Model-Based Analysis of the Start-Up Improvement of a CCPP due to Steam Turbine Warm-Keeping With Air

2019 ◽  
Author(s):  
Dennis Toebben ◽  
Tobias Burgard ◽  
Sebastian Berg ◽  
Manfred Wirsum ◽  
Liu Pei ◽  
...  
Keyword(s):  
Power Plant ◽  
Steam Turbine ◽  
Power Plants ◽  
Cold Start ◽  
Nox Emissions ◽  
Data Set ◽  
Water Steam ◽  
Hot Air ◽  
Start Up ◽  
Low Load

Abstract Combined cycle power plants (CCPP) have many advantages compared to other fossil power plants: high efficiency, flexible operation, compact design, high potential for combined heat and power (CHP) applications and fewer emissions. However, fuel costs are relatively high compared to coal. Nevertheless, major qualities such as high operation flexibility and low emissions distinctly increase in relevance in the future, due to rising power generation from renewable energy sources. An accelerated start-up procedure of CCPPs increases the flexibility and reduces the NOx-emissions, which are relatively high in gas turbine low load operation. Such low load operation is required during a cold start of a CCPP in order to heat up the steam turbine. Thus, a warm-keeping of the thermal-limiting steam turbine results in an accelerated start-up times as well as reduced NOx-emissions and lifetime consumption. This paper presents a theoretical analysis of the potential of steam turbine warm-keeping by means of hot air for a typical CCPP, located in China. In this method, the hot air passes through the steam turbine while the power plant is shut off which enables hot start conditions at any time. In order to investigate an improved start-up procedure, a physical based simplified model of the water-steam cycle is developed on the basis of an operation data set. This model is used to simulate an improved power plant start-up, in which the steam turbine remains hot after at least 120 hours outage. The results show a start-up time reduction of approximately two-thirds in comparison to a conventional cold start. Furthermore, the potential of steam turbine warm-keeping is discussed with regards to the power output, NOx-emissions, start-up costs and lifetime consumption.

THE LIFE ASSESSMENT OF STEAM TURBINE ROTORS FOR FOSSIL POWER PLANTS

2006 ◽  
Vol 20 (25n27) ◽  
pp. 4371-4376
Author(s):  
SUNGHO CHANG ◽  
GEEWOOK SONG ◽  
BUMSHIN KIM ◽  
JUNGSEB HYUN ◽  
JEONGSOO HA
Keyword(s):  
Power Plant ◽  
Steam Turbine ◽  
Rotational Speed ◽  
Power Plants ◽  
Thermal Power ◽  
Creep Damage ◽  
Life Assessment ◽  
Life Extension ◽  
Start Up ◽  
Operational Life

The operational mode of thermal power plants has been changed from base load to duty cycle. From the changeover, fossil power plants cannot avoid frequent thermal transient states, for example, start up and stop, which results in thermal fatigue damage at the heavy section components. The rotor is the highest capital cost component in a steam turbine and requires long outage for replacing with a new one. For an optimized power plant operational life, inspection management of the rotor is necessary. It is known in general that the start-up and shutdown operations greatly affect the steam turbine life. The start-up operational condition is especially severe because of the rapid temperature and rotational speed increase, which causes damage and reduction of life of the main components life of the steam turbine. The start-up stress of a rotor which is directly related to life is composed of thermal and rotational stresses. The thermal stress is due to the variation of steam flow temperature and rotational stress is due to the rotational speed of the turbine. In this paper, the analysis method for the start-up stress of a rotor is proposed, which considers simultaneously temperature and rotational speed transition, and includes a case study regarding a 500MW fossil power plant steam turbine rotor. Also, the method of quantitative damage estimation for fatigue-creep damage to operational conditions, is described. The method can be applied to find weak points for fatigue-creep damage. Using the method, total life consumption can be obtained, and can be also be used for determining future operational modes and life extension of old fossil power units.

