POWER PLANT GAS CONVERSIONS - Free Download PDF

1m ago
6 Views
0 Downloads
2.71 MB
37 Pages
Transcription

POWER PLANT GAS CONVERSIONSWÄRTSILÄ SPARK IGNITED GAS ENGINE (SG) CONCEPTWÄRTSILÄLÄ DUAL FUEL GAS ENGINE (DF) COCONCEPTCONVERSION CONCEPTS BASED ON EXISTINGWÄRTSILÄ VASA 32/32LN, WÄRTSILÄ 32 AND WÄRTSILÄ 46 POWER PLANTS1 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

OVERVIEW OF A GAS CONVERSIONWÄRTSILÄ DEFINITION OF A GAS CONVERSION2 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

THE CONCEPTA Wärtsilä gas conversion of an existing power plant is more than just an engine conversion. We considerall aspects from safety to reliability of the operation. Our conversion concepts follow the same latestdesign and engineering principles as new built gas power plants made by Wärtsilä.3 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ POWER PLANT GAS CONVERSIONSSome good reasons why you should convert your Power Plant to gas operation Fuel flexibility Environmental benefits (NOx 90 % reduction, SOx 95% ) Reduced fuel costs Modernization of assets, state-of-the-art technology Reduced maintenance costs4 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ POWER PLANT GAS CONVERSIONSReasons for choosing Wärtsilä as your partner World class Project Management organization– References: 20 power plants ( 79 engines of total 720 MW ) EPC provider Financing solutions We know your installation, your products and your needs Lifecycle support Long gas engine experience Guarantees Warranty5 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ POWER PLANT GAS CONVERSIONSGas conversion concepts Today we have 3 concepts– SG (Spark ignited Gas engines), mono fuel: natural gas– DF (Dual Fuel), multiple fuel: HFO, LFO and natural gas– GD (Gas Diesel), multiple fuel: HFO, LFO, crude, natural gas, associatedgas These concepts enable a very flexible operating window, and allow the operatorto select the fuel depending on availability, price and need. Wärtsilä gas conversions utilise– same state-of-the-art technology as new delivered power plants– same engine technology (parts and control) as new factory made engines– same safety and engineering concept as new delivered power plants6 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

POWER PLANT CONVERSIONMECHANICAL MODIFICATIONS TO AUXILIARY SYSTEMS7 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

POWER PLANT GAS CONVERSION CONCEPTSo what will change on my Power Plant?The most convenient time for doing a gas conversion is when the plant (or a specific engine)is subject to a major overhaul.The changes andmodifications depend onthe age of the existingPower Plant as well as theengine type installed in theplant. In the next slides wewill go through the majormodifications needed.8 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ 34SG CONCEPTExplosionventsSection view of a typical gas power plant9ExplosionventsGas regulating unit Explosion vents (rupture discs) are installed in the existingg exhaust gas ducting system in case of anexhaust gas explosion (unburned gas). The number and the location of the explosion vents depends on the layout of the existing power plant,typically 2-3 per generating set. The gas regulating unit controls the flow and pressure of natural gas supplied to the generating set.This unit is controlled by the power plant automation system. WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ 34SG CONCEPTPlan view of a typical gas power plantGas regulatingunits The exhaust gas ventilation unit purges theexhaust gas pipe in a 5-10 minute sequencewhen the generating set is stopped (part of thesafety concept). Starting air bottle size and number of bottles willbe increased for Vasa 32 based engines due toincreased air consumption during start(pneumatic air starting motors). Cooling water system modifications are donedue to more accurate temperature control anddue to modifications to the existing charge airsystem on the engine. When generating sets (engines) are convertedto gas operation, only parts related to gasoperation (similar to factory made engines) arechanged. If maintenance parts are needed,these are taken into account during the salesphase as well.10 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Exhaust gasventilating unitsEngineconversionCooling watermodifications

WÄRTSILÄ 34DF CONCEPTExplosionventsExplosionioonventsExhaust gas ventilation unitPilot fuel systemSection view of a typical gas power plant11Gas regulating unit Explosion vents (rupture discs) are installed in the existingng exhaust gas ducting systesystem in case of anexhaust gas explosion (unburned gas). The number and the location of the explosion vents depends on the layout of the existing powerplant, typically 2-3 per generating set. The gas regulating unit controls the flow and pressure of natural gas supplied to the generating set.This unit is controlled by the power plant automation system. A pilot fuel system is installed with the pilot fuel pump and new fuel injectors combining the main fueloil and pilot fuel. WärtsiläAugust 26, 2013Wärtsilä SG Gas conversion Presentation

