UNIVERSITY OF KHARTOUM THE GRADUATE COLLEGE “TECHNICAL AND MANAGERIAL DEVELOPMENT FOR RAISING EFFICIENCY IN DR. SHARIF POWER STATION” BY OMAR MOHAMED SALEH BADAY ( B.Sc, M.Sc ) A THESIS SUBMITTED IN FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF Ph.D 2004 Supervisor: Dr. ELSHEIKH ELMAGZOUB 1 ACKNOWLEDGEMENTS Acknowledgement and appreciations are due to professor El-Sheikh Elmagzoub for his kind supervision. Also my acknowledgement and appreciations to the staff members, in Dr. Sharif Power Station and other power stations abroad, who gave me enough zeal and gusto to carry out this research. 2 CONTENTS Page Acknowledgements i Contents ii Summary (English) iv Summary (Arabic) vi List of figures viii List of tables ix Notation x Chapter 1. Introduction 1 1.1: The objectives of this research 4 2. Conversion of the existing gas turbines’ Simple Cycles in Dr. Sharif Power Station 6 to Combined Cycle. 2.1: Introduction 6 2.1.1: Description of the Power Station Concerned G.Ts. 7 2.1.2: G.Ts Data Specification 7 2.2: Gas-Steam Turbines Combined (Hybrid) Cycle. 8 2.3: Burmeister & Wain Scandinavian Contractor (BWSC) offer for Combined Cycle 9 to the existing gas turbines. 2.3.1: Parts of the Project Work to be done by BWSC 11 2.3.2: Parts of the Project Work to be done by NEC 13 2.4: Study, Modification and Adaptation of BWSC offer, in accordance to Power Station 13 Technical Data. 2.4.1: Additional Supplementary Firing 13 2.4.2: Arrangement for enough Feed Water 14 2.4.3: Arrangement for enough Cooling Water 14 2.4.4: Arrangement for Cooling the Cooling Water 16 2.4.5: NOX Reduction Facility 16 2.5: Combined Cycle Efficiency Estimation by Simulation of Modules 18 2.6: Advantages of Combined Cycle Power Generation. 21 3. Combined Cycle Reliability, Availability and Performance Test. 22 3.1: Introduction 22 3.2: Reliability 23 3.3: Availability 24 3.4: Combined Cycle Performance Test 25 3.4.1: Performance Specifications 26 3.4.2: Responsibilities 27 3.4.3: Test Set-up 27 3.4.4: Measurements 28 3.4.5: Preparations 28 3.4.6: Conduct of Test 29 3.4.7: Combined Cycle Performance Evaluation 31 3.4.8: Acceptance Criteria 35 4. Exploitation of Sudan Refined Fuel Oil In Dr. Sharif Power Station 36 4.1: Introduction 36 4.2: Brief History of Petroleum Survey, Discovery and Production in the Sudan 37 4.3: Type of Sudan Crude Oils According to International Standards. 39 4.4: Refineries Functionalism and Productivity 39 4.5: Specifications of Produced Fuel Oil, Compared to International Specifications. 40 4.6: Evaluation of Refined Fuel Oil usage in the Power Station. 41 3 5. Transfer of New Technologies to Dr. Sharif Power Station For Raising the Efficiency 42 5.1: Introduction 42 5.2: Gas Turbine Air Inlet Chillers. 43 5.2.1: Vapour – Compression Refrigeration 44 5.2.2: Description of the Air Inlet Chillers 47 5.2.3: Effect of the Air Inlet Chillers 49 5.2.4: advantages of the Air Inlet Chillers 50 5.3: Steam Turbine Air-Cooled Condenser 50 5.3.1: Description of the Air Cooled Condenser 51 5.3.2: Performance of the Air-Cooled Condenser 53 5.3.3: Advantages of the Air-Cooled Condenser 53 5.4: Steam Turbine Steam Re-Heating 53 5.4.1: Steam Turbine Unit Operating Data 54 5.4.2: Advantages of Steam Reheating 58 5.5: Steam Turbine Condensate Polishing 58 5.5.1: Actual Operating Conditions & Data 59 5.5.2: Effect of Condensate Polishing 60 5.5.3: Exhausted Resin Regeneration 62 5.5.4: Advantages of Condensate Polishing 64 5.6: Steam Turbine Unit with Flue Gas Electrostatic Precipitator. 64 5.6.1: ESP Components 65 5.6.2: Effect of ESP 66 5.6.3: Advantages of ESP 70 6. Development of Power Station Management 71 6.1:Introduction 71 6.2: Objectives of Power Station Manager 72 6.3: Ways of Leading to be Adopted by Power Station Manager 79 6.3.1: Leading through Motivation 79 6.3.2: Leading through Communication 79 6.3.3: Leading through Interpersonal Skills 80 6.3.4: Leading through group Dynamics and Team work 81 6.3.5: Leading through Innovation and Planned Change 81 6.4: The Warehouse Management 81 6.4.1: Present Warehouse Management. 82 6.4.2: Upgrading of Warehouse Management 82 7. Discussion, Conclusion and Recommendation for future work. 92 7.1: Discussion. 92 7.2: Conclusion. 