CCGT WARSAW

Technical description

CONFIDENTIAL

Warszawa, April 2015

Index
1. CCGT Unit location and functional description ...............................................................
............................... 3

2. Technical description and technical data of main equipment .........................................

................................ 3

3. Other information ................................................................................................

................................ ......................................... 5

4. Performance evaluation and operation

operatio data................................................................
.................................. 5

5. Maintenance and technical status ................................................................

................................................. 6

6. Storage of dismantled CCGT ................................................................

.......................................................... 7

7. Pictures of CCGT................................................................................................
................................ ............................................ 8

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1. CCGT Unit location and functional description
CCGT was located in Czech Republic.
Republic CCGT was commissioned in 1998 and was a part of CHP Plant.
CCGT was operated mainly as the peak source for electrical power system and in emergencies.
emergencies
Generated high pressure and low pressure steam was supplied to steam headers and used for the
local district heating network and auxiliary of CHP Plant. Operation of the Plant was finished in 2010.
The CCGT Plant was located on the plot of size approx. 0,35 ha. Footprint of main equipment covers
an area of 70x25 m. Outside and inside views of CCGT are shown on pictures.
The CCGT was dismantled and transported to Poland. The works were done in two phases:
- the
he HRSG was dismantled in fourth quarter of 2012. Before dismantling of HRSG
H
representative of UDT from Poland performed detailed inspection and examination of boiler
and wrote protocols with remarks concerning boiler documentation. Technology of
dismantling and all cutting lines of boiler pressure parts were approved by UDT.
- the GT 6FA was dismantled in second quarter of 2013.

2. Technical description and technical data of main equipment

CCGT Unit includes: GE 6 FA Gas Turbine, ABB dual-pressure Heat Recovery Steam Generator and all
necessary auxiliary equipment.

Technological diagram of CCGT Unit

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Gas Turbine GE 6FA – basic data (+8oC)

Description Unit Value

Type GE6101FA
Gross electric power MWe 69,95
Simple cycle gross electrical efficiency % 34,09
Temperature at turbine inlet (TIT) °C 1288
Temperature at turbine outlet (TET) °C 582
Compressor pressure ratio 14,
14,8
Exhaust gas flow kg/s 205,8
Turbine speed rpm 5100
Generator speed rpm 3000
Frequency Hz 50
Combustion annular
no. of nozzles 6
Gas-supply
supply pressure requirement bar 27
NOx emissions
control system Dry Low NOx
N
water steam injection no
emissions (corrected to 15% O2) ppmvd 25

HRSG ABB - basic data

Description Unit Value
Type Dual pressure
Live steam (HP) flow kg/s 30,7
MP steam flow kg/s 4,2
Live steam (HP) parameters bar/oC 120 / 520
o
MP steam parameters bar/ C 16 / 290
o
Flue gas temperature at HRSG outlet C 80
Flue gas stream to the stack kg/s 208
Total capacity MWt 115
- capacity in steam-water
steam cycle MWt 100
- nominal output of water economizer MWt 15,0

All CCGT Unit technical as-built documentation (mainly in Czech or German (Gas Turbine))
Turbine) has been
transported to Warsaw and are available in electronic version.

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3. Other information
Main building
Due to limited area for CCGT Unit only HRSG was placed in building. Gas turbine and GT generator,
Control Package, Lube oil system (ACC - auxiliary compartment), Static Frequency Converter (SFC)
(
were placed in containers.
Gas connection
GT 6FA requires gas pressure
ssure not lower than 27 bar. The network gas pressure was higher than
27 bar therefore gas compressors were not installed.
Power output
Gas turbine (GT) drives the generator. The
Th basic parameters of generator: 11,5 kV, 87,5 MVA, 50 Hz.
The main LV switchgears was BFA10 0,4kV.
0,4 There was no 6 kV switchgears.
Generated electricity was transferred to electric power system by step up transformer 115/11,5 kV
(95 MVA).

