Abstracts - VGB PowerTech Journal 7/2010

The Pro-quality Approach Leading to a Better Performance and Future Perspectives

Franz Bauer and Wolfgang Benesch

During planning and erection of new power plants a lot of bad experience with poor quality has been made. This has caused an initiative within VGB to develop an approach which defines a kind of frame for the required quality over the whole process chain. This approach will be elaborated as a master standard, i.e. already existing VGB Standards will be allocated to the corresponding specific process steps.

Achieving the Required Level of Quality in the Construction of New Power Plants - Not Simply a Question of Quality Assurance

Ralf Nowack, Gereon Thomas and Ute Hartfil

RWE employs two possible processing models for the construction of new power plants: the turn-key- and the lot award. Both models make the same claim, namely the construction of a state-of-the-art power plant in compliance with quality standards and legal requirements. Changing market conditions mean that due to competition and available production and manufacturing capacities, a global supplier market must be accepted. Control of these suppliers is a special challenge for operators and plant constructors alike, as new technologies and the use of new materials require appropriate and acceptable quality of execution.

Building 1100 MW Power Plants - Challenges for the Next Generation of Plant Construction Teams

Rob Droste and Thomas Maas

Replacement projects have started in Europe in order to modernise the whole power production fleet. The challenges most projects face, are related to providing the specified quality and to complying with current legislation. The mandatory essential safety requirements should be implemented during the design phase and proper follow-up during procurement and construction of the power plant should be ensured. Total Quality Management has been implemented at the projects of E.ON Kraftwerke using risk management and continuous improvement methodologies.

Quality Monitoring of Steam Turbine Sets for Current New Construction Projects of the Vattenfall Europe Generation AG

Hans Mandel, Marco Redieß and Udo Klauke

Vattenfall Europe Generation AG is currently building three new power plant units in Germany. The first unit is an extension of the lignite-fired power plant in Boxberg in Saxonia. The other project with two units under construction is located in the south of Hamburg (Moorburg). Both projects were developed by Vattenfall Europe Generation AG, Cottbus, as builder and Vattenfall Europe Power Consult GmbH, Vetschau, as the general planner. The importance of quality monitoring during manufacturing and assembly was considered from the very first beginning.

VGB-R 171 - Supply of Technical Documentations (Technical Plant Data, Documents) for Power Plants

Gert Obst and Christiane Lammel

According to legal requirements, technical documentation is part of the project to be supplied. The updated Guideline VGB-R 171 "Guideline for the Supply of Technical Documentation for Fossil-fired and Regenerative Powers Stations" was adapted to current needs and is now presenting a guide for supplying technical information, (data and documents). The reasons for revision and the foci are outlined. Reference is made to the targets and application possibilities.

Materials Specification VGB-R 109 and Processing Standards - First Experiences of a New Power Plant for Quality Control Purposes

Jörg M. Bareiß, Andreas Helmrich und Martin Bantle

New boilers in Europe are based on the PED (European Pressure Equipment Directive 97/23/EC). New materials are required for 600°C- and/or 620°C power plants that are mainly not described by PED and/or the harmonised standard EN 12952. Thus, additional requirements and regulations for boiler manufactures are needed. With a view on new materials, application and experiences with VGB-R 109, as part of customer contract for materials, will be discussed more detailed.

Evaluation of Hydrostatic Pressure Tests with "Increased" Test Pressure at Waste-fuelled Power Stations

Olaf Baumann, Karl-Heinz Herter, Ulrich Schirmer and Xaver Schuler

The essential safety requirements according to the pressure equipment directive (PED) also state specific quantitative requirements in terms of pressure testing (hydrostatic test) for the manufacturer to carry out within the scope of final assessment. In comparison to the pressure tests carried out up to now, aspects related to material-mechanical and safety-relevant points of view have to be considered if "increased" pressure of the pressure test according to PED will be applied to recurrent pressure tests. Consequences resulting from "increased" pressure tests are demonstrated by taking waste incinerators as an example.

Rostock Power Plant - 2009 Inspection and Overhaul under Special Conditions

Norbert Wudke, Michael Bertsch and Christian Pohle

The turbine and generator inspection in the Rostock power plant - originally scheduled for the period April 2009 to June 2009 - had to be moved forward for nearly four months due to fan damage. The planned inspection was to cover all turbine parts as well as hydrogen-, oil and ultra-pure water system in the generator area. Prior to the main inspection, the electrical net efficiency had dropped to 535 MW due to insufficient operation of the HP-part and aging. At the time of inspection the operating hours amounted to some 94,000 hours with 84 cold and 1,500 warm start-ups.

Increasing the Efficiency and Lifetime Extension of Turbine Condensers by Means of Monitoring their Condition and Operation

Wolfgang Czolkoss

Loss in capacity and operational availability in steam power plants is often caused by adverse conditions in turbine condensers. Therefore, monitoring the condition and overall operation of the turbine condenser is an important part of maintaining an efficiently operating power station and preventing costly tube replacements. The operation of the tube cleaning system is of particular importance. Reference on monitoring tube cleaning as well as on the detection and elimination of malfunctions are given in order to detect fouling and corrosion problems in due time and to launch remedial measures.

Special Inspection Programme for Chloride-induced Tension-crack Corrosion in Austenitic Components

Carsten George

Small leakages caused by chlorine-induced transgranular stress corrosion cracking (TGSCC) were detected at a reactor cleanup filter. A special test programme to delimit and verify this issue was performed during the outages 2008 and 2009. The asbestos sealings were identified as relevant chloride source. Experience from this extensive test programme can be useful for future refurbishment projects.

New Layout Formula for Amine-based CO2 Scrubbing Plants of the PCC Type

Vanessa Kubacz and Hans Fahlenkamp

The model presented enables predicting the absorption and desorption of CO2 from power plant flue gases with different amines. The laboratory for environmental technology at the TU Dortmund develops a rate-based model, which enables the simulation of CO2 absorption and desorption with aqueous amine solutions and amine blends. The model was validated at different pilot plans. Additionally the transient results generated by the model were validated with the commercial software Aspen Dynamics®.

Combination of Geothermal Energy and Sewage Sludge Combustion - Options and Limits

Sebastian Janczik and Martin Kaltschmitt

Geothermal plants for energy conversion generally require quite extensive technology causing high generation cost. Combined utilisation of geothermal energy and sewage sludge can optimise the situation. For this purpose reference units are defined and analysed based on technical and economic criteria. This is the basis for drawing conclusions regarding the potentials and limitations for a combination of geothermal power plants and sewage sludge combustion.

Designation Codes for Document Kind Classification Code (DCC Key)The Guideline VGB-B 103: A Useful Contribution for the Documentation of Power Plants

Wolfgang Ernst and Jochen Hantschel

Reliability, availability and economic operation of power plants are increasingly characterised by quick access to actual information. Relating to various types of document designation (drawing number, part number, file name, etc.) manufacturers´/suppliers´/engineers´ demand for quick and proper access to information could not be fulfilled until now. So the VGB Working Panel "Reference Designation and Plant Documentation" realised that there is urgent need for a detailed synchronisation of document allocation. A project group was set up to analyse the existing key catalogues and to establish a new VGB Guideline.