NRG Energys Hunterstown Combined Cycle Power Plant Safety Message - - PowerPoint PPT Presentation

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NRG Energys Hunterstown Combined Cycle Power Plant Safety Message - - PowerPoint PPT Presentation

Apr 07, 2023 147 likes •376 views

Welcome to NRG Energys Hunterstown Combined Cycle Power Plant Safety Message A backpack should weigh no more than15-20% of the body weight of a child. Lighten the load and make sure your child is wearing a pack that matches his/her size

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SLIDE 1

Welcome to NRG Energy’s Hunterstown Combined Cycle Power Plant

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SLIDE 2

Safety Message

A backpack should weigh no more than15-20% of the body weight of a

  • child. Lighten the load and make sure

your child is wearing a pack that matches his/her size to avoid back injury.

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SLIDE 3

Hunterstown Site

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SLIDE 4

Hunterstown CCGT

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SLIDE 5
  • State of the Art Technology
  • 3 GE 7FB.04 Combustion Turbines
  • 1 GE D-11 Steam Turbine
  • Air-Cooled Condenser
  • RO/CDI Water Treatment
  • Fuel Supply
  • Natural Gas Only
  • Water Supply
  • Groundwater
  • Construction Started
  • April 2001
  • Ground Breaking June 20,2001
  • Commercial operation
  • July 30, 2003

Artist’s Rendering – Hunterstown Project

  • Net Capacity Ratings:
  • Summer
  • 758 Mw w/o Duct Burners
  • 810 Mw w Duct Burners
  • Winter
  • 818 Mw w/o Duct Burners
  • 892 Mw w Duct Burners

Hunterstown Combined Cycle Power Plant

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SLIDE 6

6

Combined Cycle Gas-Fired Generation Process

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Hunterstown Plant Cycle

FEEDWATER HEATER #1 & #2

RECIRCULATION PUMP

AIR COOLED CONDENSER DEAERATOR

CONDENSATE TANK GLAND STEAM CONDENSER STEAM JET AIR EJECTOR CONDENSER CONDENSATE POLISHER CONDENSATE PUMPS (1 0F 3) DRAIN POT DRAIN POT PUMP STEAM TURBINE GENERATOR LP TURBINE

AIR COMPRESSOR COMBUSTION TURBINE

S T A C K

L.P. DRUM I.P. DRUM H.P. DRUM

EVAPORATIVE COOLER

AIR

COMBUSTER

HEATED NATURAL GAS

WATER

COMBUSTION TURBINE GENERATOR COMPRESSOR COMBUSTION TURBINE

HP TURBINE IP TURBINE

LP EVAPORATOR HP ECONOMIZER #3 IP ECONOMIZER #1 IP EVAPORATOR LP SUPERHEATER HP ECONOMIZER #2 HP ECONOMIZER #1 IP SUPERHEATER SCR CATALYST HP EVAPORATOR FUTURE CO CATALYST HP SUPERHEATER #3 REHEATER #2 HP SUPERHEATER #2 REHEATER #1 HP SUPERHEATER #1

UNHEATED NATURAL GAS

DUCT BURNER

BOILER FEED PUMP

D C B STOP CONTROL B E A C COMBINED REHEAT D HP STOP & CONTROL D E S U P E R H E A T E R S E FUEL GAS HEAT EXCHANGER

NATURAL GAS FUEL IN FUEL OUT

UNITS 2 & 3 HRSG LP ECONOMIZERS A NON- RETURN VALVE REVERSE FLOW VALVE COLD REHEAT STEAM STOP BALANCE UNITS 2 & 3 COLD REHEAT D F F F B Y P A S S B Y P A S S B Y P A S S UNITS 2 & 3 HP STEAM UNITS 2 & 3 HRH STEAM UNITS 2 & 3 LP STEAM

UNIT 1 (1 OF 3) HEAT RECOVERY STEAM GENERATOR (1 OF 3)

G G

HUNTERSTOWN COMBINED CYCLE POWER PLANT

WATER AIR OR SATURATED STEAM HP STEAM IP STEAM; COLD OR HOT REHEATED STEAM LP STEAM NATURAL GAS

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Hunterstown - GEA Air Cooled Condenser Description Design Configuration Summary

  • 1. Dogbone Joint – boundary between LP Steam

Turbine and Condenser

  • 2. Fifty (50) Bay arrangement in a 5 X 10

configuration.

