Introduction to the Symbolic Projects Completed by Nanguang Power
Author:Nanguang Power Source from:Nanguang Power1729

Founded on October 8, 1991, Shenzhen Nanguang Power Co., Ltd. is a well-established Sino-foreign joint venture located in Shenzhen SEZ (Special Economic Zone), China’s exemplary show-window exhibiting its open-up experiments.
Its main business scope covers such areas as equipment installation, commissioning, modification, inspection and overhauling for gas turbine and steam turbine power stations.

 

Our company carried on installation, commissioning, transformation and overhauling for a number of steam turbine power units, packaged contracted about turnkey projects for power stations in our capability of packaged contract for thermal power units under 125 MW, and supplied spares and their accessories necessary for installation and repair of gas turbine gensets.

 

Our company possesses professional teams of installation and overhauling, who are experienced in practices and capable in tech strength. Our technical personnel and professional workers are involved in all aspects, including main and accessory equipments and their control systems (MARK I, MARK II, MARK IV and MARK V), generator and its control and excitation systems, as well as installation, transformation, commissioning, overhauling, operation guarantee, maintenance and training of gas turbine power units, and they make outstanding achievements in conversion of gas turbine’s fuel system, and installation, overhauling and commissioning for GE series units, as well as removal and transformation for old type gas turbines.

 

As a backbone of our company, NTC is the only one industrial base for manufacturing heavy gas turbine power units in China besides production of various levels of steam turbine power units and big and light motors, and moreover, the jumbo enterprise, integrating technology and research, design, manufacturing, installation and commissioning into one entity, also imports technologies of MS6000 gas turbines in whole set from GE. Our company carried on installation, commissioning and operation guarantee projects for a number of steam turbine power units, and MS6000 and MS9000 gas turbine power units manufactured by NTC.

 

As a sole distributor for GE’s gas turbine spare parts in China, our company can provide customers with gas turbine spare parts at a favorable price. The spare parts surrogated to import by our company occupy more than 80% of total imported gas turbine spares in China. Besides, we can also supply hone made bolts & nuts, seals for unit installation, and other accessory spares.

 

Please see below for the introduction to the symbolic projects in several aspects carried on by our company:

 

1. Installation and overhauling project for 9E gas turbine

 

Suzhou Blue Sky Gas Co-Gen Power Co., Ltd., occupying 85 thousand square meters in area, is an environment-friendly and energy-saving enterprise mainly supplying heat and power, located in scenery-picturesque Suzhou Sino-Singapore Industrial Park, east to Jinji Lake and north to Wusong River. The company is jointly invested by Golden Concord, Suzhou Industrial Park Municipal & Public Development Group Co., Ltd., Suzhou Suxin Assets and Investment Co., Ltd., and Sino-Singapore Suzhou Industrial Park Ventures Co., Ltd. The company newly assembled two sets of 9E combined cycle gas turbine power units that can adopt natural gas as fuel and supply heat and power in combination. As one of important constructions in Suzhou, the project includes two units of GE 9E gas turbines, and the investment for the first phase of the project exceeded one billion RMB Yuan while installed capacity was 360 MW. Our company carried on installation for the two 9E gas turbine power units in the project.

 

We attached much importance to the project. Prior to initiation of the project, we digested the relevant technical data from GE and design institute, mobilized capable installation team, made scrupulous plan of construction and timing schedule. During the construction, leaders of our company paid visit to the site for direction, supervision and arrangement. With the support and assistance from the enterprises such as Suzhou Blue Sky Gas Co-Gen Power Co., Ltd. and Jiangsu No.1 Power Construction Company, all our personnel overcame difficulties, minded about safety, assured quality, and ensured the completion of the project in due time.

 

The project installation started from May 08. And at 16:18 hours on Sep. 08, 2005, the first turbine was connected to the grid with a successful power generation; while the second turbine made a one-time success for connection into the grid at 22:18 hours on Oct. 27, 2005.

 

Then, we signed and completed an installation contract with Shenzhen Meishi Power Plant for two sets of China-made 9E gas turbine power units manufactured by NTC.

 

For a number of times, our company has carried on overhauling, intermediate overhauling, minor repair and emergency overhauling for 9E gas turbines owned by Suzhou Blue Sky Gas Co-Gen Power Co., Ltd., Shenzhen Fuhuade Electric Power Co., Ltd. and Shenzhen Bao Chang Power Supply Co., Ltd.

