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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
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