Steam Turbine Hot Standby: Electrical Pre-Heating Solution

2019 ◽  
Author(s):  
Y. Kostenko ◽  
D. Veltmann ◽  
S. Hecker
Keyword(s):  
Heat Transfer ◽  
Power Plant ◽  
Steam Turbine ◽  
Power Plants ◽  
Heating System ◽  
Heating Process ◽  
Steam Turbines ◽  
Start Up ◽  
New Apparatus ◽  
General Aspects

Abstract Growing renewable energy generation share causes more irregular and more flexible operational regimes of conventional power plants than in the past. It leads to long periods without dispatch for several days or even weeks. As a consequence, the required pre-heating of the steam turbine leads to an extended power plant start-up time [1]. The current steam turbine Hot Standby Mode (HSM) contributes to a more flexible steam turbine operation and is a part of the Flex-Power Services™ portfolio [2]. HSM prevents the turbine components from cooling via heat supply using an electrical Trace Heating System (THS) after shutdowns [3]. The aim of the HSM is to enable faster start-up time after moderate standstills. HSM functionality can be extended to include the pre-heating option after longer standstills. This paper investigates pre-heating of the steam turbine with an electrical THS. At the beginning, it covers general aspects of flexible fossil power plant operation and point out the advantages of HSM. Afterwards the technology of the trace heating system and its application on steam turbines will be explained. In the next step the transient pre-heating process is analyzed and optimized using FEA, CFD and analytic calculations including validation considerations. Therefor a heat transfer correlation for flexible transient operation of the HSM was developed. A typical large steam turbine with an output of up to 300MW was investigated. Finally the results are summarized and an outlook is given. The results of heat transfer and conduction between and within turbine components are used to enable fast start-ups after long standstills or even outages with the benefit of minimal energy consumption. The solution is available for new apparatus as well as for the modernization of existing installations.

Investigation of Steam Turbine Warm-Keeping by Use of Air

2019 ◽  
Author(s):  
Dennis Toebben ◽  
Piotr Luczynski ◽  
Manfred Wirsum ◽  
Wolfgang F. D. Mohr ◽  
Klaus Helbig
Keyword(s):  
Heat Transfer ◽  
Steam Turbine ◽  
Power Plants ◽  
Calculation Model ◽  
Heat Radiation ◽  
Technical Solution ◽  
Fe Model ◽  
Steam Turbines ◽  
Data Set ◽  
Start Up

Abstract The changing energy landscape leads to a rising demand of more flexible power generation. A system for steam turbines warm-keeping provides the ability to shutdown conventional power plants during periods with a high share of renewable power. Simultaneously, these power plants are ready for grid stabilization on demand without an excessive consumption of lifetime during the start-up. One technical solution to keep a steam turbine warm is the use of hot air which is passed through the turbine. In addition, the air supply prevents corrosion during standstill and also enables the pre-warming after maintenance or long outages. This paper investigates the warm-keeping process of an intermediate pressure steam turbine (double shell configuration) through the use of dynamic numerical Finite-Elements (FE) simulations. As a representative test-case, warm-keeping calculations during a weekend shutdown (60h) are conducted to investigate the temperatures, their distribution and gradients within the rotor and the casing. For this purpose an improved numerical calculation model is developed. This detailed 3D FE model (including blades and vanes) uses heat transfer correlations conceived for warm-keeping with low air mass flows in gear mode operation. These analytical correlations take heat radiation, convection and contact heat transfer at the blade roots into account. The thermal boundary conditions at the outer walls of rotor and casing are determined by use of experimental natural cool-down data. The calculation model is finally compared and verified with this data set. The results offer valuable information about the thermal condition of the steam turbine for a subsequent start-up procedure. The warm-keeping operation with air is able to preserve hot start conditions for any time period. Most of the heat is transferred close to the steam inlet of the turbine, which is caused by similar flow directions of air and steam. Thus, temperatures in the last stages and in the casing stay well below material limits. This allows higher temperatures at the first blade groove of the turbine, which are highly loaded during a turbine startup and thus crucial to the lifetime.

