TEST METHODS FOR STEAM POWER PLANTS
CONTENTS INTRODUCTION FUNDAMENTALS OF THERMODYNAMICS APPLIED TO THERMAL POWER PLANTS ANALYSIS OF THERMAL PLANTS CON?GURATION FUELS: ANALYSIS OF PLANT PERFORMANCE AND ENVIRONMENTAL IMPACT FUNDAMENTALS OF RELIABILITY FUNDAMENTALS OF MAINTENANCE FUNDAMENTALS OF RISK ANALYSIS RELIABILITY ANALYSIS OF GAS TURBINE COMBINED-CYCLE GAS AND STEAM TURBINE POWER PLANT RELIABILITY ANALYSIS RISK-BASED INSPECTION AND MAINTENANCE (RBIM) OF POWER PLANTS INTRODUCTION ABSTRACT THIS CHAPTER PRESENTS THE MOTIVATION FOR THE DEVELOPMENT OF THE PRESENT BOOK BECAUSE THE NEED FOR ELECTRICITY IS PERVASIVE IN OUR SOCIETY, THERE IS A CONTINUING INTEREST IN THE TECHNOLOGY OF ELECTRIC POWER PRODUCTION AND DISTRIBUTION THE CHAPTER PRESENTS SOME FORECASTS OF ELECTRIC POWER PRODUCTION THAT INDICATE THE MASSIVE USE OF THERMAL POWER PLANTS, ?RED WITH COAL OR NATURAL GAS IN ORDER TO IMPROVE THE EF?CIENCY OF THOSE POWER PLANTS, THE USE OF OVERALL EQUIPMENT EFFECTIVENESS (OEE) AS A KEY PERFORMANCE INDICATOR IS DISCUSSED FINALLY THE LINK BETWEEN RELIABILITY AND MAINTAINABILITY CONCEPTS AND THE OEE INDEX IS PRESENTED 1 INTRODUCTION ACCORDING TO THE REPORT INTERNATIONAL ENERGY OUTLOOK (IEO) 2010 [2] THE WORLD NET ELECTRICITY GENERATION PROJECTION INCREASES BY 87%, FROM 188 TRILLION KILOWATT HOURS IN 2007 TO 250 TRILLION KILOWATT HOURS IN 2020 AND 352 TRILLION KILOWATT HOURS IN 2035 ALTHOUGH THE RECESSION SLOWED THE RATE OF GROWTH IN ELECTRICITY DEMAND IN 2008 AND 2009, GROWTH RETURNS TO PRE-RECESSION RATES BY 2015 IN GENERAL, IN OECD COUNTRIES, WHERE ELECTRICITY MARKETS ARE WELL ESTABLISHED AND CONSUMPTION PATTERNS ARE MATURE, THE GROWTH OF ELECTRICITY DEMAND IS SLOWER THAN IN NON-OECD COUNTRIES, WHERE A LARGE AMOUNT OF POTENTIAL DEMAND REMAINS UNMET ACCORDING TO THAT REPORT, THE TOTAL NET GENERATION IN NON-OECD COUNTRIES INCREASES BY 33% PER YEAR ON AVERAGE, AS COMPARED WITH 11% PER YEAR IN OECD NATIONS THE OECD (ORGANIZATION FOR ECONOMIC CO-OPERATION AND DEVELOPMENT) PROVIDES A FORUM IN WHICH GOVERNMENTS CAN WORK TOGETHER TO SHARE EXPERIENCES AND SEEK SOLUTIONS TO COMMON PROBLEMS THE FOLLOWING COUNTRIES ARE CONSIDER AS OCDE MEMBERS FOR THE STATISTICS OF INTERNATIONAL ENERGY OUTLOOK: THE UNITED STATES, CANADA, MEXICO, AUSTRIA, BELGIUM, CZECH REPUBLIC, DENMARK, FINLAND, FRANCE, GERMANY, GREECE, HUNGARY, ICELAND, IRELAND, ITALY, LUXEMBOURG, THE NETHERLANDS, NORWAY, POLAND, PORTUGAL, SLOVAKIA, SPAIN, SWEDEN, SWITZERLAND, TURKEY, THE UNITED KINGDOM, JAPAN, SOUTH KOREA, AUSTRALIA, AND