Modernization of thermal power plants in accordance with new requirements is on the agenda of many enterprises in Russia and abroad.

A modern thermal power plants (TPP) must ensure reliable, safe and efficient production of electric energy under changing load conditions.

High level of equipment wear, unacceptable power losses and insufficient automation of TPPs prevent the achievement of these goals.

Leading engineering companies are developing advanced technologies for automation, power regulation, optimization of fuel combustion conditions and much more.

Modernization and expansion of thermal power plant

Currently, European countries have begun to abandon obsolete expansion and modernization thermal power plants that run on fuel oil and coal.

They are being replaced with more sustainable energy facilities using renewable energy sources, including solar photovoltaic power plants and wind power plants.

This creates new challenges for thermal power plants, including the need to operate in strict cyclic modes associated with increased wear and tear of equipment.

Stricter environmental legislation and depletion of fossil fuel reserves are forcing power generating companies to look for engineering solutions to improve energy efficiency and reduce emissions, especially NOx and SOx.

The main goals of thermal power plant expansion and modernization are:

• restoration of the design parameters of process systems;
• significant extension of equipment service life;
• reduction of fuel consumption and minimization of operating costs;
• improvement of environmental performance in accordance with standards;
• improvement of reliability and stability of operation.

Restoration of design parameters is a condition for further electricity production, and compliance with environmental requirements helps to avoid fines.

Depending on the economic situation of the power plant and the possibility of selling electricity and heat, it is desirable to carry out a comprehensive modernization of the facility with the simultaneous implementation of all the above goals.

The most expensive and often controversial goal of modernization is to increase efficiency.

With unchanged cycle parameters (pressure, temperature), turbine modification can be of practical importance: changing the blade profile, replacing seals, etc. Such solutions will increase the turbine efficiency by several percent.

If the goal is achieved with relatively small investments, the benefits are undeniable. However, if we take into account the complex procedure for replacing the rotor, the economic efficiency of the project may decrease. When determining the feasibility of these measures, the actual operating time of the turbine unit should be taken into account.

Currently, the greatest benefits can be achieved with the simultaneous production of electricity and heat. Turbine modernization in this direction does not present serious technical problems, and the economic benefits ensure a quick return on investment.

Natural barriers to this method of  expansion and modernization of thermal power plants in an unsuitable location and posed a limited demand for thermal energy.

An important goal is to extend the service life of expensive equipment. The situation in Russia and the post-Soviet republics is such that the actual service life of many thermal power plant units exceeds the standard resource. Frequent load fluctuations and unscheduled equipment shutdowns complicate the situation.

Modernization and expansion of thermal power plants under EPC / EPCM contracts requires significant investments, but timely and well-planned measures can significantly extend the service life of equipment and improve overall performance.

When developing a TPP modernization program, it is necessary to take into account external and internal factors. They affect the approach and scale of the work performed.

External factors include, first of all, information about the expected economic situation in the national economy and trends in energy demand, the cost of energy, spare parts and equipment.

Internal organizational and technical conditions create a much lower degree of uncertainty and risk. A detailed study of weak points in the system of diagnostic, operational and repair procedures is part of our individual approach to the needs of each customer.

Theoretically, there are two approaches to modernization:

• single-stage , with a complete upgrade of the facility during a long downtime;
• multi-stage , performed during several successive shutdowns.

For economic reasons, and given the uncertainty of forecasts regarding the conditions of production and sale of electricity, in practice the second method may be more relevant.

Specialists will conduct a detailed feasibility study and will always suggest the best solution.

Assessment of technical condition before modernization

Regardless of the initial goals of the customer, the key factor in making an economically sound decision is the assessment of the technical condition of the unit.

This stage requires systematization and analysis of the operation history, as well as comprehensive diagnostic tests and measurements. Particular attention is paid to the condition of critical elements of the power unit (turbine, boiler, electric generator, main steam pipelines, etc.).

Assessment of the technical condition of the TPP power unit is important for predicting the suitability for further operation of critical elements and their reliability. Knowledge of the current state of the metal, the actual geometry of the structural elements, actual operating conditions, and the causes of damage (including an assessment of the possibility of elimination) create the prerequisites for assessing the individual durability of the elements.

Unsatisfactory technical condition of these elements creates significant risks, therefore, it requires urgent measures as part of the modernization / repair program.

If the purpose of the modernization and expansion of thermal power plants is to increase the efficiency of the turbine, measurements should be taken to prepare a heat balance of its individual elements before starting work.

Experience shows that the most difficult stage of assessing the technical condition of a TPP power unit is the analysis of retrospective data. Preparation of the final forecast also requires significant technical knowledge and experience.

The most important is the correct assessment of the current state of the metal, which requires a detailed analysis of the equipment design and its operating conditions.

The location of the research and measurements should correspond to the location of the actual damage/wear zones. This provides the most complete picture.

Plans for modernization and service life extension of individual elements of the power unit should correspond to the capabilities of the power plant and the needs of the enterprise. The result of the technical assessment and economic analysis serves as the basis for choosing the modernization method and assessing the correctness of the adopted procedure.