Thermo-Structural Analysis of Steam Turbine Start-Up With and Without Integrated Pre-Warming System Using Hot Air

2020 ◽  
Author(s):  
Piotr Łuczyński ◽  
Lukas Pehle ◽  
Manfred Wirsum ◽  
Wolfgang F. D. Mohr ◽  
Jan Vogt ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Steam Turbine ◽  
Power Plants ◽  
Thermal Contact ◽  
Steam Turbines ◽  
Operating Modes ◽  
Hot Air ◽  
Start Up ◽  
Simulation Strategy ◽  
Transient Thermal

Abstract Motivated by the urgent need for flexibility and start-up capability improvements of conventional power plants in addition to extending their life cycle, General Electric provides its customers with a product to pre-warm steam turbines using hot air. In this paper, the transient thermal and structural analyses of a 19-stage IP steam turbine in various start-up operating modes are discussed in detail. The presented research is based on previous investigations and utilises a hybrid (HFEM - numerical FEM and analytical) approach to efficiently determine the time-dependent temperature distribution in the components of the steam turbine. The simulation strategy of the HFEM model applies various analytical correlations to describe heat transfer in the turbine channel. These are developed by means of extensive unsteady multistage conjugate heat transfer simulations for both start-up turbine operation with steam and pre-warming operation with hot air. Moreover, the complex numerical setup of the HFEM model also considers the thermal contact resistance (TCR) on the surfaces between vane and casing as well as blades and rotor. Prior to the analysis of other turbine start-up operating modes, the typical start-up turbine process is calculated and validated against an experimental data as a benchmark for subsequent analysis. In addition to heat transfer correlations, the simulation of a turbine start-up from cold state uses an innovative analytic pressure model to allow for a consideration of condensation effects during first phase of start-up procedure.

Life Prediction of High Pressure Steam Turbine Rotor

2006 ◽  
Vol 321-323 ◽  
pp. 707-710
Author(s):  
Gee Wook Song ◽  
Bum Shin Kim ◽  
Jung Seob Hyun
Keyword(s):  
Power Plant ◽  
Steam Turbine ◽  
Fatigue Damage ◽  
Power Plants ◽  
Rotation Speed ◽  
Operation Mode ◽  
Turbine Rotor ◽  
Operation Condition ◽  
Steam Turbine Rotor ◽  
Start Up

The operation mode of thermal power plants has been changed from the base load to duty cycle. From the changeover, fossil power plants cannot avoid frequent thermal transient state, for example, start up and stop, which results in thermal fatigue damage at the heavy section components. The rotor is the highest capital cost component in steam turbine and requires long outage for replacing the new one. For optimized power plant operation life and inspection management of rotor is necessary. It is known as general that start-up and shutdown operation greatly affect on steam turbine life. The start-up operation condition is especially severe because of the rapid temperature and rotational speed increase, which causes damage and reduction of main components life of steam turbine. The start-up stress of rotor which is directly related life is composed of thermal and rotational stresses. The thermal stress is due to the variation of steam flow temperature and rotational stress is due to the rotation speed of itself. In this paper, the analysis method of start-up stress of rotor which considers simultaneously temperature and rotation speed transition is proposed, which includes a case study regarding 500MW fossil power plant steam turbine rotor. Also, the method of damage quantitative estimation of fatigue damage to operation condition is described. The method can be applied to find weak points to the fatigue damage. Using the method, total life consumption can be obtained, and can be also used for determining future operation mode and the life extension of old fossil power units.

