Minutes of Meeting VGB-Technical Committee: Generation and Technology VGB-Technical Group: PGMON Power Generation Maintenance Optimisation Netzwork 61st Meeting on 14 October 2020; Onlinemeeting Participants: Andrejkowic Milan CEZ Basus Martin CEZ Hoffmann Martin CEZ Krempasky Jakub CEZ Krickis Otto Latvenergo Le Bris Yves EDF Martin Conor ESB Meinke Sebastian Vattenfall Tereso Bruno EDP Wels Henk DNV GL Wolbers Patrick DNV GL VGB Secretariat: Göhring Sven VGB Agenda Welcome (Henk Wels) TOP 1: Use of parts from decommissioned coal-fired power plants Milan Andrejkovic, CEZ TOP 2: CCGT eHGPI Martin Hoffman, CEZ TOP 3: Siemens SGT-800 gas turbine’s upgrade process, related technical issues and preliminary results Otto Krickis, Latvenergo TOP 4: Diag Engine, a new monitoring solution for reciprocating engines Yves Le Bris, EDF TOP 5: RAM prediction for a district heating station consisting of aux boilers and a buffer Henk Wels, Dekra TOP 6: Ancillary Services Market: ESB CCGT Plant Flexibility Improvements Conor Martin, ESB TOP 7: Statistical analysis of VGB Forced Unavailability data on cycling CCGTs Henk Wels, Dekra TOP 8: The new VGB-Workspace Sven Göhring, VGB TOP 9: Place and date of next venue TOP 1: Use of parts from decommissioned coal-fired power plants Milan Andrejkovič & Martin Bašus, CEZ The introductory part of the presentation summarizes current information on CEZ Group's strategy and economic development in the Czech Republic in relation to the energy market, significantly affected by the Covid-19 pandemic. The history pf the power plant Prunerov 1 was presented. It was commissioned in 1967- 1968. The first reconstruction was taken in 1985-1988. This reconstruction solved recovery of important components. For example, the new rotors of steam turbines or replacement boiler’s parts. flue gas cleaner (absorber) were installed in 1996 (efficiency 95 %). Current state, when we shutdown power plant Prunerov 1 in June this year (4 units x 110 MWe). Next section shows part’s, which can be reused. The presentation shows examples of used components and spare parts in portfolio CEZ GROUP. The greatest interest is in control components and electric engines 6 kV. A stator of generator will be removed in November and taken to a service centre. There will be checked and repaired, then will be taken to power plant Ledvice. The same subject is with the transformer. The process of selling parts was shown - firstly, we do marketing research and if there is interest, then run the usual sales process. TOP 2: CCGT eHGPI Martin Hoffman & Jakub Krempaský, CEZ In first part of the presentation, CEZ presented actual operated CCGT units. CEZ is currently operates 1 CCGT power plant, which was started in 2014 at the perimeter of the coal-fired power plant. The operations are independent of each other; power plants have a common raw water supply. Total power output of CCGT is over 800 MW, multishaft arrangement of 2 gas turbines, HRSG boiler and steam turbine. Since commissioning, the market demand for operation of the power plant has been steadily rising. Subsequently, CEZ presented the possibilities of adjustments to the employees´ time fund, these possibilities are approached very sensitively and very rarely. Second part of the presentation was about power outage conducted at that time at CCGT Pocerady power plant. Main content of this power outage includes hot gas path inspection and power upgrade. Gas turbine, compressor, generator and auxiliary equipment are inspected and reconditioned during this outage. CEZ presented some organizational and technical insights regarding this power outage together with a brief overview of the works currently done there. CEZ also presented several improvements which are implemented during the power outage. Improvements concern replacement of several stages of compressor and gas turbines blades and vanes, optimized combustion and installing new designed equipment with increased durability. Results of these improvement are increased electrical power output of both gas turbines, lower start up times and higher operation flexibility. TOP 3: Siemens SGT-800 gas turbine’s upgrade process, related technical issues and preliminary results Otto Krickis, Latvenergo State company AS “Latvenergo” operates two thermal plants with installed capacity 144 MW (TEC-1) and 832 MW (TEC-2). At the thermal power plant TEC-1 with electrical capacity 144 MW are installed SIEMENS SGT-800A two gas turbines in combination with one steam turbine. In order to improve efficiency of the gas turbines of TEC-1 was decided to extend planned D level inspection with turbines' upgrade package, which allows achieving the latest modification of the turbine currently available now on the market. Upgrade of the gas turbine allows increasing power by 7 MW per GT unit, as well as allows to extend time between overhauls by 10 k EOH (overall time between overhauls 30 k EOH). In the framework of the upgrade compressor's blading was exchanged to the latest