SELECTING THE OPTIMISED PUMP CONFIGURATION AND DRIVE OPTION FOR THE CONDENSATE EXTRACTION AND BOILER FEED

PUMPS FOR THE NEW ESKOM SUPERCRITICAL POWER STATIONS Willem van der Westhuizen Corporate Pump Consultant and Gugu Ngcobo Mechanical Engineer Eskom Group Technology Johannesburg, South-Africa

ABSTRACT
Eskom has embarked on a major Capital Expenditure program to cater for the growing demand for power as a result of a rapidly developing South African economy. Future developments include electrical power generation utilizing diverse technologies such as;
Fossil Nuclear Pebble Bed Modular Reactors Hydro, Open Gas Cycle Combined Cycle Wind and Solar Energy

The first two new Supercritical Fossil fired Power Stations, Medupi (6 Units, each 794 MW) and Kusile (6 Units, each 798 MW) are presently in the design and construction phase. The condensate extraction pumps and boiler feed pumps are amongst the highest consumers of auxiliary electrical power within a power station, it is therefore of utmost importance that the correct optimized pump configurations and drive options for each of these pumps is selected.

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Background to Eskom
Eskom, South Africas electricity utility: Is one of the top 10 utilities in the world by generation capacity Generates approximately 95% of electricity used in South Africa Generates approximately 45% of electricity used in Africa Number of employees, 37 857 Electricity sales, 214 850GWh Nominal capacity, 44 193MW Net maximum capacity, 40 503MW Power lines and cables (all voltages), 381 700km Carbon dioxide emissions, 221,7Mt Total water consumption, 323 190ML

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2010

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2010
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Capacity Expansion Driven By Long Term Demand Forecast

Long term forecasts - national + foreign
90000 80000 70000 Position Moderate
Eskom position based on 4% growth electricity growth supporting 6% economic growth

77960 MW

MW

60000 50000 40000 30000 2005

56710 MW

Eskom moderate position 2.3% electricity growth based economic growth of 4%

2010

2015

2020

2025

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Eskom Capacity Projects Funnel

Research Other Known Opportunities Opportunity Screening Prefeasibility Feasibility, Business Case Study

[Gross Mwe]

Build Programme

In Operations

165
PBMR CCS Carbon Capture 100 Concentrating Solar Tower xx Wave /Ocean current Energy 180 1600 Lurio Moz Batoka Gorge Zim / Zam 1400 1000 Gokwe N Zimbabwe Lebombo Swaziland 1000 CBM Botswana 30-70 Or River NamRSA 2000 35

300
IGCC

nx150
OCGT

1200 Discard Coal n x 300 n x 800 Coal-n

nx400
CCGT

18005400 Coal-5

4800 Coal-4 1500 Pumped StorageD 2100 UCG

4800 Coal-3

4800

746 Gourikwa 4764 Medupi 200 Arnot upgrade Phase I

nx100
Wind_Fleet

nx
3200 Nuclear- n

540
HFO Moambo Moz-Gas 500 Wind 2

100
Sere-Wind 1

Kusile

400
OCGT Conversion 1500 Tubatse (delayed) 3300 1000 DME IPP Peaker 2100 Nuclear (delayed)

1337 800
1352 Grootvlei Ingula 250 Komati Ankerlig

Benga Mozambique Massingir Moz 500 CBN Moz

600

1000

Kafue Lower 3500 Zambia Mmamantsw e Botswana Inga III Westcor 360 KNBE 1300 Zambi a Mphanda Nkuwa Moz 600 Monontsa PS Maropule Lesotho Botswana 360 KSB Zimbabwe 1000 Tx Mazambique Back-Bone AC/DC 1500 Moatize Moz

1600 Camden

4500 MultiSite IPP 600

750
Komati 1200 Mmamabul Botswana

Power Purchase Hydro Nuclear Oil/Gas Coal Renewables (Wind, Solar) Transmission International

400

100
Arnot upgrade Phase II

Grtvlei

Co-Gen MTPPP

6700 Kwanza Angola

60
Peaker Moz

18, 800 MW + n x 3200 MW nuc.

20,680 MW

12, 566 MW

4,533 MW

Projects (Imported Power)

Note: Power import for most of the regional projects will be lower than the stated capacity due to host country off-take

Two new Supercritical Power Stations

The first two new Supercritical Fossil fired Power Stations, Medupi (6 Units, each 794 MW) and Kusile (6 Units, each 798 MW) are presently in the design and construction phase. Both power stations have Air Cooled Condensers The Turbine contact was awarded to Alstom and the Boiler contract to Hitachi. The condensate extraction pumps and boiler feed pumps are amongst the highest consumers of auxiliary electrical power within a power station, it is therefore of utmost importance that the correct optimized pump configurations and drive options for each of these pumps is selected.

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Matimba Power Station 6x660 MW

Kendal Power Station 6x680 MW

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Progress at Medupi Power Station

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Medupi and Kusile Power Station

Condensate Extraction Pump

Condensate Extraction Pump

All existing Eskom Power Stations utilize a 2 x 100% Condensate Extraction Pump (CEP) configuration. The older type Power Stations that dont have any Main Turbine bypass systems utilizes two fixed speed CEPs with their design point the same as the Turbine Maximum Continuous Rating (TMCR) duty point. The pumps are horizontally split casing designs with a double entry suction impeller. The slow speed and double suction impellers are specifically considered in order to satisfy the NPSH requirements of the pumps.