 

2. Conversion project from oil to natural gas for gas turbine power plants

 

Since 1998, our company has been carrying out conversion projects from oil to natural gas for MS5000 gas turbines. For several years we have successfully implemented conversion projects from oil to natural gas for 10 GT units, accumulating profuse experience, and forming technical priority.

 

Jingbian Gas Power Plant in northern Shaanxi Province purchased two sets of old type PG5301N gas turbine gensets from Beijing No.1 Thermal Power Plant with the aim of constructing Changqing Gas Turbine Power Plant in Maowusu Desert. Our company carried on the projects of removal and conversion from oil to natural gas. Sichuan Yinghui Natural Gas Power Co., Ltd. purchased 3 sets of PG5361 gas turbine units from Xiamen Gas Turbine Power Plant. Among the turbine units, 2 were removed to Jiangyou, and the last one was removed to Wutongqiao of Leshan, and the units would be converted from oil to natural gas user. Winning a tender for the projects, our company was rewarded a packaged contract about dismantling, encasement and transportation for all equipments in Xiamen Power Plant, installation and overhauling for 3 GT gensets, as well as conversion from oil to natural gas and the corresponding commissioning and 72-hour test-run.

 

Suzhou Coastal Cogeneration Power Co., Ltd. is a Sino-American joint venture power enterprise, which owns 2 sets of S106B gas-steam combined cycle power installations (2 units of PG6551B gas turbines and 2 units of condensing steam turbines) with the installed capacity 10 MW mainly used as peak shaving. Since put into production in 1997, the power plant has always using the light diesel, but with the rocketing international oil prices, the cost of power generation turned to higher and higher for the recent years. In order to reduce the cost of power generation, increase economic benefits for power plant, and completely solve the pollution affecting the ambient environment around the plant, through reasoning in varied aspects, the plant decided to convert the gas turbine unit from oil to natural gas user, which would consume the natural gas transferred by 0.4 MPa town gas pipeline network of Suzhou Natural Gas Network Co., Ltd. For a rapid and excellent completion of the project, Shenzhen Coastal, through considerations on varied factors, eventually chose our company as a packaged contractor of the conversion project.

 

According to the contract signed on Jul. 12, 2004, after conversion the gas turbine power unit not only can burn natural gas and light diesel respectively, but also burn mixed fuel light diesel/natural gas, and can implement online fuel shift during operation, smooth transition, and sufficiently satisfy the requirements on the security of the equipment economical operation and fire fighting. The conversion project included: design of the relevant equipments and construction drawings, correction and commissioning of gas turbine software and hardware, purchase and set assembly of installations, installation of equipments involved in the project, construction of the conversion project, test & commissioning for systems and the whole unit after conversion. On Dec. 8, 2004, the conversion project from oil to natural gas was completed successfully, and passed through 108-hour of test-run in the grid. Until then, the two units of gas turbines could use the natural gas transferred by the lines of the Project of Natural Gas Transferring West to East from Tarim Basin in Xinjiang.

 

The conversion project from oil to natural gas for the gas turbines in Suzhou Coastal was the first item of conversion for power plant since the completion of the Project of Natural Gas Transferring West to East, which not only sets an example and enlightens the power enterprises along the line of the Project of Natural Gas Transferring West to East, but also indicates the initiation of conversion for gas turbines in power plants in east and south China. Then, by seizing this opportunity and making an efficient use of natural gas the valuable resource, our company carried on and completed the conversion projects from oil to natural gas for 6B gas turbines in Zhuhai Hongwan, Ningbo Fengke, Changzhou Suyuan and Shenzhen Bao Chang in succession.

 

3. Uprating and conversion projects for systems

 

Our company has priority in conversion and commissioning of turbine control system.

 

As early as 1996, we successfully completed the uprating of a repaired MARK II control panel to MARK V control panel for Liuzhou Zhenxing Power Co., Ltd.

 

On Jun. 10, 2005, we successfully completed the “Uprating Project of MARK VI Control Panel” in Jinxi Natural Gas Chemical Co., Ltd. In the project, GE supplied the most advanced MARK VI Speedtronic control system, and under GE’s direction, Nanguang Power assisted to implement the site installation and adjustment. The gas turbine unit owned by Jinxi Natural Gas Chemical Co., Ltd. is a 5001R type made by Alstom, and its original control panel is MARK IV of GE. The uprating of control system is the first conversion project of MARK VI for the domestic owners, which is much meaningful for great batches of control panel uprating in the future.

