93 MWe natural gas fired Combined Cycle Power Plant

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Conrad Bryce Matthews
6 years ago
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1 93 MWe natural gas fired Combined Cycle Power Plant 1. Power Plant General Description This is a Combined Cycle Cogeneration Power Plant (CCCPP) located in (Milan) able to supply about 30 t/h of surplus steam at 80 bar/520 C (50 t/h with post-firing) for any technological application over and above 93 MW of electric power output. It was first synchronized in October 1997 and entered into commercial operation on February 1998; last full load operation was in March, 8th, As a single-shaft line, it is mainly composed by: one (1) General Electric MS6001FA gas turbine (Frame 6FA) one (1) Heat Recovery Steam Generator (HRSG) producing steam at two different pressure levels (80 and 3 bar) one (1) General Electric condensing steam turbine, with steam extraction one (1) General Electric generator, connected both to gas and steam turbine The step up transformer is provided with three windings since the original design foresees the predisposition to add a second steam turbine with its own generator.

2 2. Performances and emissions The following table summarizes the main figures of the Combined Cycle Cogeneration Power Plant CCPP nominal Gross Output MWe 93 Gas Turbine nominal power MWe 70 Steam Turbine nominal power MWe 23 Surplus Steam at 80 bar / 520 C t/h 30 Surplus Steam with post-firing t/h 50 The Power Plant complies with the following emission limits (referred to 15% O2): NOx emissions 15% O2 50 CO emissions 15% O Main equipment list The following table summarizes the key data for the main items of the plant with relevant running hours: Equipment Manufacturer Model Running hours GT General Electric MS 6001FA ST Nuovo Pignone HNK 50/ Generator General Electric 7AG Gas compressors Nuovo Pignone 2 x 2HM/ / Step-up transformer 11,5132 kv HRSG Henry Vogt ABB 112 MVA + 29 MVA

3 4. Boffalora Power Plant General Layout

4 5. Gas Turbine The following table summarizes Gas turbine s main figures: Manufacturer # General Electric / NP Model # MS6001FA (Frame 6FA) Serial number # st synchronizing # October 1997 Fuel # Natural Gas Power ISO cond. MWe 75,9 Heat ISO cond. kj/kwh Speed rpm 5231 Control System # GE Speedtronic Mark V Starting device # Generator driven Air Compressor type # Axial, regulating IGV Compressor stages # 18 Turbine stages # 3 Combustion chambers # 6 NOx reduction system # DLN2 Fuel gas pressure Bar Gearbox Manufacturer # Renk Tacke Gear Speed ratio rpm 5.500/3.000 Lube oil system # Common to Gas and ST The Gas Turbine was covered by a Long Term Service Agreement (LTSA) with OEM till the end of operation (up to 2012). Several Gas Turbine s Capital spare parts are available. Major Inspection was performed at OH, in 2003; next Major Inspection is planned at OH.

5 Gas Turbine Case Combustion Chambers

6 Gas Turbine Speed Reducer Gearbox Gas Turbine Inlet Air Filter

7 6. 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. License # Henry Vogt Machine Co. (USA) Designer # MIR (Italy) Manufacturer # COMEF (Italy) Manufacture Year # 1997 Type # Water tubes, horizontal gas flow, natural circulation HP section # Economizer, Evaporator, Superheater HP steam pressure Barg 83 HP steam temperature C 523 HP steam flow t/h 106,7 HP flow with Post-firing t/h 135 LP section # Economizer, Deareator, Evaporator, SH LP steam pressure Barg 3 LP steam temperature C 191 LP steam flow t/h 18,6 Post-firing Manufacturer # De Jong-Coen Post-firing Fuel # Gas Steel Stack m 50 (h) BMS manufacturer # Hartman & Braun

8 Heat Recovery Steam Generator

9 7. Steam Turbine The Steam Turbine is manufactured by General Electric / Nuovo Pignone. Turbine is provided with turning gear and SSS Gears make clutch allowing connection/disconnection between the Turbine itself and the Generator. Steam Turbine Major Inspection was perfo0rmed in Manufacturer # General Electric / Nuovo Pignone Model # HNK 50/ st synchronizing # October 1997 Power output Mwe 23,05 Inlet steam pressure HP Bar 82 Inlet steam temperature HP C 515 Inlet steam pressure LP Bar 2,2 Inlet steam temperature LP C 191 Condensing pressure Bar 0,06 Turbine Speed rpm Steam Condenser # Surface type / Water cooled Condenser Manufacturer # Wellman Graham Condensing Tubes Material # A249 TP 304L

10 Turbine Discharge Case Local Instrument Panel

11 Water cooled Steam Condenser

8. Synchronous Generator Generator last inspection (including visual and borescope inspection, polarization index, insulating resistance test and stator winding resistance) was performed in 2009.

12 8. Synchronous Generator Generator last inspection (including visual and borescope inspection, polarization index, insulating resistance test and stator winding resistance) was performed in Manufacturer # General Electric Model # 7AG Power output MVA 110 Power Factor Cos-fi 0.85 Cooling System # Air to Water Cooled Speed Rpm (2-pole) Frequency Hz 50 Rated Voltage V Rated Current A Insulation Class # F Excitation type # Static Excitation Model # EX2.000 General El Generator Starter # Static type Static Starter Model # Air insulated bus ducts downstream Generator Directo-Matic General Electric

9. Fuel Gas Compression Station Gas Compressors have been overhauled in 2010.

13 9. Fuel Gas Compression Station Gas Compressors have been overhauled in Compressors Manufacturer # Nuovo Pignone Number of Units # 2 (1 duty, 1 stand-by) Model # 2HM/1 Type # Reciprocating Rated Flow Rate Nmc/h Design Press. (inlet/outlet) Bar g 16 / 29 Design Temp. (inlet/outlet) C 20 / 65 Speed Rpm 740 Mechanical Power kw 500 Regulation Steps % Electric Motor Manufact. # ABB Motor Voltage V 6.300, 3-phase Motor Cooling System # Water Motor Lube System # Upgraded to oil free

14 Gas Compression Station

15 10. 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. Transformer Make # ABB Manufacture Year # 1996 Number of Units # 1 Manufacture Year # 1997 Installation # Outdoor Windings # 3-phase (1 primary HV; 2 secondary MV) Frequency Hz 50 Voltage level (HV) kv /- 8x1.25% Voltage levels (MV1-MV2) kv 11.5 Rated Power (HV/MV1/MV2) MVA / 112 / 29.5 Rated Current (HV/MV1/MV2) A 584,4 / / Connection groups # YN-d11-d11 Cooling Type # Onaf

16 Bus duct connection between Generator Circuit Breaker and Main Transformer

(With the possibility of conversion to HFO firing)

Ref.-No.: GT - 346 Entire 230 MWel Combined Cycle Power Plant -1 x 155 MWel V94.2 Gas Turbine Generator with HRSG - 1 x 75 MWel Steam Turbine Generator (With the possibility of conversion to HFO firing)