Modernization should be applied to those elements and structural units that economically justify these expensive measures.

Modernization of power boilers of thermal power plants

Increasing the energy efficiency of thermal power plants usually includes upgrading power boilers, in particular, installing modern burner devices, shut-off valves and automation. As part of the upgrade, it is possible to change the burner capacity. Specialists provide a full range of engineering and technical services related to upgrading power boilers of thermal power plants.

The current state of many power units of thermal power plants in Russia and other republics of the former USSR is characterized by complete physical wear and tear and requires new technical solutions. The individual approach of our engineers ensures increased safety and efficiency of operation of steam boilers of old series.

As a result of installing modern burners and automation, fuel consumption is reduced, atmospheric emissions from thermal power plants are reduced, operating conditions are optimized and the operating parameters of boilers are adjusted more smoothly.

Modernization of thermal power plant generators

Increasing the efficiency and profitability of thermal power plants is directly related to the operation of electric generators.

The engineering company provides comprehensive services in the field of generator modernization, including design, procurement and installation of new equipment, as well as testing and commissioning. Based on our many years of experience, the optimal solution for the modernization of such facilities is EPC / EPCM contracts.

Strict environmental legislation, changes in the electricity market and operating conditions of thermal power plant units dictate new requirements for the operation of generators. Engineers will help prepare your facility for the challenges of the future.

Specialists develop new technologies in the energy sector and integrate modern technical solutions with existing facilities.

GATE LINK CAPITAL LP priorities are your economic interests, sustainability, efficiency and safety.

Thanks to innovative technologies, customers improve the performance and expansion of thermal power plants, increase maintenance intervals, reduce atmospheric emissions and make maintenance more flexible and convenient.

Together with our partners, we offer a wide range of options for the modernization and expansion of thermal power plants generators, focused on the specific needs of your business. Contact our consultants to learn more about services in this area.

Wireless technologies and systems for monitoring thermal power plants

Currently, most of the maintenance and operation of thermal power plants is done manually.

Businesses lose precious energy and risk unscheduled equipment shutdowns due to breakdowns. Atmospheric emissions do not always meet standards, and steam energy is wasted due to leaks.

Smart power plants of the future are based on automated monitoring systems that keep equipment in excellent condition with minimal intervention by maintenance personnel. Wireless sensors and computers detect problems at an early stage, increasing the reliability of the facility.

To facilitate the work of maintenance teams, the company offers innovative solutions for the modernization and expansion of thermal power plants under EPC contracts. These technologies will be in high demand at facilities that operate under load fluctuations caused by the spread of renewable energy.

Cyclic operation with frequent stops and starts creates unfavorable operating conditions for equipment and accelerates its wear by 1.5-2.5 times. This requires more thorough monitoring of the condition of units and technical maintenance.

Unfortunately, not all equipment at thermal power plants has protection systems. To monitor the condition of cooling towers, pumps, coolers and other equipment, random manual checks are carried out periodically.

Wireless technologies replace labor-intensive manual operations and increase the efficiency of monitoring. Thanks to wireless sensors, engineers can monitor all TPP equipment from the control room.

One of such innovative solutions is a wireless vibration sensor, which is mounted on rotating equipment for continuous monitoring of its condition.

Along with vibration sensors, modern TPPs use more complex multi-parameter monitoring systems that cover several system indicators. The implementation of such systems ensures continuous monitoring of liquid flow, temperature, pressure, conductivity and other important parameters.

Multi-parameter monitoring systems help prevent malfunctions and save hundreds of thousands of dollars on unscheduled shutdowns and equipment repairs.

Our company’s engineers develop individual technical solutions for automation and monitoring for thermal power plants under EPC / EPCM contracts. As our clients’ experience shows, these investments pay off quite quickly.

Comprehensive probing of TPP operating parameters helps to increase thermal efficiency. This is the most important step towards energy efficiency.

Control and monitoring systems are transforming the energy industry.

Old power plants can be easily upgraded by deploying these systems to improve the reliability, safety and energy efficiency of the facility.

Our services for modernization and maintenance of thermal power plants

By using innovative solutions and technical support in turnkey contracts, we and our partners offer investors the most attractive thermal power plant modernization projects.

We manage all aspects of thermal power plant projects, from feasibility study to financing, implementation and restart, as well as other activities during the project.

Detailed planning is the key to a successful modernization.

We provide customers with full support from the very beginning, using a comprehensive approach to design and engineering work and paying special attention to economic aspects.

After the project is completed, an experienced technical support team maintains stable operation of power facilities and reduces downtime to a minimum. We and our partners have modern technologies and knowledge to effectively and safely manage thermal power plants throughout their entire life cycle.

Our skills and methods allow us to anticipate and avoid problems, identifying vulnerabilities long before potential failures in the power plant.

A wide range of services for financing, design, modernization and maintenance of equipment allows our customers to optimize the operating parameters and increase the service life of thermal power plants and equipment.

We provide a full range of services in the energy industry.

For more information on TPP modernization, please contact our consultants.

GATE LINK CAPITAL LP
E-MAIL: credit@gatelinkcapitallp.com
Website: https://gatelinkcapital.com/