modification, as well as HGP was impacted too. During inspection of the first gas turbine were found several technical issues: defective pinion of the gearbox and alignment problems of the compressor. After opening gearbox casing was identified one damaged tooth of the turbine's pinion as well as bearing pads had signs of the deposits and melting. Results of the blue contact test were outside acceptance criteria. In order to put unit in operation as fast as possible damaged gearbox was replaced with completely new gearset. After upgrade of the turbine to the version SGT-800A4 as well as replacement of the gearset, output of the gas turbine increased more than by 7 MW and efficiency improved in average by 1.5 %. TOP 4: Diag Engine, a new monitoring solution for reciprocating engines Yves Le Bris, EDF In order to avoid too much maintenance EDF R&D center developed in the mid-2005, some dedicated algorithmic to monitor reciprocating engine of the nuclear fleet. 11 defects have been mathematically processed. Though, to those different degradation processes had been associated mathematical signatures in terms of impact on the acyclism signal. Several indicators have been created on the basis of those signatures This Adaptable solution can be used for diesel or gas engines, from 100 kW to 20 MW, with 2 and 4 strokes, for L and V technology and whatever base load or back-up engines. DIAG ENGINE is easy to use with an outside implementation and a minimum instrumentation, only 2 sensors are required; This service offers an engine spot complete health check and expertise, and cylinder by cylinder the defects are analyzed. Remote continuous health monitoring and early fault detection can be proposed. EDF is independent from manufacturers and O&M companies and with more than 2 GW of diesel engines, has a strong expertise and return of experience as a diesel generator set operator. TOP 5: RAM prediction for a district heating station consisting of aux boilers and a buffer Henk Wels, Dekra Background Vattenfall realizes a remotely operated Heat Transfer Station with auxiliary boilers and a heat buffer connecting the heat distribution networks for the NW and SE side of Amsterdam. The connection is beneficial as production for NW by a Waste-to-Energy plant has a surplus while production for SE by a CCGT can be further optimized. The Heat Transfer Station is being built by a contractor under a fixed price contract including a RAM analysis to check if RAM demands are being met (so called RAM specification). The contractor has realized a RAM model in a documented Excel spreadsheet. The contractor RAM analysis was reviewed by DNV GL. This analysis was by no means simple as many operating conditions are possible with regard to number of boilers in operation, delivery to NW and/or SE, operation with/without buffer, etc. As not all components are in use at each operating situation, boiler and pump redundancy had to be handled carefully. Similarly, there are 2 essentially products. What if a boiler producing for NW fails? Will NW have priority over SE? Review method DNV GL was involved as third party assessor and reviewed by separate memos each product of the contractor, such as the RAM analysis proposal, a preliminary RAM spreadsheet with input data and the RAM report. Some preferred ways of handling RAM specification are given in the UNIPEDE guideline. Working in parallel to the contractor, DNV GL produced a documented data analysis using practice data for auxiliary boilers, a Fault Tree analysis for the electrical systems, a Reliability Block Diagram containing system states (full out, 50 % production due to failures, etc.), a heat production duration curve resulting in estimated operating hours of auxiliary boilers and a full report of these activities. That made comparison with contractor results easy with the additional advantage that errors from both sides could be removed by comparison. TOP 6: Ancillary Services Market: ESB CCGT Plant Flexibility Improvements Conor Martin, ESB Conor Martin from Generation Asset Performance represented ESB Generation & Trading at PGMON 61 in October. Before the presentation details commenced a high level introduction to the ESB Group was presented for the benefit of new members of PGMON. ESB Generation & Trading then presented an update on CCGT plant flexibilities which have been implemented in the ESB portfolio in recent years. Some background detail on the creation of a system services (DS3) market in the Irish energy sector was provided to give some context around the commercial drivers for flexibility improvements and upgrades. The influence of wind penetration on demand and price was highlighted to show what the TSO requires to maintain system stability and the services it requires for different generator technologies. An overview of the changes implemented at Poolbeg CCGT plant was given to highlight how and low merit lower efficiency plant can be sustained commercially by providing fast start capabilities.