WÄRTSILÄ 34DF CONCEPTPlan view of a typical gas power plantGas regulatingtingunit The exhaust gas ventilation unit purges theexhaust gas pipe in a 5-10 minute sequencewhen the generating sets are stopped (part ofsafety concept). Starting air bottle size and number of bottles willbe increased for Vasa 32 based engines due toincreased air consumption during start(pneumatic air starting motors). Cooling water system modifications are donedue to more accurate temperature control anddue to modifications to the existing charge airsystem on the engine. When generating sets (engines) are convertedto gas operation, only parts related to gasoperation (similar to factory made engines) arechanged. If maintenance parts are neededthese are taken into account during the salesphase as well.12 WärtsiläAugust 26, 2013Wärtsilä SG Gas conversion PresentationExplosionventsExhaust gasventilating unitPilot FuelSystemStarting airabottlesEngineconversionCooling watermodifications

POWER PLANT CONVERSIONELECTRICAL & AUTOMATION MODIFICATIONSTO AUXILIARY SYSTEMS13 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

OVERVIEW OF TYPICAL ELECTRICAL ANDAUTOMATION SYSTEM OF A POWER PLANTWOIS/WISE14 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ 34SG CONCEPTLV switchgearmodificationsPlan view of a typical control, electrical &automation room LV switchgear modifications are done due tonew consumers, e.g. exhaust gas ventilationfan. DC panels are added for 24V DC power for theengine control system. Control panels are upgraded to latest PLCstandard. New common control panels andengine control panels are installed or existingones modified depending on the age of thesystem. New operating stations for the plant areinstalled. WOIS (Wärtsilä Operator’s InterfaceSystem) monitors and operates the functions ofthe plant and WISE (Wärtsilä InformationSystem Environment) is the reporting/management system of the plant. If thehardware is up to date, only software changesare required.15 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion PresentationDC nce/store roomStairsNew controlpanels ormodifications onlyPantryControlRoomChangingRoom /mOfficeNew operatingstations (WOIS) of modificationsonlyOffice

WÄRTSILÄ 34DF CONCEPTLV switchgearmodificationsPlan view of a typical control, electrical &automation room LV switchgear modifications are done due tonew consumers, e.g. exhaust gas ventilationfan. DC panels are added for 24V DC power for theengine control system. Control panels are upgraded to latest PLCstandard. New common control panels andengine control panels are installed New operating stations for the plant areinstalled. WOIS (Wärtsilä Operator’s InterfaceSystem) monitors and operates the functions ofthe plant and WISE (Wärtsilä InformationSystem Environment) is the reporting/management system of the plant.DC nce/store roomStairsNew controlpanels ormodifications onlyPantryControlRoomChangingRoom /mOfficeNew operatingstations (WOIS) of modificationsonly16 WärtsiläAugust 26, 2013Wärtsilä SG Gas conversion PresentationOffice

ELECTRICAL & AUTOMATION, TYPICAL GAS OPC datagatewayHardcopylaser printerWOIS workstationWOIS workstationCentral control panel,common sectionWISE workstationCentral control panel,enginewise sectionCentral control panel,enginewise sectionCFC011CFC0n1Local auxcontrol panelLocal auxcontrol panelWLANAccess point(Optional)AVR, Automatic voltageregulatorControlRoomCFA901Engine hallPLC, orRIORemote I/O modulePower monitoring unit, orMV-swg, LV-swg (Project specific)Protection relayEngine UNICC17Ethernet switchLocal DisplayyPlant network, Ethernet, TCP/IP, Twisted pairsEthernetGatewayPlant network, Ethernet, TCP/IP, Fiber opticsEmbeddedcontroller WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion PresentationBJA011RIOBJA0n1

MAIN CONTROL PANELSStandardized control panels, yet ready for plant specific interface design(mainly Common panel)Genset Control panel CFC0n1:Common panel CFA901: Genset related meters(P, Q, V Ax3) Manual Control Interface Power Monitoring Unit Protection Relays Synchronizing interface Double frequency meter Double voltage meter Synchroscope Mimic for single line diagramPLC for Plant controlPLC for Genset control18 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

