Manjung 4

Transcription

Manjung 4

“CASE STUDY: THE MANJUNG 4 & 5 1,000MW
ULTRA-SUPERCRITICAL COAL-FIRED POWER
STATIONS IN MALAYSIA ─ SIMILARITIES AND
DIFFERENCES”
Power-Gen Asia
Bangkok, Thailand
E. William Baker and Hiroshi Kubota
3 September 2015
TEPSCO/MINCO Joint Venture
1
1.
Introduction to the First Phase of the Manjung
Project
2
1.1
The Original Reclaimed Island
3
1.2
The Existing Manjung 1 -3 Units (3 x700MW
Subcritical Coal-fired Units)
4
2.
Initial Technical Selection for Manjung Unit 4
During the initial Feasibility Study, TNB
Janamanjung and their Technical Advisor
considered the following technologies for the new
1,000MW unit:
 PF Coal
 Circulating Fluidised Bed
 Integrated Gasification Combined cycle (IGCC).
Steam Parameter Classification
Type
Pressure
Temperature
Efficiency Range
1.
Subcritical
< 220 bar(g)
538 / 538°C
35 - 37%
2.
Supercritical
< 240 bar(g)
593 / 593°C
37 - 39%
3.
Ultra-supercritical
< 270 bar(g)
600 / 600°C
39 - 41%
5
2.1
Final Size and Technology Selection (Cont’d.)
Process Flow Diagram for Manjung 4
6
2.2
Proposed Layout of Manjung Unit 4
1,000MW Plant Layout from the original RFP
7
2.3
Modifications to the Existing Coal Yard and
Extension for Manjung 4
8
2.4
Manjung 4 Project Schedule
Awarded to Alstom Power Systems of France and China
National Machinery Import & Export Corporation (CMC).
 Notice to Proceed:
31st March 2011
 Back-energisation to 500-kV
Grid System:
15th December 2013
 First coal firing:
31st July 2014
 First power injection to
the Grid:
20th September 2014
 Taking Over by TNBJ:
14th April 2015
 Unit completed on time and within budget.
9
2.5
View of Manjung 4 as seen from the North
10
2.6
View of Manjung 4 from the Southeast
11
3.
Introduction to Manjung Unit 5
12
3.1
Manjung 5 Project Schedule
Awarded to Sumitomo Corporation, Japan (HitachiMitsubishi Power Systems) and Daelim Corporation of
South Korea.
 Notice to Proceed:
1st March 2014
 Site mobilisation:
1st March 2014
 First coal firing:
2nd January 2017
 First synchronisation:
1st April 2017
 Scheduled Commercial
Operating Date:
1st October 2017
 Unit 5 is currently about 2 months ahead of schedule.
13
3.2
Manjung 5 Seawater Cooling System
14
3.3
Cross-section of Manjung 5 CW System
15
3.4 Manjung 5 CW Pump House
View of CW Pump House Area at 31st May 2015
16
3.5
Assembly of the Tunnel Boring Machine
within the Launching Shaft
17
3.6
Current Progress of Manjung 5
Manjung 5 Boiler Erection as of 31st May 2015
18
4.
Comparison of Key Performance Parameters
Manjung 4
Location
1.
Superheater
Pressure
Temperature
Flow
282.4 bar(g)
600°C
3226 tonnes/h
60.61 bar(g)
605°C
2687 tonnes/h
Outlet
2.
Reheater Outlet
Manjung 5
1.
Location
Pressure
Temperature
Flow
Superheater
250 bar
600°C
2989.4 tonnes/h
53.8 bar
610°C
2469.8 tonnes/h
Outlet
2.
Reheater Outlet
19
5.
Optimisation of Shared Facilities
1.
Cycle Make-up Treatment System - the Filtered Water, Permeate
Water and Primary Demineralised Tanks for Manjung 4 are
shared.
2.
Raw Water Supply - the tapping point for Town’s water supply
for unit 5 has been moved from off-site to a much closer
location at Unit 4.
3.
Service Water System Modifications – the Air Preheater Washing
Pumps for Manjung 4 will also cater to Manjung 5
4.
Industrial Waste Water Treatment System – the Manjung 4
system will deal with the industrial waste water from Manjung 5
with some additional lift pumps, valves and piping.
5.
Sanitary Waste Water Treatment System – the system designed
for Manjung 4 is sufficient to deal with the waste water from
both units with the addition of piping and valves.
20
6.
Principal Environmental Features of Manjung
4 and 5
Parameter
World Bank
Recommended
Guidelines
Malaysian
Standards
DEIA Limits for
Manjung
Units 1 - 3
DEIA Limits
for Manjung
Unit 4
DEIA Limits for
Manjung
Unit 5
NO2
(mg/Nm3)
650
(750 max.)
1700 (AW)
2000 (OI)
650
500
500
SO2
(mg/Nm3)
750
(2000 max.)
3500
200 (OI)
750
500
500
-
200
200
50
50
CO
(mg/Nm3)
Particulates
(mg/Nm3)
50
n/a
50
PM10
(mg/Nm3)
EIA should
consider impact
on Public Health
Must be
adequately
considered
Must be
monitored and
reported to DoE
every 3 months
Must be
Must be
monitored and
monitored and
reported to DoE reported to DoE
every 3 months. every 3 months.
21
7.
Challenges to Managing the New Assets
1. Operations and Maintenance
 O&M services for Manjung 4 are an
extension to the existing facility.
 For Manjung 5, REMACO, a TNB subsidiary
will operate the new plant.
 Operational training for the once-through
boiler technology.
2. Simulator Training
 Simulators have been installed for Manjung 4
and are under design for Manjung 5.
 The Manjung 4 simulator was used for
operator training during commissioning.
22
7.1
Challenges to Managing the New Assets
(Cont’d.)
3. Outage Management
 The addition of Forced Air Cooling Systems
 Manjung 1-3 and 4 have Forced Air Cooling
Systems as add–ons to the original contracts.
 These systems have been provided by Alstom,
the OEM for the turbine packages.
 Manjung 5 will have a Forced Air Cooling
System as well.
23
7.2
Benefits of Using Force Air Cooling for Outage
Management
24
End of Presentation
Thank you for your kind attention.
25

Manjung 4

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