December 2022, Issue 12 (822)
TABLE OF CONTENTS
Arkadiusz Dobrzycki, Władysław Opydo, Sebastian Zakrzewski
Influence of additional dielectric coatings on parametres of a high-voltage gas insulation system
POWER ENGINEERING AND ECOLOGY
Mirosław Nowak, Szymon Ptak
Fire safety analysis of a landfill of biomass to be used for energy generation purposes
BULLETIN OF IASE
Tadeusz Mączka, Bartłomiej Borkowski, Michał Ostrycharczyk, Halina Pawlak-Kruczek
Induction reactor for the thermal conversion of organic materials to syngas
Antonina Kieleczawa, Michał Białecki, Radosław Izakiewicz, Piotr Pietras, Roman Skakowski, Wojciech Szubert
Some modern and optimised functions and modules of the DCS MASTER-Proster operator system
Roman Skakowski, Dariusz Wojtanowicz, Jerzy Drutko, Wojciech Szubert, Edward Ziaja, Antonina Kieleczawa, Michał Białecki
Implementation of new standards of LFC system Local Nodes for hydropower and conventional power plants realised in IASE Sp. z o.o. systems
BULLETIN OF PRO NOVUM
Jerzy Trzeszczyński
Project Power Units 2025+. Assumpions for the strategy for continuing the operation of 200 MW class power units.
Selected issues
Jerzy Trzeszczyński, Paweł Galbarczyk, Wojciech Murzynowski, Radosław Stanek, Marcin Hatłas, Mateusz Kusibab, Paweł Zając
Improving the flexibility of 200 MW class units by using capabilities and reserves of the control-side as well as remaining life
Marcin Hatłas, Wojciech Murzynowski, Jerzy Trzeszczyński
The parametric digital twins as a source of information and knowledge ensuring the safe operation of equipment and installations of power unit
Agnieszka Trzeba-Tobolska, Sławomir Rajca
Diagnostics and repairs ensuring failure-free operation of turbine sets at Zakład Elektrociepłowni PKN ORLEN S.A.
Roman Michał Wojciechowski, Jerzy Trzeszczyński, Wojciech Murzynowski
Examples of implementation of diagnostic supervision on the BC 50 power unit
Cezary Kolan, Krzysztof Brunné, Adrian Sobczyszyn, Stanisław Noworyta, Adam Szczepek, Dariusz Gała
The use of metallographic tests in the diagnostics of elements operating under creep conditions
Sławomir Rajca, Sebastian Pośpiech, Adam Dragon
Diagnostics supporting the repairs and operation of steam turbines
Marcin Kijowski, Bartosz Borcz, Mateusz Nowak
Feedwater pipelines – an ugly duckling of conventional energy
Marcin Kijowski, Radosław Stanek, Mateusz Nowak
Diagnostic supervision of steam pipelines in the remote mode in order to optimize the scope, time and costs of diagnostics
II/XXIV Symposium DIAGNOSTICS OF POWER EQUIPMENT AND INDUSTRIAL INSTALLATIONS
Safety and availability of power units and equipment during the transformation of the Polish power sector (I)
OVERTIME LECTURE…
Bogumił Dudek
The numbers don’t lie
SUMMARIES
Arkadiusz Dobrzycki, Władysław Opydo, Sebastian Zakrzewski
Influence of additional dielectric coatings on parametres of a high-voltage gas insulation system
Described is the influence of the presence of additional dielectric coatings placed on surfaces of electrodes in a high-voltage GIS insulation system on the electric strength and wnz (partial discharges) intensity. Conducted tests show that application of additional insulation coatings significantly increased strength of the tested samples. Thus, the application of additional dielectric coatings on the electrodes’ surfaces should be considered as a purposeful action to improve the work parameters i.e. the increase in the electric strength and reduction in wnz intensity in the insulation system.
Keywords: high-voltage GIS insulation system, dielectric coatings of electrodes, electric strength increase
Mirosław Nowak, Szymon Ptak
Fire safety analysis of a landfill of biomass to be used for energy generation purposes
Described are selected issues related to the use of biomass for energy generation purposes in power plants. Particular attention is paid to the process of self-heating which often occurs in biomass heaps and is mainly caused by biological and chemical processes taking place inside them. Described is, based on a selected example, a system of thermal imaging cameras monitoring the stored biomass. Given is the principle of the system operation and the obtained data are analysed and then compared with meteorological data and the results of manual temperature measurements at selected points. Presented is the potential of the monitoring system, the possibilities of qualitative and quantitative data analysis and indicated are potential directions of further research.