ELECTRICAL & AUTOMATION, ENGINES Wärtsilä’s own hardware and softwaredesigned for the harsh embedded environment Same engine automation platform for PowerPlants and Ship Power: UNICTM Gas plant engines––––––19 WärtsiläLDU Local Display UnitESM Engine Safety ModuleMCM Main Controller ModuleCCM Cylinder Control ModuleIOM Input/Output ModulesPDM Power Distribution ModuleAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

PLANT OPERATIONThe start/stop sequencecan be followed whilethe PLC controls theallyysequences automaticallyWOIS display;Control DisplayGenset start andstop commandsGenset start andstop commandsTypical examplesfrom operator,pWOIS point ofviewThe Starting conditionsare checked to be “all green”before start order is givenGenset breakerSynchronizationis automatic in synch“auto” mode Active power setpoint Power factor setpoint(Fuel mode selectionfor multi-fuel engines)20 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

POWER PLANT CONVERSIONENGINE MODIFICATIONS – SG CONCEPT21 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ SG CONCEPTGas engine conversion portfolio – which engine types and models can be converted?6L8LVasa 32 34SG( 370 / 375 kW/cyl )Wärtsilä 32 34SG( 450 / 460 kW/cyl standard rating )( 480 / 500 kW/cyl if generator allows )Wärtsilä 46 50SG *)( 975 kW/cyl standard rating )( 1045 / 1070 kW/cyl if generator allows )*) Older design platform (A, 905 kW/cyl) can not be converted to SG22 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation9L12V16V18V20V

PERFORMANCE OF CONVERTED POWER PLANTSHeat rate (kJ / kWh)Engine power (kW / cyl)Existing engine Type of conversionBeforeAfterBeforeAfterVasa 32 34SG (50 Hz)8,5408,290375345Vasa 32 34SG (60 Hz)8,4808,290370330Wärtsilä 32 34SG (50 Hz)8,2168,130460450Wärtsilä 32 34SG (60 Hz)8,2168,130450435Wärtsilä 46 50SG8,1007,900975975Estimated performance figures above, installation specific performance figures can be given once needed inputs for calculations are known (ambientconditions, gas quality and pressure, etc).23 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ SG CONCEPTMain gas pipingand main gas valvesTurbo chargers andcharge air coolersEngine componentsto be added orreplaced Normal maintenanceparts are not part ofconversion scope HFO/LFO equipmentwill be dismantled Only main componentslisted. All engine typeshave specificcomponents to be addedor replaced, even varyingfrom engine to engine.Exhaust gas pipingand insulation boxPre-chamberPh bvalveUNIC C3 enginecontrol systemPre-chamberPre-chhambbergas pipingpipingNew camshaftpiecesiNew connecting rods(if not marine type) and bearingsFlywheel and startingmotors (Vasa 34SG only24 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion PresentationNew cylinder headsand cylinder headequipmentBlock machinedfor 340 / 500 mm boreNew pistons, rings, linersand gudgeon pins

CONVERTED NUMBER OF INSTALLATIONS: 4POWER: 95 MWPortugal1 x 12V34SG(4 MW)2004Peru4 x 18V34SG(24 MW)2008NEW DELIVERED Number of installations: 550Power: 8300 MW Engines: 1520 Countries: 58REFERENCE25 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion PresentationTurkey2 x 18V34SG(12 MW)20063 x 18V50SG(55MW)

POWER PLANT CONVERSIONENGINE MODIFICATIONS – DF CONCEPT26 WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

WÄRTSILÄ DF CONCEPTGas engine conversion portfolio – which engine types and models can be converted?6L8L9LVasa 32 32DF( 370 / 375 kW/cyl )Wärtsilä 32 34DF( 450 / 460 kW/cyl standard rating )Wärtsilä 46 50DF(975kW/cyl standard rating )*) Older design platforms, Wärtsilä46 A and B ( 905 kW/cyl) can not be converted to a full output DF27 WärtsiläAugust 26, 2013Wärtsilä SG Gas conversion Presentation12V16V18V20V

PERFORMANCE OF CONVERTED POWER PLANTSHeat rate (kJ / kWh)Engine power (kW / cyl)Existing engine Type of conversionBeforeAfterBeforeAfterVasa 32 32DF (50 Hz)8,5408,480375350Vasa 32 32DF (60 Hz)8,4808,480370335Wärtsilä 32 34DF (50 Hz)8,2168,433460450Wärtsilä 32 34DF (60 Hz)8,2168,433450435Wärtsilä 46 50DF (50 Hz)8,1007,930975950Wärtsilä 46 50DF (60 Hz)8,1007,880975975Estimated performance figures above, installation specific performance figures can be given once needed inputs for calculations are known (ambientconditions, gas quality and pressure, etc).28 WärtsiläAugust 26, 2013Wärtsilä SG Gas conversion Presentation

DF CONVERSIONCONVERSION CONCEPT Same engine components as in new factorybuilt DF engines. Well proven and reliable ported gas injectionwith pilot fuel oil concept. Same operating safety concept as for newpower plants. Latest engine control and automation system(same as new power plants).