NEW ZEALAND THE RAPID INCREASE IN WORLD ENERGY PRICES FROM 2003 TO 2008, COMBINED WITH CONCERNS ABOUT THE ENVIRONMENTAL CONSEQUENCES OF GREENHOUSE GAS EMISSIONS, HAS LED TO RENEWED INTEREST IN ALTERNATIVES TO FOSSIL FUELS—PARTICULARLY, NUCLEAR POWER AND RENEWABLE RESOURCES AS A RESULT, LONG-TERM PROSPECTS CONTINUE TO IMPROVE FOR GENERATION FROM BOTH NUCLEAR AND RENEWABLE ENERGY SOURCES—SUPPORTED BY GOVERNMENT INCENTIVES AND BY HIGHER FOSSIL FUEL PRICES ACCORDING TO DOE [2] FROM 2007 TO 2035, WORLD RENEWABLE ENERGY USE FOR ELECTRICITY GENERATION WILL GROW BY AN AVERAGE OF 30% PER YEAR, AS SHOWN IN FIG 1, AND THE RENEWABLE SHARE OF WORLD ELECTRICITY GENERATION WILL INCREASE FROM 18% IN 2007 TO 23% IN 2035 COAL-?RED GENERATION INCREASE FORECAST IS AN ANNUAL AVERAGE OF 23%, MAKING COAL THE SECOND FASTEST-GROWING SOURCE FOR ELECTRICITY GENERATION IN THE PROJECTION THE OUTLOOK FOR COAL COULD BE ALTERED SUBSTANTIALLY, HOWEVER, BY ANY FUTURE LEGISLATION THAT WOULD REDUCE OR LIMIT THE GROWTH OF GREENHOUSE GAS EMISSIONS GENERATION FROM NATURAL GAS AND NUCLEAR POWER—WHICH PRODUCE RELATIVELY LOW LEVELS OF GREENHOUSE GAS EMISSIONS (NATURAL GAS) OR NONE (NUCLEAR)—ACCORDING TO PROJECTIONS, WILL INCREASE BY 21 AND 20% PER YEAR, RESPECTIVELY TRILLION KILOWATTHOURS YEAR NUCLEAR RENEWABLES NATURAL GAS COAL LIQUIDS FIG 1 FORECAST OF WORLD NET ELECTRICITY GENERATION BY FUEL, 2007–2030, DOE [2] TEST METHODS FOR STEAM POWER PLANTS THE CATEGORY LIQUIDS INCLUDE PETROLEUM BASED FUELS, SUCH AS DIESEL OIL OR CRUDE OIL, AND THE CATEGORY RENEWABLE INCLUDES HYDROELECTRIC, WIND AND OTHER RENEWABLE ELECTRIC POWER GENERATION THOSE PROJECTIONS ARE BASED ON A BUSINESS-AS-USUAL TREND ESTIMATE, GIVEN KNOWN TECHNOLOGY AND TECHNOLOGICAL AND DEMOGRAPHIC TRENDS THE IEO 2010 CASES ASSUME THAT CURRENT LAWS AND REGULATIONS ARE MAINTAINED THROUGHOUT THE PROJECTIONS MOST OF THE WORLD’S ELECTRICITY IS PRODUCED AT THERMAL POWER PLANTS (TPP), WHICH USE TRADITIONAL FUELS, COAL, GAS AND FUEL OIL, AND UP TO 20% OF THE WORLD’S ELECTRICITY IS PRODUCED BY HYDROELECTRIC POWER PLANTS (HPP) IN COUNTRIES WITH WELL-TO HYDROPOWER, THE ?GURE IS MUCH HIGHER: NORWAY (99%), BRAZIL (92%), AUSTRIA, CANADA, PERU, NEW ZEALAND—OVER 50% ACCORDING TO THE DOE [2] FORECAST, COAL-?RED GENERATION ACCOUNTED FOR 42% OF THE WORLD ELECTRICITY SUPPLY SUSTAINED HIGH PRICES FOR OIL AND NATURAL GAS MAKE COAL-?RED GENERATION MORE ATTRACTIVE ECONOMICALLY THE NATURAL GAS AS AN ENERGY SOURCE FOR ELECTRIC POWER GENERATION IS ATTRACTIVE FOR COMBINED-CYCLE