**2400 starts, which ever come first

* **Based on 2 shifts per day

Gas Turbine Maintenance Policy

PartsMax. Lifespan

(EOH)

Transition piece (*) 24,000

Combustor basket (*) 24,000

Turbine vane

#1 (*) 50,000

#2 (*) 50,000

#3 80,000

Cross frame tube 24,000

Fuel nozzle 50,000

Inspection Interval

8,000

8,000

16,000

16,000

16,000

8,000

8,000

Repair Interval

8,000

8,000

16,000

16,000

-

-

-

• MHI M701F3

Turbine vane#3 80,000

#4 100,000

Turbine blade

50,000

50,000

50,000

100,000

#1 (*)

#2 (*)

#3 (*)

#4

Ring segment

50,000

50,000

80,000

100,000

#1 (*)

#2 (*)

#3

#4

16,000

16,000

16,000

16,000

16,000

16,000

16,000

16,000

16,000

16,000

-

-

16,000

16,000

32,000

48,000

16,000

16,000

-

-

(*) : “Roll-in and Roll-out” Procedure is applied.

Gas Turbine Maintenance Policy

• GE 9FA+e

PartsMax. Lifespan

(OH)

Transition piece (*) 40,000

Combustor liner (*) 40,000

Turbine nozzle

#1 (*) 48,000

#2 (*) 48,000

#3(*) 72,000

Cross frame tube 8,000

Fuel nozzle (*) 24,000

Inspection/Repair Interval

8,000

8,000

24,000

24,000

24,000

-

8,000

Turbine nozzle#3(*) 72,000

- -

Turbine bucket

48,000

48,000

72,000

-

#1 (*)

#2 (*)

#3 (*)

-

Shroud Block

48,000

48,000

72,000

-

#1 (*)

#2 (*)

#3 (*)

-

24,000

-

24,000

24,000

24,000

-

24,000

24,000

24,000

-

(*) : “Roll-in and Roll-out” Procedure is applied.

Gas Turbine Technology at TJPS

• GT’s Major Component

• Compressor Section

• Combustor Section

• Turbine Section

34

Gas Turbine Major Component

• Compressor Section

35

Gas Turbine Major Component

• Compressor Section

36

Gas Turbine Major Component

• Compressor Section

37

Gas Turbine Major Component

• Compressor Section

38

Gas Turbine Major Component

• Combustor Section

• Turbine Section

Combustor Basket

Row 1 Vane Row 1 Blade

Row 1 Ring Segment

39

Transition Piece

Fuel Nozzle Assembly

Row 2 Blade

COMBUSTOR SECTION TURBINE SECTION

Gas Turbine Major Component

• Combustor Basket – parts where the combustion takes place

Fuel Nozzle Assembly

Gas Turbine Major Component

• Transition Piece – to channel hot gas to turbine

Gas Turbine Major Component

• Turbine Section

Gas Turbine Major Component

• Turbine Section

Gas Turbine Major Component

Turbine blade

Turbine vane

Stage 1-2 Blade & Vane: Coated with Thermal Barrier

Coating + CoNiCrAIY Coating

Stage 3-4 Blade& Vane: CoNiCrAIY coating Only.

-To Reduce metal Corrosion & temperature

Steam Turbine & HRSG

LP

Steam TurbineGenerator Gas Turbine

Combustor

Fuel

HRSG

HP

LP

IPIP

LP steam

TurbineTurbine

CondenserHP

RH

IP

HP steam 10～15MPa 538/566℃

IP steam（LTR）

IP steam（HTR）

Compressor

HRSG

HRSG (Heat Recovery Steam Generator)

ECO. ECO.

PRHTRPRHTR

EVAEVA

DeNOxDeNOx

SH, RHSH, RH

DeNOxDeNOx

Gas FlowGas Flow

Vertical Gas Flow Type HRSGVertical Gas Flow Type HRSG Module ShippingModule Shipping

PD1 HRSG

HRSG Type VNC(Triple)

Design Condition Air Temp=32deg-C

GT Type M701F

System Layout 2 on 1 x 1

HP

Steam

Flow Rate 273.7 t/h

Press. 129 bar(a)

Temp. 540.0 deg-C

47

IP Steam Flow Rate 38.9 t/h

Press. 38.7 bar(a)

Temp. 270 deg-C

LP

Steam

Flow Rate 40.4 t/h

Press. 6.5 bar(a)

Temp. 257 deg-C

RH

Steam

Flow Rate 303.4 t/h

Press. 35.9 bar(a)

Temp. 568.0 deg-C

HRSG

HP 2ryECO IP 2ryECO

LP EVA

LP

ECO

PRE HEATER

IP 1ry

ECO

HP 1ry

ECO

48

GT Exhaust GasIP 2ryRHHP 2rySH

IP 1ryRH

HP 1rySH

HP EVA

IP SH LP SH

HP 3ryECO

IP EVA

HP 2ryECO IP 2ryECO

Steam Turbine

49

To

HRSG RH

FromHRSGHP-SH

FromHRSGIP-SH

FromHRSGLP-SH

Steam Turbine