Korea, Brunei, US projects selected for 1996 `Project of the Year` award

Korea Electric Power Corp.`s Taean thermal power plant has been selected to receive a 1996 `Project of the Year` award–making it the second consecutive year KEPCO has been a winner

By Douglas J. Smith

Managing Editor

An independent panel of judges has chosen an electric power plant project in the US and two projects in Asia to receive Power Engineering (PE) and Power Engineering International (PEI) magazines` 1996 “Project of the Year” awards. This year PE and PEI received 26 high-quality entries for projects in Asia, Europe, Central America and Africa. Because of the high quality of this year`s entries, choosing winners was difficult. PE and PEI`s 1996 “Project of the Year” award winners are:

– Department of Electric Service`s Gadong Power Station, Negara Brunei Darusslam Extension submitted by Black & Veatch, Kansas City, Mo., USA. Major participants in this project were General Electric USA, TBV Power UK, AEG and Siemens.

– Korea Electric Power Corp.`s Taean Thermal Power Plant submitted by ABB Inc., Windsor, Conn., USA. Major participants in this project were Korea Power Engineering Corp., Korea; Korean Heavy Industries & Construction Co. (Hanjung), Korea; ABB Combustion Engineering USA; and ABB-KWL, Germany.

– Inter-Power/AhlCon Partners` Colver Power Project, USA, submitted by Inter-Power/AhlCon Partners, L.P., Sewickley, Pennsylvania, USA. Major participants in this project were Bechtel Power Corp., USA; Foster Wheeler Pyropower Inc., USA; and Greystone Materials. In addition, the project owners wish to acknowledge the participation of Inter-Power of Pennsylvania Inc., Constellation Power Inc., Ahlstrom Development Corp., General Electric Capital Corp., A/C Power, Miltech Energy Service Inc., Penn Line services Inc., the Commonwealth of Pennsylvania, the Cambria Township Water Authority and the Cambria Township Supervisors.

Colver Power Project

All of the projects were judged according to the economic, social and environmental benefits that the project gives to the community and its customers. The Colver Power Project is one winner that meets all of the criteria. According to the project`s owners, Inter-Power/AhlCon Partners, L.P., the Colver Power Project is a unique blend of technological resources with a win-win approach that has created a profitable, environmentally and culturally successful operation in western Pennsylvania, USA. The project, constructed in the bituminous coal mining region near Colver, Pa., USA, is a resource recovery facility that has been designed to burn gob, a bituminous coal waste left over from more than 100 hundred years of coal mining in the region. Today, the Colver Power Project is able to dispose the gob without any further pollution of the environment. As the piles of gob are consumed, more than 130 acres of underlying land will be reclaimed, restored and revegetated using the alkaline ash from the combustion of the gob.

A contract was awarded for the project in March 1993, followed by a ground-breaking ceremony in April and start of construction in November. Initial synchronization of the plant with the electric power grid occurred on Feb. 6, 1995, and the plant went into commercial operation on May 16, 1995. Net output of the project is 102 MW–all of which is purchased by Pennsylvania Electric Co. (Penelec). The Colver project uses a circulating fluidized-bed boiler, supplied by Pyropower Corp.(now Foster Wheeler Pyropower), which generates 785,000 lb/hr (98.9 kg/s) at 2,525 psig (174 bar) and 1,005 F (540 C) reheat. According to the project`s owners, this is the first 2,525 psig (174 bar), single reheat circulating fluidized-bed boiler, firing bituminous coal waste (gob), to go into operation worldwide.

The circulating fluidized-bed boiler has two reheater sections and three superheaters. Each of the superheaters have independent temperature controls. Feedwater enters the boiler at 482 F (250 C) from a feedwater system. The feedwater system includes five feedwater heaters and a deaerator. Air emissions from the plant are controlled by a state-of-the-art emission control system that utilizes limestone injection, staged combustion with thermal DeNOx, and a 16 compartment fabric filter baghouse. According to the plant`s owners, air emissions from the plant already meet US Environmental Protection Agency mandated limits scheduled for the year 2000. Table 1 shows the operating and design criteria for the Culver Power Project.

On site there is a covered area where 10,000 tons of fuel can be stored and handled. Inventory control and blending of the fuel to optimize its Btu and ash content are handled by a laminated bar code reader and card system and an auger truck sampler. The fuel handling and blending system is also integrated into an on-site computerized database. The Cambria Township Water Authority (CTWA) is the municipal water authority that supplies water to the area. However, the earthen dam that formed the reservoir needed replacing. As a result, the project, working with the CTWA, constructed a new dam and reservoir now known as the “Ventura dam and Colver reservoir.” Water use fees paid by the project will be used to finance any future improvements that might be necessary to the dam and reservoir.

Roadways in the area were also another problem as they were two-lane, rural thoroughfares not designed to handle the expected 100 or more round trips per day of commercial transportation. Because the States` Department of Transportation had limited resources for new road development, the project`s owners decided to purchase 125 acres of land and build a new road. After completion this road was handed over to the Department of Transportation. In the opinion of the owners, the project has fulfilled the developers dream of providing local employment and cleaning up the environment, while making a return on its investment. In its first year of operation the owners report that the plant achieved an availability factor of 98.32 percent.