POWER PLANTS BECAUSE OF ITS FUEL EF?CIENCY AND RELATIVE LOW EMISSIONS THE COAL-?RED POWER PLANTS ARE BASED ON RANKINE THERMODYNAMIC CYCLE THIS FACILITY GENERATES ELECTRICITY BY PRODUCING STEAM IN A STEAM GENERATOR AND EXPANDING THE STEAM THROUGH A TURBINE COUPLED TO AN ELECTRICAL GENERATOR THE SAME RANKINE CYCLE CAN BE USED WITH LIQUID FUELS THE NATURAL GAS ?RED PLANTS ARE BASED ON BRAYTON THERMODYNAMIC CYCLE WITH COMBUSTION TURBINES, IN EITHER SIMPLE OR COMBINED-CYCLE APPLICATIONS THOSE COMBUSTION TURBINES CAN ALSO BE ADAPTED TO OPERATE AS DUAL FUEL MACHINES, USING DIESEL OIL OR NATURAL GAS AS FUEL THE THERMAL POWER PLANTS ARE VERY IMPORTANT FOR SOCIAL DEVELOPMENT AND MUST BE DESIGNED AND OPERATED ACCORDING TO THE MOST SUITABLE AVAILABLE TECHNOLOGIES THE ?NAL PRODUCT, THE ELECTRICAL GENERATION, MUST RE?ECT RESPONSIBLE APPLICATION OF ECONOMIC AND ENGINEERING PRINCIPLES BASED ON SOCIAL AND ENVIRONMENTAL CONCERNS THE PURPOSE OF THIS BOOK IS TO DISCUSS THE OPERATIONAL ASPECTS ASSOCIATED WITH THERMAL POWER PLANTS AIMING AT NOT ONLY ACHIEVE THERMODYNAMIC BASED PERFOR- MANCE STANDARDS BUT ALSO PERFORMANCE INDEX ASSOCIATED WITH ENVIRONMENTAL AND OPERATIONAL ASPECTS 2 PERFORMANCE INDEX PROCESS COMPANIES ARE ADOPTING A NEW CONSOLIDATED APPROACH TO PERFORMANCE IMPROVEMENT BASED UPON THE USE OF A KPI (KEY PERFORMANCE INDICATOR) KNOWN AS OVERALL EQUIPMENT EFFECTIVENESS (OEE) OEE IS A VERY SIMPLE METRIC TO IMMEDIATELY INDICATE THE CURRENT STATUS OF A INDUSTRIAL PROCESS AND ALSO A COMPLEX TOOL ALLOWING YOU TO UNDERSTAND THE EFFECT OF TEST METHODS FOR STEAM POWER PLANTS THE VARIOUS ISSUES IN THE PROCESS AND HOW THEY AFFECT THE ENTIRE PROCESS OEE CAN BE CALCULATED AS: OEE = AVAILABILITY PERFORMANCE QUALITY Ð1Þ AVAILABILITY REFERS TO THE PROCESS EQUIPMENT BEING AVAILABLE FOR PRODUCTION WHEN SCHEDULED AT THE MOST BASIC LEVEL, WHEN A PROCESS IS RUNNING IT IS CREATING VALUE FOR THE END USER WHEN A PROCESS IS STOPPED, IT’S CREATING A COST WITH NO ASSOCIATED VALUE WHETHER IT’S DUE TO MECHANICAL FAILURE, RAW MATERIALS OR OPERATOR ISSUES, A PIECE OF EQUIPMENT IS EITHER PRODUCING OR NOT PRODUCING BY COMPARING SCHEDULED RUN TIME TO ACTUAL RUN TIME, THE AVAILABILITY COMPONENT OF OEE ALLOWS FOR A DETERMINATION OF LOST PRODUCTION DUE TO DOWN TIME PERFORMANCE IS DETERMINED BY HOW MUCH WASTE IS CREATED THROUGH RUNNING AT LESS THAN OPTIMAL SPEED PERFORMANCE ALLOWS FOR A DETERMINATION OF HOW MUCH PRODUCTION WAS LOST BY CYCLES THAT DID NOT MEET THE IDEAL CYCLE TIME QUALITY FOCUSES ON IDENTIFYING TIME THAT WAS WASTED BY PRODUCING A PRODUCT THAT DOES NOT MEET QUALITY STANDARDS BY COMPARING THE QUANTITY OF GOOD TO REJECT PARTS THE PERCENT OF TIME ACTUALLY ADDING VALUE BY PRODUCING GOOD PRODUCT IS EXPOSED THE DE?NITION USED FOR GENERAL INDUSTRIAL PROCESS CAN BE ADAPTED FOR ELECTRICITY GENERATION THE PERFORMANCE OF THE THERMAL POWER PLANT CAN BE REPRESENTED BY ITS EF?