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28.
28.1
Design Criteria of thermal power plants
Introduction
Over the last two decades, the average cost and construction time of "greenfield" fossil fuel-fired power plants has been reduced by approximately 50%, even as their performance has improved. This is the result of technological changes and increased competitive pressures arising from the deregulation of power markets. This section provides an overview of steps taken by the power industry to respond to this challenge by designing and building standardized power plants based on sound technical solutions and optimized economics, with short preparation and construction times and a high degree of operational reliability.
28.2
Basic design criteria
While designing and construction of any power plant the following criteria is used:
standardization of power plant designs modularization; automation of power plant design; technological improvements; impact of above changes on design and manufacturing of power plants operational reliability operating efficiency capacity requirement local environmental requisites logistical support services and Infrastructure facilities available local and national government regulations most important criteria is capital cost and operational cost economy in terms of Rs/MW for building a power plant and Rs/kWh of operation and maintenance of the plant.
flexibility in operation manpower availability and requirement for operation and maintenance
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Modularization significantly reduces the costs of thermal power plants. Compared w ith the customized approach for project design and construction, modularization can significantly reduce project-financing costs (by up to 10%) in three categories: detailed engineering and supervision, price contingencies and interest during construction. In the case of the power industry, the "tailor" is the engineering designer and supplier of fossil-fired power plants. For many years, the market was one in which practically every power plant was designed and customized for the clients special requirements. Price levels and project time schedules permitted this "tailor-made" concept. For the supplier of power plants, the key demands to be faced are project cost, construction time and risk guarantees (Figure 28-1).
Figure 2 8 - 1 : Driving forces in power plant construction
28.3
Standardization of power plant designs
To retain competitiveness, suppliers of fossil-fired plants have begun to develop and build standardized power plants based on sound technical solutions, optimized economics and repeated applications. Short preparation and construction times as well as a high degree of
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reliability during operation characterize these plants. Developments affecting the cos and commissioning of fossil fuel-fired plants are: ts
The viability of standard power plant concepts: With only a few hundred power plants being ordered every year worldwide, global suppliers (less than a dozen), must generate and work from standard power plant concepts, which nevertheless have to meet a wide variety of operational conditions and requirements. The problem is complex since each client, even when refraining from substantial requests for individual design features, has nevertheless to specify its requirements in terms of; characteristics of intended fuels, plant capacity, local ambient conditions of temperature and humidity as well as local emission standards.
The client must then evaluate each suppliers offer according to its own criteria of capital costs, efficiency, service, maintenance, etc.
In some countries additional criteria such as well as stringent conditions (e.g. available space, emissions, noise level, architecture, environmental permits) associated with the use of existing sites and their infrastructure must also be considered. To determine the viability of using standard concepts for fossil-fired plants, a project database can be used to analyze all combined, open cycle and steam power plants worldwide in terms of capacity ( MW), fuel requirements, power system frequency and regional location.
Coal-fired Steam Power Plant: In the case of 50 Hz markets, the two most important power capacities are 210 and 500 MW. Now a days 500 MW and above capacities are very common A standardized approach for combined and open cycle power plants is clearly more viable than for steam power plants. This is primarily due to:
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Huge development cost limits all suppliers to a very restricted number of gas turbines for different power ranges. Gas is a homogeneous fuel (compared to coal), so the designer does not need to take into account significant fuel quality variations
Basing their approach on the demand analysis of orders, equipment suppliers have developed standard plants.
28.4
Power Plant Modularization
Over the last decade modular design, fabrication and construction of power plants has gained widespread acceptance worldwide. For the concept to be successful, the approach needs to be able to tailor each power plant as closely as possible to the clients needs without requiring major redesign of key plant components. The subsequent question was how these conflicting requirements of standardization and customization could be molded into a successful approach? A first step towards a more flexible design is to provide options to the reference version for each major functional unit A typical options used of 2 x 700 MW power is given below (
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Figure 28-2) which include boiler, turbine and auxiliary loads.