Keywords: biomass, fire hazard, fire alarm system
Tadeusz Mączka, Bartłomiej Borkowski, Michał Ostrycharczyk, Halina Pawlak-Kruczek
Induction reactor for the thermal conversion of organic materials to syngas
Sewage sludge is a residue of wastewater processing, and consists of high moisture content which should be decreased before gasification from the fuel, to obtain valuable synthetic gas. In Poland the interest is strengthened by the fact that since 1st of January 2016 it is not allowed to landfill stabilized sewage sludge with a heating value exceeding 6 MJ/kg. Since sewage sludge contains significant amounts of inorganics, on dry basis, thermal processing at high temperatures becomes increasingly interesting. The paper presents the results of conceptual design of gasification reactor with induction heating where the gasification process under high temperature of dry sewage sludge could be obtained. Also temperature parameter in the reactor measurement were performed in a prototype induction heating batch reactor where there is perspective of the state of the art of high temperature reactors for conversion of sewage sludge into combustible gas. Set-up induction reactor is consisted of graphite crucible, high frequency (about 80 kHz) power source – power regulation up to 4.5 kVA, induction coil, thermal insulation, feeding system of sewage sludge and delivering of CO2.
Keywords: sewage sludge, gasification, induction reactor, pyrolysis, syngas
Antonina Kieleczawa, Michał Białecki, Radosław Izakiewicz, Piotr Pietras, Roman Skakowski, Wojciech Szubert
Some modern and optimised functions and modules of the DCS MASTER-Proster operator system
The Polish automation system of a current name DCS MASTER has been developed in our Institute for over 40 years by many generations of engineers-technologists, IT specialists and mathematicians. Presented are here novelties concerning the development of Master automation system referring to operator stations i.a. in the range of a user interface functionality, modules for extended operation of object incidents, system access authorisation, implementation of filters making the analysis of various system data resources easier as well as methods to switch the operator and engineer stations into the archival measurements visualisation mode. Moreover, described is the so-called “push through actions log” storing informations connected with implemenation of temporary changes in DCS MASTER controllers logic operation and their influence on operation of an object devices.
Keywords: automation systems, operator stations, user interface, object incidents, login module, measurements archives
Roman Skakowski, Dariusz Wojtanowicz, Jerzy Drutko, Wojciech Szubert, Edward Ziaja, Antonina Kieleczawa, Michał Białecki
Implementation of new standards of LFC system Local Nodes for hydropower and conventional power plants realised in IASE Sp. z o.o. systems
Presented is the general structure and functions of a new, automatic load frequency control LFC system related to the Central Node (CN) and Local Nodes (LNs) as well as the contribution of the Instytut Automatyki Systemów Energetycznych Sp. z o.o. into realization of the Local Nodes IT system. In this system, developed in the Institute and being introduced gradually in hydropower and conventional power plants, implemented are the latest existing PSE S.A. standards for LFC Local Nodes. The elaborated in the Institute system for LFC LNs enables generation of energy in LNs power plants according to plans, control and regulation from the LFC Central Node.
Keywords: LFC, ARCM, LFC/SMPP Central Node, LFC Local Node, LFC LNs IT system, LFC standards
Jerzy Trzeszczyński
Project Power Units 2025+. Assumpions for the strategy for continuing the operation of 200 MW class power units.
Selected issues
Continuation of the operation of 200 MW class power units currently has no rational alternative. It gives hope to cover the projected negative power balance in the Polish power system after 2025 and may ensure a significant increase in generation from renewable sources, which will be safe for the National Power System. Meeting this challenge requires an urgent development of a strategy for the operation of 200 MW units, including in particular maintaining the technical condition at a level ensuring safety and availability, taking into account the increasingly regulatory nature of their operation, in the perspective of around 2035, as well as financing these units, after the introduction of ETS 550 fees and the expiry of support from the Capacity Market.
Keywords: Project Power Units 2025+, 200 MW class power units, operation strategy
Jerzy Trzeszczyński, Paweł Galbarczyk, Wojciech Murzynowski, Radosław Stanek, Marcin Hatłas, Mateusz Kusibab, Paweł Zając
Improving the flexibility of 200 MW class units by using capabilities and reserves of the control-side as well as remaining life
The acquired knowledge and experience moved Pro Novum to develop a Method, the main advantages of which are universality and low implementation costs, which means that it can be implemented with an economic benefit even on units whose further operation may be relatively short due to failure to meet all emission requirements and no benefits from the Power Market as well as special system services. The article presents the genesis, basic assumptions, implementation conditions, functional description and advantages of the Pro Novum Method.