- CIENCY THE EF?CIENCY OF A POWER PLANT IS USUALLY MEASURED AS A RATIO OF ITS ELECTRICAL OUTPUT TO THE AMOUNT OF HEAT USED, EXPRESSED AS A PERCENTAGE TYPICAL COMMERCIAL PLANTS RANGE FROM ABOUT 30–65% EF?CIENCY THE MORE EF?CIENT PLANTS COST MORE TO BUILD EF?CIENCY DEPENDS MORE ON HOW THE ENERGY IS USED RATHER THAN HOW IT IS PRODUCED BECAUSE RATINGS ARE BASED ON CONVERSION OF HEAT TO ELECTRICAL POWER THE QUALITY OF THE POWER PLANT IS ASSOCIATED WITH THE PARAMETERS (VOLTAGE AND FREQUENCY) OF THE GENERATED ELECTRICITY IN COMPARISON WITH THE REQUIRED STANDARDS THE AVAILABILITY OF THE POWER PLANT IS ASSOCIATED WITH THE RELIABILITY AND MAINTENANCE PLANNING OF EACH PIECE OF EQUIPMENT INSTALLED IN THE PLANT THE AVAILABILITY DEPENDS ALSO ON THE SKILLS OF OPERATORS AND MAINTENANCE TEAMS THE USE OF OEE INDEX CAN HELP THE ELECTRICITY-GENERATING POWER-STATIONS MANAGERS TO INVESTIGATE THEIRS COMPETENCE IN MAINTAINING RELIABLE EQUIPMENT AT COMPETITIVE COSTS ALTHOUGH THAT INDEX CAN BE USED TO EVALUATE CHANGES IN OPERATIONAL PROCEDURES OR EQUIPMENT UPDATE AIMING AT IMPROVING PLANT PERFORMANCE THE PLANT MANAGERS USE IT TO HIGHLIGHT THE STRENGTHS AND WEAKNESS OF EQUIPMENT MAINTENANCE PRACTICES ACCORDING TO ETI, OGAJI AND PROBERT [3] THE AVAILABILITY AND QUALITY RATE FOR THE WORLD’S BEST POWER- STATIONS ARE HIGHER THAN 98% THE OEE CAN ALSO BE USED AS INDEX TO DEMONSTRATE THE RELATION BETWEEN THE PLANT PERFORMANCE AND THE ISSUES RECOMMENDED BY PAS 55 [1] PAS 55 IS THE BRITISH STANDARDS INSTITUTION’S (BSI) PUBLICLY AVAILABLE SPECI- ?CATION FOR THE OPTIMIZED MANAGEMENT OF PHYSICAL ASSETS THE SPECI?CATION STATES THAT ORGANIZATIONS MUST ESTABLISH, DOCUMENT, IMPLEMENT, MAINTAIN, AND CONTINUALLY TEST METHODS FOR STEAM POWER PLANTS IMPROVE THEIR ASSET MANAGEMENT SYSTEM IN THIS CONTEXT, ASSET MANAGEMENT SYSTEM REFERS COLLECTIVELY TO THE OVERALL POLICY, STRATEGIES, GOVERNANCE, PLANS AND ACTIONS OF AN ORGANIZATION REGARDING ITS ASSET INFRASTRUCTURE AIMING AT DISCUSSING THE ASPECTS ASSOCIATED WITH PERFORMANCE EVALUATION OF THERMAL POWER PLANTS, THE BOOK PRESENTS CHAPTERS ASSOCIATED WITH THERMAL AND ENVIRONMENTAL PERFORMANCE OF POWER PLANTS AND ALSO