 

4. Removal and conversion from oil to natural gas for old type turbines of gas turbine power plants

 

In 1998 Jingbian Natural Gas Power Plant in the northern Shaanxi Province purchased two sets of second-hand PG5301N gas turbine power units from Beijing No.1 Thermal Power Plant with the aim of constructing Changqing Gas Turbine Power Plant in Maowusu Desert. The 2 sets of units were made by Hitachi in the 1970s, and their control system was MK I while fuel system used heavy oil singly. As a northwestern province in China, Shaanxi is profuse in reserves of natural gas, the power plant decided to convert the units to natural gas user. Overcoming difficulties of missing files and incomplete equipments, our company carried on installation, overhauling, commissioning, and conversion of fuel system and its control system (MK I control panel) from oil to natural gas user, as well as performance test and 1-year operation guarantee. Our company completed all the work in the project, including conversion design, choice of spares types, surrogate for imported spares and production of domestic parts, assembly of special parts, site construction and handover after completion. The units were put into production in Aug. 1999, and in Aug. 2000, the operation guarantee expired, when all the indexes reached or exceeded set values. With excellent service, our company won favorable comments and trusts from the power plant, and so far we’ve been keeping delightful cooperation with each other.

 

In 2001 Sichuan Yinghui Natural Gas Power Co., Ltd. purchased 3 sets of PG5361 GT gensets from Xiamen Gas Turbine Power Plant, 2 of which were removed to Jiangyou and one was removed Wutongqiao of Leshan, and all of the power units were converted from oil to natural gas user. As a successful bidder, our company won the general contract about dismantling, encasement and transportation for all equipments in Xiamen Power Plant, and installation, overhauling as well as conversion for the 3 GT gensets in fuel system and its control system (MK II control panel and remote control installation) from oil to natural gas user, and commissioning and 72-hour of test-run for the conversion. Before dismantling of power units and during 72-hour of test run after conversion, performance test was implemented, resulting in the fact that all the indexes were outstandingly improved. All the work, from conversion design, choice of imported spares, surrogate for importing spares and production of home-made spare parts, assembly of special parts and site construction, systematic theory and practice training to handover after completion, were implemented by our company. Since 2001 when the power units were put into production, they were reliable in operation state, and therefore, the whole projects received favorable comments from the owner.

 

5. Repair and control panel uprating for gas turbine power units in the power plant in Liuzhou

 

On Jul. 19, 1996, Liuzhou suffered an extremely severe calamity of flood, and Gas Turbine Power Plant of Liuzhou Zhenxing Power Co., Ltd. was harshly stricken. A set of PG5361 gas turbine power unit and the MK II control panel, control system and excitation of generator, MCC, and rechargers were damaged by flood immersion, and flood water depth even reached horizontal joint while many other equipments were immersed in water. Required by the municipal govenment of Liuzhou, the power plant must regain power generation to satisfy the urgent needs of peak power consumption in the city. Entrusted by Liuzhou Zhenxing, our company not only dispatched professionals, but also invited GE’s representative to the stricken power plant, discussing repair plan altogether. Considering everything for customer and hurrying up for customer’s urgent needs, we came to agreement with Liuzhou Zhenxing at once, entirely carrying on the repair project for the gas turbine power unit damaged by flood immersion, so as to ensure fastest renewal of power plant’s connection into grid and power generation as required by the municipal government Liuzhou. For the following year, our company imported spare parts from GE and implemented site installation and commissioning for Liuzhou Zhenxing again, successfully uprating MK II control panel to MK V control panel.

 

6. Conversion project for heavy oil treatment in gas turbine power plants

 

In the past, heavy oil treatment system in gas turbine only adopted the treatment equipment in centrifugal separation type in our country, which was mainly imported from Alfa Laval. In 1999, a set of electrostatic oil treatment equipment, imported from PETROLITE of Germany in 1989 but left unused for a long time, was successfully installed on a PG6541 gas turbine of Ningbo Shunlong Fengshan Thermal Power Co., Ltd. by our company. After treatment, the flow of heavy oil as well as the oil quality can entirely conform to requirements of an MS5000 gas turbine. Through several years of operation, the power plant has obtained rich benefits from the treatment. The first success of the adoption of electrostatic oil treatment equipment in heavy oil treatment for gas turbine broke through the exclusive priority of centrifugal oil treatment equipment, introducing one more option for the endusers, and promoting substantial reduction of import price of heavy oil treatment equipment for gas turbine.