4. Performance evaluation and operation data

Operational data of CCGT Unit in the years 1998-2010 are shown in the table below:

Electricity Heat Gas

Year
generation generation consumption
MWh GJ Nm3
1998 7 609 26 625 4 951 247
1999 425 460 2 625 485 133 138 230
2000 349 516 2 311 520 108 758 480
2001 43 162 271 840 14 078 012
2002 47 518 301 389 15 933 930
2003 19 647 113 264 6 456 597
2004 4 580 27 603 1 542 577
2005 3 680 21 163 1 286 843
2006 23 491 235 973 7 760 702
2007 2 889 29 011 975 603
2008 4 987 50 708 1 669 595
2009 13 062 125 682 5 082 302
2010 801 7 801 286 968

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The performance data of CCGT:
Economizer
Power output of GT HRSG capacity
capacity
HP steam LP steam
MWe % % % MWt
(t/h) (t/h)
70 100 109 100 14 100 15,4
52,5 75 94 86 12 86 12,9
35 50 83 76 10 71 10,3

The table presents the total operation hours of GT:

Year Start-up Outages Operation hours
per year total per year total per year total
1998 109 109 80 80
1999 50 159 27 107 5 331 5 331
2000 52 211 24 131 5 679 11 010
2001 20 231 6 137 1 378 12 388
2002 51 282 25 162 844 13 232
2003 37 319 6 168 408 13 640
2004 20 339 2 170 84 13 724
2005 18 357 5 175 72 13 796
2006 56 413 27 202 325 14 122
2007 18 431 3 205 46 14 168
2008 21 452 3 208 88 14 256
2009 11 463 1 209 244 14 500
2010 9 472 3 212 18 14 517

5. Maintenance and technical status

Gas turbine - GE 6FA

Gas turbine was commissioned in 1998. Since this time turbine worked about 14 517 hours.
Borescope inspection was carried out in 2012.
2012 Detected minor defects but after that time the GT was
not operated.
The re-use
use of the turbine requires maintenance - typical Major Inspection after 25 000 hours of
operation.
HRSG - ABB
During whole operation time the HRSG did not have any important failures. There were done all
necessary inspection and overhauls.
Auxiliary equipment
During operation period till December
Dec 2010 all equipment of CCGT Unit was maintained in good
technical condition. All necessary inspections and overhauls were done. The technical condition of
auxiliary equipment should be confirmed.

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6. Storage of dismantled CCGT

The CCGT was dismantled and transported to Warsaw (Poland) by Wood Gro
oup. The works were
done in two phases:
- the HRSG was dismantled
tled in fourth quarter of 2012,
- the GT GE 6FA and auxiliary equipment was dismantled in second quarter of 2013.
2013
Preservation methods and program have been defined and implemented to protect CCGT main
equipment against corrosion:
Gas Turbine scope (GT)
- continuous dry air scavenging: core engine using Munters equipment
Generator GT scope
- electrical heater resistor in permanent operation
Auxiliary compartment (lube oil system) ACC scope
- partly filled with corrosion inhibitor
Control package (MCC)
- air conditioning put in operation
Transformer
- refilled with oil
Load gear box
- filled with corrosion inhibitor

HRSG scope
- boiler pressure part like superheaters, evaporators and economizers is stored under tents.
The boiler pressure parts were protected against corrosion. The special powder was injected
inside and outer sides were sprayed by special fluid.
- other heavy elements like: drums, pipes, flue gas ducts etc. are covered by canvas,
- steel structure of boiler and boiler house is stored without cover,
- valves, pumps, electrical cabinets and other boiler fittings are stored in heated hall.
Auxiliary equipment of gas turbine set:
- valves, pumps, electrical cabinets, transformers
tran are stored in heated hall
- other auxiliary equipment pipes, air ducts etc. are stored outside (if it is required under canvas).

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7. Pictures of CCGT

Outside view

Gas turbine

8
 Reduction Gear Box

Lube oil handling system (ACC)

9
 Control Package (MCC)

Transformer 115/11,5kV (95MVA)

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