PRESENTS THE CONCEPTS OF RELIABILITY, MAINTENANCE AND RISK ANALYSIS APPLIED TO POWER PLANT MANAGEMENT EACH CHAPTER IS WRITTEN BY AN EXPERT IN THE SUBJECT 3 CHAPTER CONTENTS AFTER A BRIEF INTRODUCTION TO THE BOOK, IN CHAP 2 IT IS REVIEWED THE FUNDAMENTAL PRINCIPLES OF THERMODYNAMICS AIMING AT ITS APPLICATION TO POWER PLANTS CYCLE ANALYSIS NEXT, THE THREE MOST COMMON THERMODYNAMIC CYCLES ARE STUDIED STARTING WITH THE BRAYTON CYCLE, THE DIESEL CYCLE, AND THE RANKINE CYCLE THESE IDEAL CYCLES ARE THERMODYNAMIC OPERATING MODELS FOR GAS TURBINES, DIESEL ENGINES, AND STEAM TURBINES, RESPECTIVELY THERMAL EF?CIENCIES, OPERATING CONDITIONS AND CYCLE VARIATIONS ARE ALSO ANALYZED CHAPTER 3 PRESENTS THE TYPICAL THERMAL POWER PLANTS CON?GURATION EXPLORING THE EQUIPMENT TECHNOLOGY USED FOR EACH CON?GURATION THE CHAPTER DISCUSSES GAS AND STEAM TURBINES, STEAM GENERATORS (INCLUDING HEAT RECOVERY STEAM GENERATORS) AND HEAT EXCHANGERS IT ALSO DISCUSSES THE EF?CIENCY AND OPERATIONAL ASPECTS OF EACH PLANT CON?GURATION IN SINGLE OR COMBINED-CYCLE CHAPTER 4 PRESENTS THE ENVIRONMENTAL IMPACTS OF THE THERMOELECTRIC PLANTS INSTALLATION AND OPERATION THE MOST SIGNI?CANT IMPACTS OCCUR DURING OPERATION BECAUSE SOLID, LIQUID AND GASEOUS WASTES ARE GENERATED CONTINUOUSLY AND PERMA- NENTLY IN SIGNI?CANT QUANTITIES THE MAGNITUDE OF THE IMPACTS DEPENDS MAINLY ON THE AMOUNT, TYPE OF WASTE AND THE ABILITY OF THE ENVIRONMENT TO ABSORB THEM THEIR NATURE, QUANTITIES AND CHEMICAL AND PHYSICAL CHARACTERISTICS DEPENDED MAINLY ON BOTH THE TECHNOLOGY AND THE FUEL EMPLOYED IN THE POWER PLANT IN CHAP 5 THE BASIC DE?NITIONS SUPPORTING COMPONENT AND SYSTEM RELIABILITY ANALYSIS ARE PRESENTED RELIABILITY AND FAILURE RATE CURVES ARE PRESENTED AIMING AT PROVIDING INFORMATION REGARDING THE FAILURE MODES OF COMPONENTS THE FAILURE MODE AND EFFECTS ANALYSIS (FMEA) AND FAULT TREE ANALYSIS (FTA) METHODS FOR SYSTEM RELIABILITY ANALYSIS ARE PRESENTED IN CHAP 6 THE BASIC CONCEPTS ASSOCIATED TO MAINTENANCE PLANNING ARE PRESENTED IN ORDER TO IMPROVE POWER PLANT MAINTENANCE PLANNING THE RELIABILITY CENTERED MAINTENANCE PHILOSOPHY IS DETAILED PRESENTED THE IMPROVEMENT IN MAINTENANCE PLANNING HAS A DIRECT EFFECT ON POWER PLANT AVAILABILITY, INCREASING THE PLANT OEE IN CHAP 7 THE BASIC CONCEPTS ASSOCIATED WITH RISK ANALYSIS OF COMPLEX SYSTEMS ARE PRESENTED, INCLUDING THE DISCUSSION OF RISK QUANTI?CATION IN A SYSTEMS FRAME- WORK RISK-INFORMED DECISION MAKING IS INTRODUCED ON THE BASIS OF BENE?T-TO-COST TEST METHODS FOR STEAM POWER PLANTS