100 7.3: Recommendation for Future Work 102 References 104 Appendix (A) I 4 SUMMARY This Ph.D thesis is considered as an extension to the author’s M.Sc thesis “Performance promotion and efficiency improvement in Dr. Sharif Power Station”, which was presented in University of Khartoum in 1997. The M.Sc thesis covered the period from 1994 to 1996, when most of the technical problems appeared in Dr. Sharif Power Station, specially after the commercial run of Phase II Units Nos 3 & 4. The author dealt with scientific methods to solve the power station standing problems in order to promote the deteriorated performance and to raise the already degraded efficiency. The M.Sc thesis showed all the technical and managerial studies that had been carried out by the author in this regard. Those studies are now shown briefly in chapter 1 ‘Introduction” of this Ph.D thesis. The title of the Ph.D thesis is “ Technical and Managerial Development for raising efficiency in Dr. Sharif Power Station”. While the M.Sc thesis dealt with Remedial studies for promoting the performance, and hence improving the efficiency, the Ph.D thesis is now dealing with development studies for raising the efficiency to higher levels through using modern sophisticated technologies in power generation. The author, in order to fulfill the research objectives stated at the end of chapter 1, has divided his research into four main studies and many subordinate studies, which are all shown under seven chapters, in addition to an appendix covering one technical study been done by the author. At the beginning of each chapter a short summary is written as an introduction to it. The first main field of study is dealing with conversion of the existing gas turbines’ simple cycles in Dr. Sharif Power Station to combined cycle. This main study represents the most important part of this research. It starts with explaining the gas-steam turbines combined (Hybrid) cycle. It shows the power station GTs data specification. Then it describes in detail the Burmeister & Wain Scandinavian Contractor (BWSC) offer to NEC to convert KNPS simple cycle gas turbines to combined cycle. It shows the parts of the project works to be done by BWSC and by NEC, with all the field research carried out in Dr. Sharif power station (formerly KNPS) to modify and adapt BWSC offer in accordance to the power station technical data. This mainly covers the need for supplementary firing, for enough feed water, for enough cooling water and for enough cooling of the cooling water. A sub-study for NOx reduction facility is also done. The author shows that an estimation has been done to the proposed combined cycle overall efficiency by simulation of modules, where genuine data were fed to a computerized program prepared by the author to identify the raise in efficiency from the simple cycle to the Combined Cycle. A conclusion to the first study shows the advantages of the combined cycle power generation, and a related sub-study has been prepared for proving reliability, availability and performance test of combined cycle. The second field of study is dealing with exploitation of Sudan refined fuel oil in Dr. Sharif power station. It is divided into the following parts or sub-studies: Brief history of petroleum survey, discovery and production in the Sudan, type of Sudan crude oils according to international standards, refineries functionalism and productivity, specifications of produced fuel oil compared to international specifications, and evaluation of refined fuel oil usage in the power station. A 5 complete field research has been carried out in Dr. Sharif power station covering the exploitation of Al Obeid refinery fuel oil stating all problems and remedies arose from some differences in specifications, but which are in general much less than the first problems arose from Abu Jabra refinery fuel oil. The third field of study, is dealing with usage of new technologies in Dr. Sharif power station for raising the efficiency. The author in this chapter has got use of his 20 years experience in power generation in the Arabian Gulf Countries, dealing with modern sophisticated technologies. His aim is to introduce them to engineers and planners to use them for development of power generation in the Sudan. Five sophisticated technologies are being field studied with comparison results and are all shown in details as: Gas turbine air inlet chillers, steam turbine air-cooled condenser, steam turbine steam re-heating, steam turbine condensate polishing, and steam turbine unit with flue gas electrostatic precipitator. The advantages of each of these modern sophisticated technologies are included at the end of each field study of them accordingly. The fourth field of study is dealing with development of power station management. The study stresses on the role of the power station manager, the objectives he has to fulfill and the ways of leadership he has to adopt. The objectives are mostly to reduce costs, to keep good housekeeping, to improve plant performance, to develop the plant, to save money as a result of above techniques and safety techniques.