  • 3. Each bay contains 4 condenser (K) bays and 1

dephlegmator (D) bay.

  • 4. Each bay contains a 2 speed fan motor/gearbox

arrangement.

  • 5. Two (2) Hibon Hogger Pumps
  • 6. Steam Jest Air Ejector
  • 7. Deaerator Condensate Tank
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Hunterstown - GEA Air Cooled Condenser Description Thermal Design Conditions Turbine Design Exhaust Steam Flow 1,690,000 lbs./hr. Turbine Exhaust Pressure 4.6 in Hg(a) Exhaust Enthalpy 1078.8 Btu/lb. Ambient Air Temperature 90

  • F
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Hunterstown - GEA Air Cooled Condenser Equipment Dogbone Joint

Manufacturer Microflex Size 232 ½” X 281 7/8” Belt 10 5/8”

Fans:

Fans Number 50 Manufacturer Howden Type Diameter 32’ SX6 Number of Blades 6 Weight of Complete Fan, lbs. 10,188 Weight of One Blade, lbs. 1149

Gearboxes

Number 50 Manufacturer Merger Type Parallel Shaft Gear Model UNIPA 300-2 Sp Ratio 16.63:1 Weight without oil, lbs. 4300

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Hunterstown - GEA Air Cooled Condenser Equipment Tube Bundles

Number K- Type 320 D- Type 80 Tube Type AE436-D/AE510 Active Tube Length, MM 9600-K, 7500-D Active Tube Field Width, MM 2900 Number of rows of tubes 2 Material, Tubes and Fins Carbon Steel, galvanized

Fan Motors:

Fans Number 50 Manufacturer A.O. Smith Type Vertical, Flange Mounted IPW-55 Frame 449TSD Speed 1195/595 RPM Electrical Data 460 VAC, 3 PH, 60 HZ Power Rating HP 150/37.5 Weight, lbs. 2590

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Hunterstown - GEA Air Cooled Condenser Equipment Air Removal Equipment

Service Type Condenser Holding Steam Jet Air Ejector Manufacturer Schutte & Koerting Capacity (each) 17.5 SCFM, 78.71b./hr, air+173.71b./hr, vapor@l.O" HgA Skid mounted steam jet air ejector package consisting of two 100% two- stage ejector trains w/inter & after condenser. 1st Stage Ejector

  • Qty. (2), 6" T4S2-7B

2nd Stage Ejector

  • Qty. (2), 3" S3B

Motive Steam Consumption, lbs.lhr 1st Stage 1111, 2nd Stage 1135 @150 psig 390°F Service Deaerator Holding Type Steam Jet Air Ejector Number 2 Manufacturer Croll-Reynolds 2

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Hunterstown - GEA Air Cooled Condenser Equipment

Hogging Vacuum Pump Service Condenser Hogging Type AL-l 00 Liquid Ring Vacuum Pump Number 2 Manufacturer Hibons Electric Motor, kW/HP 186.5/250 Drain Pumps Number 2 Type Vertical Condensate Drain Pump Manufacturer Goulds Model No. DWT-9RCLC Capacity 340GPM Power Rating 5HP

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Hunterstown - Operation

Hunterstown Combined Cycle Historical Operating Summary

Year Days of Operation Overnight Runs Cold Starts Warm Starts Hot starts 2003 17 N/A 7 3 7 2004 57 N/A 13 6 38 2005 112 N/A 21 12 80 2006 98 N/A 13 6 79 2007 139 N/A 16 12 111 2008 131 N/A 16 8 107 2009 160 42 20 11 87 2010 199 94 10 7 88 2011 263 224 3 7 29 2012 274 266 5 1 2 2013 256 185 4 3 64 2014 244 230 2 4 8 2015 227 218 1 8