Performance Assessment of a Transient Model for HRSGs in Combined Cycle Power Plants

2003 ◽  
Author(s):  
Sepehr Sanaye ◽  
Arash Moradi ◽  
Farid Bashiri ◽  
Amir Saeed Dashti ◽  
Daryoush Mehranian ◽  
...  
Keyword(s):  
Power Plants ◽  
Performance Test ◽  
Cold Start ◽  
Combined Cycle ◽  
Operational Parameters ◽  
Transient Model ◽  
Water Steam ◽  
Operational Conditions ◽  
Start Up ◽  
Transient And Steady State

Heat Recovery Steam Generators (HRSGs) are major Componets in Combined Cycle Power Plants (CCPPs) which are particulary subject to severe thermal and flow stresses specially during cold start-up period. Hence it is important to predict the operational parameters of HRSGs such as temperature of steam, water steam, water, tube metal and flue gas at various parts sections during the transient operation as well as steady sate conditions. In this paper, the transient model proposed by Pasha and Jolly et al. [2,3] has been selected and developed as a program (HRSG) to predict the operational conditions of the whole HRSG elements during transient and steady state operations. The program is able to analyze arbitrary number of pressure levels and any number of elements such as superheater, evaporator, economizer, deaerator and desuperheater. To assess the correct performance of the developed model and program, and to predict the capability of the method in predicting variations of temperature with time at various elements, three groups of data verifications were performed. First, the numerical outputs were checked against the same outputs reported by Jolly et al. [3]. Second, the theoretical results were checked with experimental data obtained for HRSG at Tehran CCPP during cold start run. The variations with time of gas, metal, water and steam temperatures at various sections of HRSG were among the studied parameters. Third, the model outputs were checked against the data reported for the HRSG performance test at Neyshaboor CCPP, at base and part loads. In all above cases the theoretical and measured or reported values were compared and satisfactory closeness was found.

scholarly journals Changes in Power Plant NOx Emissions over Northwest Greece Using a Data Assimilation Technique

Atmosphere ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 900
Author(s):  
Ioanna Skoulidou ◽  
Maria-Elissavet Koukouli ◽  
Arjo Segers ◽  
Astrid Manders ◽  
Dimitris Balis ◽  
...  
Keyword(s):  
Power Plant ◽  
Data Assimilation ◽  
Energy Production ◽  
Power Plants ◽  
Transport Model ◽  
A Priori ◽  
Filter Method ◽  
Nox Emissions ◽  
A Posteriori ◽  
Data Assimilation Technique

In this work, we investigate the ability of a data assimilation technique and space-borne observations to quantify and monitor changes in nitrogen oxides (NOx) emissions over Northwestern Greece for the summers of 2018 and 2019. In this region, four lignite-burning power plants are located. The data assimilation technique, based on the Ensemble Kalman Filter method, is employed to combine space-borne atmospheric observations from the high spatial resolution Sentinel-5 Precursor (S5P) Tropospheric Monitoring Instrument (TROPOMI) and simulations using the LOTOS-EUROS Chemical Transport model. The Copernicus Atmosphere Monitoring Service-Regional European emissions (CAMS-REG, version 4.2) inventory based on the year 2015 is used as the a priori emissions in the simulations. Surface measurements of nitrogen dioxide (NO2) from air quality stations operating in the region are compared with the model surface NO2 output using either the a priori (base run) or the a posteriori (assimilated run) NOx emissions. Relative to the a priori emissions, the assimilation suggests a strong decrease in concentrations for the station located near the largest power plant, by 80% in 2019 and by 67% in 2018. Concerning the estimated annual a posteriori NOx emissions, it was found that, for the pixels hosting the two largest power plants, the assimilated run results in emissions decreased by ~40–50% for 2018 compared to 2015, whereas a larger decrease, of ~70% for both power plants, was found for 2019, after assimilating the space-born observations. For the same power plants, the European Pollutant Release and Transfer Register (E-PRTR) reports decreased emissions in 2018 and 2019 compared to 2015 (−35% and −38% in 2018, −62% and −72% in 2019), in good agreement with the estimated emissions. We further compare the a posteriori emissions to the reported energy production of the power plants during the summer of 2018 and 2019. Mean decreases of about −35% and−63% in NOx emissions are estimated for the two larger power plants in summer of 2018 and 2019, respectively, which are supported by similar decreases in the reported energy production of the power plants (~−30% and −70%, respectively).