FUEL SYSTEM IN CYLINDER HEADCOMPONENTSGas manifoldInjection valveelectrical connectionGas valve electricalallaconnectionconnectioGas bellowsFine filterG valveGaslPilot fuel common900barrail 900baarGas nozzleGlMain fuelinjection pipeMain fuelinjection pumpInlet valveMain fuelquill pipePilot fuel quillpipeTTwinnozzleinjection valve

ENGINE SYSTEMS - PILOT FUEL SYSTEM (2/3)For optimum pilot and diesel fuel distributionSolenoidMain dieselneedlePilot dieselneedlePilot dieselneedleMMainfuelnozzleno

ENGINE SYSTEMS - PILOT FUEL SYSTEM (3/3) Radial piston pump with internal fuellubrication (engine driven on 50DF andelectrical motor driven on 34DF) Suction throttling controlled pressureregulationfilter Duplex fine filter Valve block with safety valve andpressure sensorsensor Double walled high pressure fuel pipesespilot pumpsafety valvefuel inlet

OPERATING MODE CHANGES (1/2)Gas mode100 Running on GAS with MDO pilot fuel injection. Automatic and instant trip to diesel mode in alarm situationswithout loss of engine power and speed.80– Automatic trip to diesel mode after 5 minutes at engine loadsbelow 10%.Diesel mode% Load Automatic transfer to diesel mode on request at any loadwithout loss of engine power and speed. Running on HFO* or MDO with MDO pilot fuel injection. Automatic transfer to gas mode on request at loads below80% without loss of engine power and speed.100* Wärtsilä 34DF & 50DFDiesel modeGas mode

OPERATING MODE CHANGES (2/2)Gradual transfer at any loadInstant transfer at any load(duration 1 hour)Gas modeDiesel modeDiesel modeNatural gas MDO pilotMDO MDO pilotHFO MDO pilotGradual transfer at any loadTransfer at loads 80% MCR(duration 1 hour)(duration 2 minutes)Gas modeDiesel modeDiesel modeNatural gas MDO pilotMDO MDO pilotHFO MDO pilotmin. duration 30 minutes for HFO1

REFERENCE LIST – DUAL FUEL GAS CONVERSIONSSTATUS, 2012Project NameCountryYearConversion typeStatusAlmeidaPortugal20041 x 12V32 HFO 12V32DFcReadyTearfilPortugal20051 x 12V32 HFO 12V32DFcReadyCentury PowerPakistan20053 x 12V32 HFO 12V32DFcReadyDenizliTurkey20061 x 16V46 HFO 16V50DFReadyCerestarGerman20061 x 16V46 HFO 16V50DFReadyBatamindo IIndonesia20055 x 18V32 HFO 18V32DFcReadyBatamindo IIIndonesia20067 x 18V32 HFO 18V32DFcReadyBatamindo IIIIndonesia20074 x 18V32 HFO 18V32DFcReadyCresent Textile MillsPakistan20071 x 16V32 HFO 16V32DFcReadyBilagIndia20071 x 18V32 HFO 18V32DFcReadyLucky CementPakistan20087 x 18V32 HFO 18V32DFcReadyLucky CementPakistan20093 x 12V46 HFO 12V50DFReadyCengizTurkey20107 x 18V46 HFO 18V50DFReady

REFERENCE LIST – NEW GAS ENGINESWärtsilä 32DFWärtsilä 50DFWärtsilä 34DFPower Plant engines66 engines84 engines37 enginesShip Power engines28 engines178 engines22 engines

Your name 358 10 709 [email protected] WärtsiläAugust 26, 2013Wärtsilä SG Gas Conversion Presentation

PLC for Plant control Genset Control panel CFC0n1: • Genset related meters (P, Q, V Ax3) • Manual Control Interface • Power Monitoring Unit • Protection Relays PLC for Genset control August 26, 2013 MAIN CONTROL PANELS Standardized control panels, yet ready for plant specific interface design (mainly Common panel)