A second award for KEPCO

This is the second consecutive year that the Korea Electric Power Corp. (KEPCO) has received an award. In 1995 the company`s Yonggwang nuclear power plant Units 3 and 4 received an award. This year KEPCO is being honored for its Taean thermal power plant project. Because of the growth in demand for new capacity in the Republic of Korea, KEPCO has embarked on a program to radically increase electric power production in the country. A part of KEPCO`s program is the construction of 10,000 MW of standardized coal-fired sliding pressure units of 500 MW each. Plans call for all of this new capacity to be in commercial operation by the year 2000. The Taean project consisting of 2 by 500 MW units is part of this program.

In 1991 KEPCO awarded the contract for construction of the Taean Thermal Power Project. Four years later and two months ahead of schedule, the units went into commercial operation. Taean thermal power plant is located on the west coast of Korea about 100 km southwest of the capital city, Seoul. To increase the life of the steam turbines, the units were designed to operate on a hybrid sliding scale ramp. Furthermore, to facilitate safety valve functions, rapid runback operations and rapid startup of the units, a full 100 percent capacity high-pressure bypass system and a 65 percent capacity low-pressure bypass system have been installed.

Units 1 and 2 have been designed for continuous operation, for cycling duty and for two shift daily start stop (DSS) operation. An automated sequential control system (ABS) is used for two shift DSS operation. This control system is also used for automatic starting and loading of the units from initial light-off of the steam generator to full unit load of 500 MW. With the balance of plant auxiliaries stopped and the steam generator empty of water, the ABS is capable of automatically starting and loading the unit up to its full load of 500 MW. Table 2 shows the operating data for units 1 and 2 for the period January 1996 through May 1996.

The Taean Units 1 and 2 thermal power plant project brought together the skills of many companies in Korea, the US, and Europe for the design, construction and startup of the project. Coordination of all participants was achieved through many project technical review meeting which KEPCO scheduled during the period 1991 through 1995. These meeting were invaluable in resolving the many problems that came up during the project`s design and construction phases. According to ABB Inc., many unique and innovative designs had to be implemented in order to meet the requirements of the DSS operation of the units. However, due to the close cooperation of all the participants, and the project technical review meetings, the Taean project was completed ahead of schedule.

Three GE Frame 6 turbines added

Gadong Power Station Extension is a 120 MW natural gas-fired simple-cycle combustion turbine power station built for the Department of Electrical Services in Bandar Seri Begawan, Negara Brunei Darussalam. The project involved the installation of three General Electric Frame 6 combustion turbines and the modification of an existing outdoor GEC Alsthom Frame 6 combustion turbine. With the completion of the project, all of the combustion turbines are now centrally located in a gas turbine hall. In addition to the installation and modification of the generating equipment, new 11 kV and 66 kV indoor substations were constructed and gas insulated switchgear installed. The 11 kV switchgear was supplied by AEG, and Siemens supplied the 66 kV switchgear. A control room, administration building, spare parts storage building, and a combination fire station and guard house were also constructed as part of the project.

The 66 kV gas insulated switchgear substation consists of 29 breaker bays arranged in a split radial, double busbar configuration. It has 13 outgoing transmission line positions, 6 generator transformers positions and 6 step-down transformer positions. In the 11 kV gas insulated switchgear substation, there are 26 breaker bays arranged in a split radial, double busbar configuration. This substation has 13 outgoing distribution line positions, two incoming transformer positions, 2 to 5 Mvar capacitor bank positions and one auxiliary transformer position. The Gadong power station extension was designed and constructed by a consortium of General Electric and TBV Power. Black & Veatch, as a subcontractor to TBV Power, was responsible for the design engineering. A consortium of Lahmeyer International of Germany and Juratera Damit Beca Sdn., Bhd. of Brunei was the owner`s engineer.

According to Black & Veatch International, the use of underground cables as gateways from the substation has avoided visual clutter, while the use of high-voltage, insulated systems helps to protect the environment. With commercial operation of the Gadong power station extension, in March 1995 the Department of Electric Services in Brunei has doubled its generation capacity.

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Colver Power Project, Pennsylvania, USA. Photo courtesy of Inter-Power/AhlCon Partners, L.P.

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Figure 1. 102 MW Colver Power Project`s Pyropower fluidized-bed unit.

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Vetera dam and Colver reservoir, Pennsylvania, USA. Photo courtesy of Inter-Power/AhlCon Partners, L.P.

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Korean Electric Power Corp.`s Taean thermal power plant. Photo courtesy of ABB Inc., USA.

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Editor`s comments:

Although the deadline for submitting entries for consideration for awards in 1997 is many months away, it is not too early to start thinking about entering. Entry forms can be requested by e-mail at douglas@pennwell.com or by calling Connie Carney at (918) 832-9286. You can also use the e-mail address for information on becoming one of our judges.