scholarly journals A new method for determining allowable medium temperature during transient operation of thick-walled elements in a supercritical power plant

2010 ◽  
Vol 31 (3) ◽  
pp. 55-72
Author(s):  
Piotr Duda ◽  
Dariusz Rząsa
Keyword(s):  
Power Plant ◽  
Power Plants ◽  
New Method ◽  
Optimum Operating ◽  
Transient Operation ◽  
Medium Temperature ◽  
Heating And Cooling ◽  
Optimum Parameters ◽  
Start Up ◽  
Working Parameters

A new method for determining allowable medium temperature during transient operation of thick-walled elements in a supercritical power plantConstruction elements of supercritical power plants are subjected to high working pressures and high temperatures while operating. Under these conditions high stresses in the construction are created. In order to operate safely, it is important to monitor stresses, especially during start-up and shut-down processes. The maximum stresses in the construction elements should not exceed the allowable stress limit. The goal is to find optimum operating parameters that can assure safe heating and cooling processes [1-5]. The optimum parameters should guarantee that the allowable stresses are not exceeded and the entire process is conducted in the shortest time. In this work new numerical method for determining optimum working parameters is presented. Based on these parameters heating operations were conducted. Stresses were monitored during the entire processes. The results obtained were compared with the German boiler regulations - Technische Regeln für Dampfkessel 301.

scholarly journals Efficiency of Using the Auxiliary Boiler for Peak Power Generation by a Steam Turbine of NPP

2021 ◽  
Vol 64 (1) ◽  
pp. 78-90
Author(s):  
V. A. Khrustalev ◽  
M. V. Garievskii
Keyword(s):  
Power Plant ◽  
Nuclear Power Plant ◽  
Steam Turbine ◽  
Nuclear Power ◽  
Power Plants ◽  
Normal Operation ◽  
Heat Output ◽  
Generation Process ◽  
System Effect ◽  
Industrial Enterprises

The article presents the technique of an estimation of efficiency of use of potential heat output of an auxiliary boiler (AB) to improve electric capacity and manoeuvrability of a steam turbine unit of a power unit of a nuclear power plant (NPP) equipped with a water-cooled water-moderated power reactor (WWER). An analysis of the technical characteristics of the AB of Balakovo NPP (of Saratov oblast) was carried out and hydrocarbon deposits near the NPP were determined. It is shown that in WWER nuclear power plants in Russia, auxiliary boilers are mainly used only until the normal operation after start-up whereas auxiliary boiler equipment is maintained in cold standby mode and does not participate in the generation process at power plants. The results of research aimed to improve the systems of regulation and power management of power units; general principles of increasing the efficiency of production, transmission and distribution of electric energy, as well as the issues of attracting the potential of energy technology sources of industrial enterprises to provide load schedules have been analyzed. The possibility of using the power complex NPP and the AB as a single object of regulation is substantiated. The authors’ priority scheme-parametric developments on the possibility of using the thermal power of the auxiliary boilers to increase the power of the steam turbine of a nuclear power plant unit equipped with WWER reactors unit during peak periods, as well as the enthalpy balance method for calculating heat flows, were applied. The surface area of the additional heater of the regeneration “deaerator – high pressure heaters” system and its cost were calculated. On the basis of calculations, it was shown that the additional power that can be obtained in the steam turbine of the NPP with a capacity of 1200 MW due to the use of heat of the modernized auxiliary boiler in the additional heat exchanger is 40.5 MW. The additional costs for the implementation of the heat recovery scheme of the auxiliary boiler at different prices for gas fuel and the resulting system effect were estimated in an enlarged way. Calculations have shown the acceptability of the payback period of the proposed modernization.

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