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ACC Operations and Maintenance Early History

2003-2006: Operations: Daily Cycles and learning skills of ACC Operation Focus on Water Chemistry Control Maintenance: Lube Oil Samples 2007-2009 Operations: Daily Cycles proficient ACC Operations Focus on Water Chemistry Control Maintenance: Lube Oil Samples Steam Turbine LP Diaphram replaced. Dogbone Joint Replacement Lube Oil Samples 2010-2011 Operations: Daily Cycles proficient Summer ACC Operations now expanding into Winter Operation skill develop (Ran ACC in Manual during Winter Operations) Focus on Water Chemistry Control Maintenance: Steam Turbine Minor Dogbone Joint Re-Alignment and Replacement Water Wash ACC using General Contractor Lube Oil Samples

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ACC Operations and Maintenance History

2012 Operations: Daily Cycles proficient Summer ACC Operations now expanding into Winter Operation skill develop (Ran ACC in Manual during Winter Operations) Focus on Water Chemistry Control Maintenance: Water Wash ACC using General Contractor Lube Oil Samples 2013 Operations: Daily Cycles proficient Summer ACC Operations Winter Operations ran ACC in Manual Focus on Water Chemistry Control Maintenance: Water Wash ACC using General Contractor Performed Helium Leak survey, replaced man-way gaskets Lube Oil Samples

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ACC Operations and Maintenance History

2014 Operations: Daily Cycles proficient Summer ACC Operations Winter Operations ran ACC in Manual Focus on Water Chemistry Control Maintenance: Water Wash ACC using General Contractor Replaced all man-way gaskets Replaced Rupture Disc Performed helium Leak survey Repaired ACC tube leaks found in K75 and K74 Replaced 1st Merger Gearbox with spare Lube Oil Samples 2015 Operations: Daily Cycles proficient Summer ACC Operations re-configured ACC Control Logic to enable Winter Operations in AUTO control Focus on Water Chemistry Control Maintenance: Experience 1st On-line ACC Tube Leak on Row 1 during Winter Operation that impacted Operations hired GEA for repairs plugged (4) four tubes. Water Wash ACC using JS Solutions Contractor Performed Helium Leak survey, replaced man-way gaskets Lube Oil Samples

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ACC Operations and Maintenance Future Plans

Future Plan Operations: Daily Cycles proficient Summer ACC Operations re-configured ACC Control Logic to enable Winter Operations in AUTO control Continue strong focus on Water Chemistry to reduce FAC and Iron content. Continue reliability checks on ACC focused on oil analysis, vibration, coil monitoring, and motors. Maintenance: Water Wash ACC using specialized contractor Continue Helium Leak Check surveys Continue replacement project of ACC Polyvinyl Fan Casings with Reinforced Fiberglass Fan Casings Modifications to gearboxes to reduce oil leak potential Replacement of Lube Oil Cooler Hoses due to age Lube Oil Samples Change in Lube Oil from Omala 302 to 220.

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Hunterstown Cycle Chemistry

  • Makeup water: Wellwater, UV, Multi-media filters, Reverse Osmosis, CDI

Supplemented with mobile demineralizer as needed

  • AVT (O) all ferrous units; Powdex condensate polishing
  • ACC Inspections 2005 – 2008 Evidence of FAC

DHACI 4C Street entry tube orifices - white FAC Turbine exhaust ducts – shiny white patches FAC

  • Increased chemistry pH to 9.8 across steam cycle (ammonia feed)
  • Recent ACC and turbine exhaust inspections – No evidence of FAC
  • Recently began using on-line Hach turbidimeter to monitor low-level iron

in condensate

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Air Cooled Condenser Construction

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Low noise ACC Fan Blades in Assembly

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Air Cooled Condenser Construction Feb. 19, 2003