 

In Jun. 2000, entrusted by Shenzhen Yueliangwan Gas Turbine Power Plant for a 9E gas turbine heavy oil treatment, our company imported a set of PETROLITE electrostatic heavy oil treatment equipment with treatment capability of 50 cubic meters per hour, and in good operational state. In Nov. 2001, from PETROLITE we also imported electrostatic desalters for petroleum chemical plants in Tehran, Iran and Naples, Italy, two construction projects contracted by CPCC Construction Co. Ltd.

 

7. Transformation project for gas turbine fluel

 

For heat preservation, at present the most measurement is Outer Heat Preservation, which is lower in cost and convenient in construction. The Outer Heat Preservation, however, has many defects, such as direct heat effect to flue body, cracks and rusts easy to happen, hard inspection for cracks, difficult overhauling and short overhauling duration.

 

At the end of 1997, our company carried on the overhauling project for #2 turbine unit in Shenzhen Meishi Power Plant. The turbine unit is PG5341 type in combined cycle operation, made by John Brown, and through many years of operation, its exhaust chamber and exhaust flue were severely damaged. There were a number of wear & tear on the flue body, of which, the longest one was 1.5 meters in length, so a great volume of gas leaked, not only causing hazard but also affecting the efficiency of combined cycle. Through lots of overhauling though, the problem could not be solved basically, and the power plant had to implement yearly overhauling by 3-4 times of replacement of expansion joint and flue body, directly spending about 500 thousand RMB Yuan each year. Researching, discussing and reasoning with the owner for many times, our company put forward the transformation plan as “dismantling of mufflers, replacement of outer heat preservation with inner heat preservation, enhancement of gas turbine output, saving cost of repair and ensuring safe operation”. After the transformation, leakage of gas was eliminated, and both gas outlet temperature and boiler’s gas inlet temperature achieved instructions and requirements of combined cycle, and the operational state was good. Since the completion of the project, so far flue deformation or gas leakage by torn flue body has not occurred, and because of the safety enhancement, expansion of flue’s life span, convenience of overhauling, and saving cost and increasing turbine output, our achievements were welcomed by the power plant.

 

8. Upgrade project of 3-D technology for steam turbine

 

The worldwide technical developments of steam turbine, since the 1970 have stepped into the third generation, namely, the application of full 3-D design concept mainly with aerodynamics as calculation measurement, and the outstanding symbolic example of the technology is Bowed-Twisted Blade in integrated molding, which can enhance efficiency of steam turbine. At present, in the world most manufacturers of heavy gas turbines, such as Mitsubishi, ABB, GE, Westinghouse, Hitachi, Siemens, Alstom, and the turbine industry in China, are energetically researching and developing new generation of steam turbine with Bowed-Twisted Blades, and some enterprises have put their research into operation. Test results issued by the leading companies of steam turbines worldwide indicated that only by one measurement of adopting full 3-D Bowed-Twisted Blade, efficiency of steam turbine can boost by 1.5-2% or even more. Besides the new technology, contributed by other mature and advanced technologies, such as new type of blade pattern in high efficiency, optimized meridian flow passage section and enthalpy drop distribution in each stage (velocity ratio) and new types of steam seal and surrounding strap, efficiency of steam turbine will be improved further. Proved by facts, the new generation of steam turbine typically modeled by full 3-D Bowed-Twisted Blades has turned into the commanding point of steam turbine industry in the current world, which, if coming true, will push the manufacturing industry of steam turbine onto a new height.

 

The N15-3.43 turbine owned by Shenzhen Jingang Power Co., Ltd. was a single casing, impulse and condensing steam turbine made by NTC, and the design of its flow passage was only as old as the tech level in the 1950s-1960s, and therefore, the thermal performance and efficiency were lower. In order to improve the performance and efficiency of the turbine unit, in May 2001, entrusted by Shenzhen Jingang Power Plant, Beijing Full 3-D Dynamic Engineering Co., Ltd. designed and our company cooperating with NTC implemented upgrade and site installation for the turbine unit.

 

In the modernized the upgrade for the flow passage, all the rotor and stator blades were replaced, and in updated diaphragms and rotors, we also adopted a number of most advanced technologies in the steam turbine industry.

 

As the first full 3-D upgrade for an old type turbine unit, NTC attached much importance to the project, and their general engineer participated to manage the project himself. With full wing cooperation from the site representative of Beijing Full 3-D Dynamic Engineering, it only took two and half months to complete the procession for all converted parts of the turbine, and then, our company dispatched our most excellent personnel to the site for installation, who spent only 13 days to complete the project and made a successful one-time start. According to Jingang Power Plant’s statistics, after the upgrade the efficiency of full load of the turbine enhances by 6.5%, and the investment can be returned only for about one year of operation, so the benefits are outstandingly worthy.

