PLANT VISIT REPORT WAIGAOQIAO THERMAL P O W E R S TA T I O N PHASE-III 2X1000 MW SHANGHAI, CHINA (13TH MARCH 2010) RELIANCE INFRASTRUCTURE LTD. A-31, SEC-64, NOIDA. S A S A N E N G I N E E R I N G D E P T.
@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
CONTENT 1.00.00
INTRODUCTION OF VISIT
2.00.00
CAPACITY
3.00.00
LOCATION
4.00.00
UNIQUE FEATURES OF PLANT
5.00.00
PHOTO GALLARY
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China 1.00.00 INTRODUCTION During the period 1995 to 2005 rapid buildup of generation capacity was stressed in China. Maximum numbers of thermal units installed during this period were with subcritical/supercritical technology of 600 MW class. After 2005 China start adopting clean coal technology, the highly efficient bigger 900/1000 MW ultra supercritical units are come into operation. These bigger units are now used as base load stations. The old inefficient units are phased out or now used only during peak time. After completion of engineering meeting with SEC on 12th March, on the day of our return to India on 13th March, we got an opportunity to visit Waigaoqiao Thermal Power Station to see recently installed 2x1000 MW ultra supercritical units. 2.00.00 CAPACITY Waigaoqiao is presently second largest thermal power plant in the world. Its total installed capacity is about 5000 MW. This plant was constructed in three (3) phases. ¾ Phase-I (4 x 300 MW, subcritical) = 1200 MW ¾ Phase-II (2 x 900 MW, ultra supercritical) = 1800 MW ¾ Phase-III (2 x 1000 MW, ultra supercritical) = 2000 MW Rank
World's Biggest Thermal Power Plants Capacity Configuration Fuel (MW) (Unit Size / Technology)
Boiler / Turbine Manufacturer Foster Wheeler/B&W /GE
Power Plant
Location
Taichung
Taiwan
5,500
Bitumin ous coal
10x550 MW (sub critical)
2a
Waigaoqiao
China
5,000
Bitumin ous coal
4x300 MW (sub critical) 2x900 MW (Ultra supercritical) 2x1000 MW (Ultra supercritical)
2b
Guodian Beilun Power Station
China
5,000
Bitumin ous coal
5x600 MW 2x1000 MW (Ultra supercritical)
3
Zouxian
China
4,400
Bitumin ous coal
4x600 MW (sub critical) 2x1000MW (ultra supercritical)
Dongfang/Hitachi
4
Kendal
South Africa
4,374
6x672 MW (subcritical)
CEI/Siemens
5
Majuba
South Africa
4,113
3x665 MW, 3x716 MW (supercritical)
Steinmüller/ Siemens
1
Low grade Bitumin ous coal Low grade Bitumin ous coal
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Alstom/Siemens
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China 2.00.00 LOCATION The plant is about 18 km from the centre of Shanghai, in the Pudong District, on the south bank of the Yangtze River, which provides cooling water and also coal transport, from the Shenfu and Dongshen mines. 3.00.00 UNIQUE FEATURES OF 1000 MW UNITS 1. 1000 MW unit is of state of art design & technology, the tower type boiler and turbine/generator are manufactured and supplied by SEC under license of Alstom & Siemens respectively. 2. Ultra supercritical steam parameters (HPT inlet pressure – 252 bar & MS/RH steam temperature – 605 deg C) are used for 1000 MW units 3. The unit is operated with only single 1x100% TDBFP, there is no standby/startup motor driven boiler feed pump. 1x100% TDBFP is used during startup which takes steam from station auxiliary steam header during startup. 4. TD BFP is located on mezzanine floor and having separate condenser. 5. 2x100% condensate extraction pumps are used for 1000 MW unit. 6. Dual pressure condenser is used which gives advantage in net turbine cycle heat rate. SEC is giving similar type of condenser in Sasan UMPP. 7. 1000 MW units are provided with 2x50% high pressure heater banks with group bypass arrangement. Same practice is being followed in India for 500 MW units. 8. Coal is received by Barges which is unloaded on dedicated jetty and stored under shed. 9. Both SCR (selective catalytic reduction) for NOx removal & FGD (Flue gas desulphurization) for SOx removal are installed for 1000MW units. 10. Instead of metallic Scaffolding for local maintenance, light weight bamboos are used for making platform & temporary maintenance structure. 11. Six (6) 5W+1S front mills are provided for 1000 MW steam generator. 12. Instead of water impounded bottom hopper continuous ash removal scraper conveyer is used. 13. 2x100% PHE and DMCW pumps are provided common for TG & SG auxiliaries cooling in each 1000 MW unit. 14. 1000 MW generator is designed for 0.9 pf. 15. Instead of open switchyard, gas insulated switchyard has been provided results in saving of space. 3 of 14
@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China 16. Turbine operating floor, ground floor in TG building, mill area, boiler area are layed with ceramic tiles which gives excellent surface finish & aesthetic looks. 17. Excellent House keeping - Power plant is very clean, properly maintained, warning sign boards are provided wherever required. 5.00.00
PHOTO GALLARY:
Turbine Hall 2 x 1000 MW
Single flow HP & double flow IP Turbine
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Steam is fed to both LP turbines by Single crossover pipe
1000 MW (0.9 pf) Generator name plate, stator weight 443 Tons 5 of 14
@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Common control room for 2 x 1000 MW units
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Critical parameters of 1000 MW unit
1x100% TDBFP (No startup MD BFP) 7 of 14
@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
1x100% TDBFP of SULZER Make
Separate Condenser for TDBFP 8 of 14
@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
2x100% Condensate extraction pumps
2x100% PHE (Common for both TG & SG Aux)
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Tower type boiler of 1000MW unit-8 (photograph taken from top of unit no-7, 121.5 m)
Three (3) pass ESP & FGD unit
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Coal storage area covered with shed
Coal Unloading jetty
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Long retractable soot blowers
Bamboo is used for temporary platforms in boiler for maintenance
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@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Scarper conveyer for bottom ash
6 Nos. front mills Arrangement 13 of 14
@Vaibhav Chauhan
Plant Visit Report Waigaoqiao TPS, Shanghai, China
Gas insulated switchyard
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@Vaibhav Chauhan