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Condensate Extraction Pump

On our newer larger plants with an output of greater than 500MW, where the condensers are larger and the pump flow greater, the condensate extraction pumps are vertical multistage with the pump element mounted in a suction can which is connected directly to the hot - well of the condensers. All the power stations, whose outputs are greater than 500 MW per Unit, have Main Turbine Bypass Systems.

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350 kW

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Condensate Extraction Pumps for Medupi and Kusile P/Ss

Option 1:
2 x 100 % Vertical Spindle CEPs One variable speed One fixed speed

Option 2:
2 x 100 % Horizontal arrange CEPs One variable speed One fixed speed
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Condensate Extraction Pumps

Horizontal CEP preferred Simple design Easier maintenance Spares holding less

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Condensate Extraction Pumps

Position of CEP Below ACC Condensate Tank Optimum suction or NPSH available to CEP Enclosed in a dedicated CEP building Traveling Crane and maintenance area provided for in building CEP Electrical system incorporated with ACC sub-station
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Medupi and Kusile Boiler Feed Pump Drive Options

Boiler Feed Pump Drive Options

Drive options technically acceptable
1. High Speed VSD E-Motor (with low speed gearbox) 2. Low Speed VSD E-Motor (with high speed gearbox) 3. Fixed Speed Motor & Voith Vorecon 4. Fixed Speed Motor & Voith Hydraulic Coupling

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Boiler Feed Pump Drive

Booster pump Main pump

Filter

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1.

High Speed VSD Electric Motor with Speed Reduction Gearbox

BFP set efficiency = 81.2 %

Booster pump N = 1500 rpm Speed Reduction Gearbox

Main pump N = 6000 rpm

High Speed VSD Electric Motor Filter

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2. Low Speed VSD Electric Motor with Speed Increase Gearbox

BFP set efficiency = 79.9 %
Booster pump N = 1500 rpm Main pump N = 6000 rpm

Low Speed VSD Electric Motor

Speed Increase Gearbox Filter

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3. Fixed Speed Electric Motor with Voith Vorecon Planetary Geared Variable Speed Fluid Drive Coupling
BFP set efficiency = 77.2 %
Booster pump N = 1500 rpm Main pump N = 6000 rpm

Fixed Speed Electric Motor

Voith Vorecon Planetary Geared Variable Speed Fluid Drive Coupling Filter

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4. Fixed Speed Electric Motor with Voith Variable Speed Fluid Drive Coupling
BFP set efficiency = 70.2 %
Booster pump N = 1500 rpm Main pump N = 6000 rpm

Fixed Speed Electric Motor

Voith Variable Speed Fluid Drive Coupling Filter

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Efficiencies of BFP Drive Options

BFP Set Efficiency % 81.2 79.9 77.2 70.2 *Power Consumption kW 24274.8 24685.2 25520.84 28103.1

BFP Drive High Speed VSD EMotor + LS Gearbox Low Speed VSD EMotor + HS Gearbox Voith Vorecon Mechanical VSD Voith Hydraulic Coupling

Capital Cost % 203 161 133 100

*Power Consumption = 2 pumps @ TMCR

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Economic Evaluation
Two models were used
Official Generation EE model
..\..\..\BFP Drive Options vs. Load Profile rev2.xls

Eskom Enterprise Engineering Steag/Evonic Hybrid Model ..\..\BFP Economic Evaluation.xls

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Capital Costs of BFP Drive Options and EE results

BFP Drive Capital Cost in R M per unit for 3 BFP sets Capital Cost % EE Results Levelised costs R/MWh

High Speed VSD EMotor + LS Gearbox Low Speed VSD EMotor + HS Gearbox Voith Vorecon Mechanical VSD Voith Hydraulic Coupling

203

187.11 4

161

186.66 2

133 100

1 186.50
186.73 3

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BFP Load vs Pump set Efficiency

90

80

Pump set Efficiency

70

60

50

40 50 60 70 80 90 100 110

Pump Load

High speed VSD %

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Low speed VSD %

Vorecon %

Voith %
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Boiler Feed Pump Power Requirement

16000

14000

Power Absorbed (kW)

12000

10000

8000

6000

4000 40 50 60 70 80 90 100 110

Pump Load

Pump shaft power Booster + Main Motor Input Power Low Speed VSD Motor Input Power Voith

Motor Input Power High Speed VSD Motor Input Power Vorecon

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SES Meliti P/S 350 MW Florina Greece

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Mannheim P/S 9 MW Vorecon BFP Drive

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Main Pump HPT 350-370-6s/29A Pressure = 275 Bar Flow = 354 l/s Temperature = 183 oC Speed = 5665 rpm Weight = 14 000 kg

ABB Electric Motor

Power = 19 700 kW Boiler Feed Pump Train Layout Speed = 1482 rpm Weight = 48 000 kg

Booster Pump Pressure = 16 Bar VOITH VORECON RW16-145 F9 Output Power = 16 192 kW Output Speed = 5770 rpm
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Flow = 354 l/s Temperature = 183 oC Speed = 1482 rpm Weight = 4 500 kg
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Weight = 45 000 kg

Closing Note!
When selecting an optimised critical pump configuration and drive option installed in a Power Plant the following need to be considered:
Power Station Operation mode Capital cost of complete pump drive train Pump set efficiency and auxiliary power absorbed Auxiliary power cost Selection of proven technology and equipment with high reliability and availability

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COMMITMENT !
If our reference list increase with 36 19 MW Vorecons We will just have to make it work! Dr. Juergen Zeschky - VOITH

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Thank You