maritsa east 2 tpp - risk eng · the overall modernization of maritsa east-2 tpp, ... new...

PROJECTS FOR MARITSA EAST 2 TPP

2000 - 2012

April 22, 2013

Replacement of an existing turbine by a new one, type К-165-130

April 22, 2013

Object: Maritsa East 2 TPP PLC, village of

Kovachevo, Stara Zagora district

Period of implementation: year 2000 - 2003

Description: The steam turbine type К-165-

130 is a new generation turbine of modern

design and high technical and economical

parameters.

By design, it is a double body turbine with

intermediate steam reheating. It is the first time

that a turbine of such power capacity is

implemented as a double body one; this

considerably simplifies its design and facilitates

its operation.

General view of turbine К-165-130

The high technical and economical parameters ensure additional 20 MW power. For nine years operation the turbine has amply paid for itself. At a later stage, within the scope of the overall modernization of Maritsa East-2 TPP, the Russian turbine was successfully coupled with a Japanese electric generator, and henceforth the aggregate steady operation continues.

One of the main elements of the turbine unit – the condenser, as well as part of the auxiliary equipment thereof, are manufactured in Bulgarian factories.

The project implementation includes the following activities: Design work – elaboration of construction-structural,

technological, electrical, and I&C parts of the design; Construction work related with the changed foundation; Dissembling and removal of the old turbine, pipelines and

reheaters; Installation of the new turbine K-165-130, complete with

all the auxiliary equipment, 35 new pipeline systems, 3 new nigh pressure reheaters;

Start-up and adjustment work, training the personnel and commissioning into normal operation (Act 16).

High Pressure Turbine installation Last stage of Low Pressure Rotor

Turbine Rotor installation

High Pressure Turbine

Turbine Lubrication System Piping work

Replacement of an existing turbine by a new one, type К-165-130 (2)

Object: Maritsa East 2 TPP PLC

Implementation period : 2003 - 2005

Description : The depot was designed for the storage of waste from Maritsa East 2 TPP for 25 years. It was built on the territory of the plant and includes:

A cell for solid domestic waste;

A cell for industrial waste;

A cell for hazardous waste;

A fence, platform scales, administration buildings, workshops, pump stations, hangar, roads, etc.

The cells for industrial and domestic waste were designed with a possibility of building a superstructure which could double its capacity. Once the hazardous waste cell got filled up it was sealed according to a reliable design, thus providing for a terrain to build a new one.

Depot for solid domestic, industrial and hazardous wastes for TPP Maritsa East 2 PLC

General view of the waste depot

The capacity of the depot providing for the storage of given quantities of waste was in agreement with the plant operating lifetime. The depot terrain was fenced with a substantial fence, a special controlled access regime was introduced, and up-to-date technical solutions were implemented, to eliminate soil, water and air contamination with disposal products. The waste depot was commissioned and fully complies with the Owner needs. It was implemented as a pilot project to serve as a construction model for all Bulgarian thermal power plants.

Hazardous wastes cell

Depot for solid domestic, industrial and hazardous wastes for TPP Maritsa East 2 PLC (2)

A complex of engineering projects for Units № 6 and № 8 of Maritsa East 2 TPP

Object: Maritsa East 2 TPP PLC.

Period of implementation: 2008 - 2011

Description : Implementation of a complex of engineering projects, as follows: 1. Replacement of generators, Unit №6 & 8. 2. Replacement of generators №6 & 8

excitation systems. 3. Replacement of generators №6 & 8 relay

protections.

Increase of Unit №6 power by 20 MW has been achieved, and that of Unit №8 power – by 15 MW.

Technical characteristics: 1. Replacement of the generators by new

ones – of power 230 МW. 2. Replacement of the Excitation systems

by new, static excitation systems. 3. Replacement of the analog relay

protections by new, digital ones, of most advanced generation.

Transport of the generator stator - outside

Transport of the generator stator – within

the turbine hall

Installation of the generator rotor Finally installed generator

Through the project implementation, a number of engineering tasks have been resolved of parts Electrical, I&C, Machine-technological and Construction-structural.

The work on Maritsa East 2 TPP site required activities to be coordinated with a number of other companies and subcontractors.

Stages of implementation:

Each project included: design work, dissembling, installation/assembling, tests and commissioning into operation.

Transformer and cabinet with

disconnector for the excitation system

Unit control room with panels and

monitor

A view of a Unit relay protection cabinet Unit relay protection cabinets Excitation system cabinets

A complex of engineering projects for Units № 6 and № 8 of Maritsa East 2 TPP (2)



Description: The procurement subject matter provides for replacement of the existing high frequency excitation systems by new static type. The contract is full-scope engineering and includes design related to Civil Construction and Electrical Parts, procurement of new excitation systems, existing equipment removal, new equipment installation, startup and checkout works. All the activities according to the factory instructions, norms and regulations are implemented to the fullest extent.

Design, procurement, dismantling, mounting and commissioning of common plant turbine generators № 5 and

№ 6 static excitation systems



Description: The projects provide for complete sets

of existing analog relay protections replacement by

new up-to-date digital protections modular built and

designed for powerful generator units. The design

ensures 100 % redundancy in terms of maximum

safety for the units electric equipment protection.

Design, dismantling, procurement, installation, commissioning and development of as-built documents of

Units 5&6 digital relay protections



Description: The projects provide for complete

sets of existing analog relay protections

replacement by new up-to-date digital

protections modular built and designed for

powerful generator units. The design ensures

100 % redundancy in terms of maximum safety

for the units electric equipment protection.

Design, dismantling, mounting, commissioning and development of as-built documents of Unit 8 digital relay

protections



Description: The procurement subject matter provides for replacement of the existing high frequency excitation system by a new static type system.

The contract is full-scope engineering and includes design related to Civil Construction and Electrical Parts, procurement of new excitation systems, existing equipment removal, new equipment installation, startup and checkout works.

All the activities according to the factory instructions, norms and regulations are implemented to the fullest extent.

Design, dismantling, mounting and commissioning of TG-8 static excitation system UNITROL 5000



Description: The task is developed in two stages - conceptual and detailed design.

At the conceptual design phase, decision was taken not to include the current mnemonic diagram as the stop valves position is displayed both in Unit 2 control system and the control panels.

Drawings of the modified operating panels with up-to-date indicating instruments and power supply units for the process protection system were developed in the detailed design, which allows for installation of larger displays of Unit 2 control system in view of convenience for the operators and achieving contemporary design of the MCR.

Drafting conceptual and detailed design for rehabilitation of process mnemonic diagram, instrumentation of Unit 2




At the conceptual design phase, decision was taken not to include the current mnemonic diagram as the stop valves position is displayed both in Unit 2 control system and the control panels.

The detailed design includes drawings of the modified electric actuators that are not included in I&C Part of Unit 2 original design and changes done during the operations. The design includes the changed dimensions of the existing control rooms and creates more comfortable workplaces for the operators.

Conceptual and detailed design development for boiler No.3 and 4 control rooms rehabilitation




At the Conceptual Design Phase of Unit 6, Employer’s Terms of Reference changing was proposed to avoid indicating instruments and implementation of display on a monitor located at the operator panel of the relevant turbine generator. The Employer accepted the proposal, and it was implemented on the remaining units at a later stage.

The detailed design includes the changes in the technological protections of the turbine generators in order to include axial offset protection with triple redundant module as well as the bearing vibrations, the mnemonic diagrams were worked out with a view to display.

Research, design, dismantling, adjustment and startup of engineering measuring equipment and TG No.5 - 8 vibration

condition analysis

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