 

Among the same type of steam turbines, the turbine in Jingang Power Plant is the first unit to be implemented full 3-D technical conversion in our country, and also, it is the first unit that NTC applied the full 3-D technology on manufacturing and conversion, and is the first unit carried on by our company in that type of conversion. Success of the conversion changed the mind of no outstanding profit brought about by the application of full 3-D technology on small type turbine. Witnessed by practices, the turbine unit after conversion can be outstandingly profitable, worthy of popularizing among the same type of turbines in our country.

 

9. Installation and commissioning for steam-gas combined cycle

 

Gas turbine can operate in single cycle and combined cycle. In single cycle operation, high temperature exhaust of turbine is released to the air. In combined cycle operation, high temperature exhaust of turbine is pooled into recovery boiler to be utilized to produce steam, which can run steam turbine to generate power again. Gas/steam united cycle power stations have the following advantages:

 

1.       High heating efficiency. In combined cycle with 55 MW of installed capacity, heating efficiency can reach 45%

2.       Short construction period and rapid favorable effect by return.

3.       Flexible operation.

4.       Less pollution to the environment.

5.       Less area occupied. In a gas/steam combined cycle power station with 55 MW of installed capacity, only 40 thousand square meters in area are occupied (200m×200m).

6.       Less staff required. In a gas/steam combined cycle power station with 55 MW of installed capacity, only 80 operation persons are required..

7.       Rapid startup and shutdown of turbine. Gas turbine takes 15 min from start to full load, and on steam turbine it only takes less than 1 hour for re-start.

8.       Cost-effective. Unit construction cost (each kW) of a combined cycle power station with 55 MW of installed capacity is 4,000 RMB Yuan.

 

In 1991, according to the technical parameters of 2 imported gas turbines of Shenzhen Futian Gas Turbine Power Plant, our company chose to supply 2 sets of steam turbine units made by NTC to form two sets of gas/steam combined cycle. One of the steam turbines were applied to FT-8 gas turbine made by Pratt & Whitney, while the other was applied to GE’s LM2500 gas turbine (shortly as One on One). As the earliest gas/steam combined cycle power station equipping home-made steam turbines in China, it has been operating in a good condition since 1992 when the station was put into operation. Since then Shenzhen Futian Gas Turbine Power Plant has made a Zero breakthrough of using home-made steam turbine unit in gas/steam combined cycle power station.

 

In 1995, our company provided Shenzhen Nanshan Power Station Co., Ltd. with a set of steam turbine receiving steam from 2 sets of MS6001B gas turbines to form combined cycle (shortly as  Two on One).

 

In 2000, we provided Shenzhen Meishi Power Plant with a steam turbine unit for combined cycle, and carried on packaged contract about installation and commissioning for the steam turbine, achieving a successful one-time connection to the grid.

 

Practices witness that by single cycle, efficiency of gas turbine is 32% or so, but when by combined cycle, efficiency of gas turbine can reach about 45%, and even exceed 50% max. Therefore, combined cycle turbine unit has turned to the mainstream in power generation market in the future, and moreover, home-made steam turbine unit can be favored with popularization.

 

10.   Test on the thermal performance of gas turbine unit and gas/steam combined cycle power equipments

 

In the first stage of construction project of combined cycle power plant affiliated to Jinhua Gas Turbine Power Co., Ltd., installation of 2 sets of PG6551B GT units made by Alstom, 2 recovery boilers made by Hangzhou Boiler and 2 sets of ST units made by NTC implemented to form 2×S610B combined cycle power system. Entrusted by the owner, we carried on the completion of test duty on the thermal performance of gas turbines and combined cycle main equipments, for check and acceptance program.

 

Test was separated into 2 stages. Stage

Stage One: test on gas turbine’s performance after installation and commissioning of single cycle gas turbine units

Stage Two: test on combined cycle power equipments.

 

Accepting the missions, our company mobilized the qualified technicians in test duty to implement the first phase work – implemented test on the thermal performance of single cycle gas turbine power units with the test representatives from Alstom, simultaneously and respectively. We put forward correction suggestion on calculation formula offered by Alstom, who accepted our suggestion later. With the data got through respective tests and arrangement by both sides, the results coincided to each other basically, successfully passing through the test on the thermal performance.

 

In the second phase, our company solely implemented performance test on the combined cycle main equipments (including gas turbine power units, recovery boilers, steam turbine power units and etc.), offering satisfactory test results to the owner.

translated by wang yifei

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