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Annexure XXVIII Output 1.1 Figure 2 8 - 2 : Typcial options used for 2 x 700 MW power plant
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For example, "via-ship" is the reference for the functional unit "coal supply" with delivery "via rail" as an option. Choosing the option in this case does not greatly change the remainder of the power plant. In the case of the functional unit "boiler", the reference is a supercritical once-through boiler and the option a sub-critical (drum-type) boiler. Choosing the option in this case requires modifications in the main steam line, ash handling, etc. Just as in the automotive industry, power plant designers have had to develop a limited number of platforms (basic power plant concepts) into which optional functional units and modules can be included as engines or special car seats are in a car platform, without significant changes to the platform itself. The key to flexible design lies in properly breaking down the power plant into adequate functional units and these units into such that most options will only directly affect a single module or, at the most, one or two in the surrounding system environment. This structure should permit requested modifications to be accommodated via selected options with minimal time spent on re-configuration.
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Design and use of modules: Both for combined cycle units and for steam power plants several modules are defined. These functional units are treated as "black boxes" for which space is reserved in the basic power plant. Since the modules for combined cycle and steam power plants overlap, multiple modules are needed in one to four options. Each module file contains the P&I drawings, geometric information, bill of quantities, isometric calculation, schedules and associated documentation. To some extent, these modules can be prefabricated. Sometimes these modules (e.g. switchgear panels) are designed to be shipped in standard containers to the plant site. If, for a given project, a module with a given option is used, then a simple computer command more or less a mouse click is sufficient to link the neutral module to the specific project. Preconditions for modularization: To realize the economic advantage of the modular approach, the client needs to permit the supplier to use this approach in bidding for a project. The approach uses a small number of basic power plant concepts with a finite number of modules and is applied by a supplier to a major share of orders for new plant. In addition, for each individual module, the plant supplier tries to reach a common understanding of its specification with a group of sub-suppliers (following the suppliers own procurement guidelines) so that each sub-supplier can provide its optimized technical solution within the space and system limits. Worldwide procure ment can be achieved and facilitated by requiring each sub-supplier to achieve his task within the module boundaries.
28.5
Technological Improvements
In addition to the factors described above, technological deployment has lead to performance gains and cost r eductions. Use of supercritical technology has achieved efficiency improvements in the range of 2 -5% for coal-fired plants, compared to subcritical technology changes in the firing temperatures can significantly increase gas turbine output and efficiency of gas-fired plants. In addition there are several technological components can be considered such as
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technology related process operational related (online optimization systems) automations and control systems
28.6
Automation of plant design
Computerization is the key to modularization because of the enormous amount of data generated, processed and shared between different groups involved in the engineering of modular power plants. Typically, computer applications include 3 -D modeling, computer automated e ngineering (CAE), computer aided engineering design (CAD), scheduling, cost calculation, construction control, procurement control, cost control and document management. This ultimately results in time savings in engineering and construction as well as increased flexibility for the customer. This approach is state-of-the art in the supply industry for fossil fuel-fired power plants. A typical example is described as follows. A computer tool for planning and logistics was developed using commercially available software. This is schematically shown in
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Figure 28-3. It includes the use of a data bank, 2D and 3D graphic information software, software for plant structure, plant construction and control as well as another software for communication and work flow management. The management system for data and documents is the hub where all data and documents are stored and from where people engaged in a project wherever their location can search, copy, mail and store their work inputs and outputs.
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28.7
Impacts on Design and Manufacturing in Developing Countries
Early indications are that this approach, combined with the impacts of globalization will cause more design and project management work to shift to developing countries. Most of the major power plant suppliers, are building up capability to design and construct modular power plants in developing countries.
28.8
Other im portant criteria
The most important criteria is capital cost and operational cost economy in terms of Rs/MW for building a power plant and Rs/kWh of operation and maintenance of the plant. The other very important criteria for designing the thermal power plants and its auxiliary system are
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operational reliability operating efficiency capacity requirement local environmental requisites logistical supports infrastructure facilities available local and national government regulations flexibility in opera tion manpower availability and requirement for operation and maintenance spares and services available others
28.9
Conclusions
The development and implementation of a new basic power plant concept for greenfield fossil fuel-fired projects with a defined number of modules responds to the worldwide trend towards considering electricity as a commodity. As with other commodities, the market will reward low-cost electricity producers and their suppliers: For the electrical utility, the concept has lead to significant reductions in project implementation time and cost as well as in project risk. In addition, plant availability has been enhanced through the provision of reliable optimized modules at least cost. For the supplier, the concept has been a key feature in maintaining competitiveness during a period of price decline. The modular structure can also be of advantage when investigating replacement power plants for existing sites needing rehabilitation in built-up areas where greenfield sites are in short supply. Source: http://www.worldbank.org/html/fpd/em/trends/modular.htm
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