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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 Africa’s 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 2011/05/13 5 .

2010 2011/05/13 6 .

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 2011/05/13 7 .

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 . 20. 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. 800 MW + n x 3200 MW nuc. Solar) Transmission International 400 100 Arnot upgrade Phase II Gr’tvlei Co-Gen MTPPP 6700 Kwanza Angola 60 Peaker Moz 18.Eskom Capacity Projects Funnel Research Other Known Opportunities Opportunity Screening Prefeasibility Feasibility.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.680 MW 12. 566 MW 4.

each 794 MW) and Kusile (6 Units.Two new Supercritical Power Stations • The first two new Supercritical Fossil fired Power Stations. each 798 MW) are presently in the design and construction phase. Medupi (6 Units. it is therefore of utmost importance that the correct optimized pump configurations and drive options for each of these pumps is selected. • The condensate extraction pumps and boiler feed pumps are amongst the highest consumers of auxiliary electrical power within a power station. 2011/05/13 9 . • Both power stations have Air Cooled Condensers • The Turbine contact was awarded to Alstom and the Boiler contract to Hitachi.

Matimba Power Station 6x660 MW Kendal Power Station 6x680 MW 2011/05/13 10 .

Progress at Medupi Power Station 2011/05/13 11 .

Medupi and Kusile Power Station Condensate Extraction Pump .

• The slow speed and double suction impellers are specifically considered in order to satisfy the NPSH requirements of the pumps. • The pumps are horizontally split casing designs with a double entry suction impeller.Condensate Extraction Pump • All existing Eskom Power Stations utilize a 2 x 100% Condensate Extraction Pump (CEP) configuration. • The older type Power Stations that don’t have any Main Turbine bypass systems utilizes two fixed speed CEP’s with their design point the same as the Turbine Maximum Continuous Rating (TMCR) duty point. 2011/05/13 13 .

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Condensate Extraction Pump • On our newer larger plants with an output of greater than 500MW. 2011/05/13 15 . have Main Turbine Bypass Systems. where the condensers are larger and the pump flow greater.well of the condensers. • All the power stations. the condensate extraction pumps are vertical multistage with the pump element mounted in a suction can which is connected directly to the hot . whose outputs are greater than 500 MW per Unit.

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350 kW 2011/05/13 17 .

Condensate Extraction Pumps for Medupi and Kusile P/S’s Option 1: • 2 x 100 % Vertical Spindle CEP’s –One variable speed –One fixed speed Option 2: • 2 x 100 % Horizontal arrange CEP’s –One variable speed –One fixed speed 2011/05/13 18 .

Condensate Extraction Pumps Horizontal CEP preferred • Simple design • Easier maintenance • Spares holding less 2011/05/13 19 .

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 2011/05/13 20 .

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Medupi and Kusile Boiler Feed Pump Drive Options .

Low Speed VSD E-Motor (with high speed gearbox) 3.Boiler Feed Pump Drive Options • Drive options technically acceptable 1. Fixed Speed Motor & Voith Vorecon 4. Fixed Speed Motor & Voith Hydraulic Coupling 2011/05/13 23 . High Speed VSD E-Motor (with low speed gearbox) 2.

Boiler Feed Pump Drive Booster pump Main pump Filter 2011/05/13 24 .

2 % Booster pump N = 1500 rpm Speed Reduction Gearbox Main pump N = 6000 rpm High Speed VSD Electric Motor Filter 2011/05/13 25 .1. High Speed VSD Electric Motor with Speed Reduction Gearbox BFP set efficiency = 81.

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 2011/05/13 26 .2.

Fixed Speed Electric Motor with Voith Vorecon Planetary Geared Variable Speed Fluid Drive Coupling BFP set efficiency = 77.3.2 % Booster pump N = 1500 rpm Main pump N = 6000 rpm Fixed Speed Electric Motor Voith Vorecon Planetary Geared Variable Speed Fluid Drive Coupling Filter 2011/05/13 27 .

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 2011/05/13 28 .4.

2 *Power Consumption kW 24274.1 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 2011/05/13 29 .9 77.2 70.Efficiencies of BFP Drive Options BFP Set Efficiency % 81.84 28103.2 25520.2 79.8 24685.

\BFP Drive Options vs.\.\..\.\BFP Economic Evaluation. Load Profile rev2.xls 2011/05/13 30 ....xls – Eskom Enterprise Engineering – Steag/Evonic Hybrid Model – .Economic Evaluation • Two models were used – Official Generation EE model – ..

50 186.73 3 2011/05/13 31 .11 4 - 161 186.66 2 - 133 100 1 186.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.

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 % 2011/05/13 Low speed VSD % Vorecon % Voith % 32 .

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 2011/05/13 33 .

SES Meliti P/S 350 MW – Florina Greece 2011/05/13 34 .

Mannheim P/S – 9 MW Vorecon BFP Drive 2011/05/13 35 .

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 2011/05/13 Flow = 354 l/s Temperature = 183 oC Speed = 1482 rpm Weight = 4 500 kg 36 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 2011/05/13 37 .

COMMITMENT ! “If our reference list increase with 36 – 19 MW Vorecons We will just have to make it work! “ – Dr.VOITH 2011/05/13 38 . Juergen Zeschky .

Thank You .