Keywords: Pro Novum Method, 200 MW class power units, universality, low implementation cost
Marcin Hatłas, Wojciech Murzynowski, Jerzy Trzeszczyński
The parametric digital twins as a source of information and knowledge ensuring the safe operation of equipment and installations of power unit
The critical components and other equipment of a power unit are subjected to variable thermal and mechanical loads. The loads cause variable stress state in components which influences their damage due to thermomechanical fatigue and creep. By the application of numerical simulation (FEM), it is possible to determine the stress state and displacements of the critical components. The obtained computation results allow to find the most stressed locations and to estimate changes in the components durability. The numerical models can be transformed to the reduced order models, which reflect the behavior of the FEM model, significantly reducing the computational cost and enable the analysis of stress state in real time and for simulated operation conditions. The application of PROM also allows implementing test and repair plans based on the analysis of the work and actual load of the components. In this paper an example of the approach to assessing the durability of critical components with the application of PMOR will be presented.
Keywords: parametric digital twins, numerical simulation (FEM), operation of power unit equipment
Agnieszka Trzeba-Tobolska, Sławomir Rajca
Diagnostics and repairs ensuring failure-free operation of turbine sets at Zakład Elektrociepłowni PKN ORLEN S.A.
The nature of the operation of turbine sets installed at the PKN ORLEN S.A. Heat and Power Plant that is, producing technological steam with specific parameters makes the requirements for high reliability and availability a very high priority. Pro Novum diagnostics performed for over 30 years and many years of cooperation with ORLEN Serwis S.A. prove that such high requirements can be met with the use of specialists with the highest qualifications and the use of renovation technologies ensuring the restoration of the original functional features by means of repair, regeneration and revitalization, especially of cast steel turbine elements. In order to meet such requirements, when performing diagnostics, we combine classic, proven diagnostic methods with advanced analytical methods and selected methods of remote diagnostics. We pay special attention to retrospectives in the field of analysis of the history and conditions of operation. Assessments are made on the basis of the results of diagnostics and analysis of repair works, and the durability forecasts are verified during the operation of turbine sets.
Keywords: Pro Novum diagnostics, failure-free operation of turbine sets, Zakład Elektrociepłowni PKN ORLEN S.A.
Roman Michał Wojciechowski, Jerzy Trzeszczyński, Wojciech Murzynowski
Examples of implementation of diagnostic supervision on the BC 50 power unit
Diagnostic supervision, also performed remotely, has almost twenty years of history in the Polish power industry. An equally long future is possible in front of it, both for new and long-operated units in the final phase of their service life, especially when its time and periods between overhauls cannot be precisely determined in advance. This type of diagnostics is most often a source of information, sometimes a source of knowledge, and when it is of appropriate quality, it can be used to verify the lifetime prognosis, create an operation strategy and optimize the date and scope of the next overhaul, which has recently become much more difficult than in the past. The article presents examples of diagnostic applications used in Veolia Energia Poznań S.A. after the last major overhaul of the duo-power unit and as part of supervision over the conditional operation of the damaged primary steam outlet header of the 1K1 boiler.
Keywords: diagnostic supervision, diagnostic applications, Veolia Energia Poznań S.A.
Cezary Kolan, Krzysztof Brunné, Adrian Sobczyszyn, Stanisław Noworyta, Adam Szczepek, Dariusz Gała
The use of metallographic tests in the diagnostics of elements operating under creep conditions
One of the basic diagnostic methods used as one of the tools for assessing the technical condition of elements is metallographic testing. In the power sector, the technique of triafol replicas is commonly used. It enables non-destructive testing, i.e. in conditions, directly on the object, in a repeatable manner, without the need to take samples. In addition, apart from the assessment of the microstructure at a given moment of operation, these tests, thanks to properly developed ranges of their implementation, allow obtaining information on the degree of advancement of microstructure degradation processes during the entire or long-term operation of the elements.
Keywords: metallographic testing, technique of triafol replicas, diagnostics
Sławomir Rajca, Sebastian Pośpiech, Adam Dragon
Diagnostics supporting the repairs and operation of steam turbines
The long-term cooperation of ZRE Katowice SA and Pro Novum sp. z o.o. has resulted in past many interesting and innovative projects that continue to benefit not only Polish power plants. These projects, especially the revitalization of cast-steel elements of steam turbine, have helped to avoid their costly replacements. In the area of diagnostics, Pro Novum supports and supplements the potential of ZRE Katowice. This approach enables joint implementation of works based on classical diagnostics (based on proven testing methods) and using advanced analytical and IT methods, including in particular – adapted to the current needs – elements of remote diagnostics. In the paper, the above-described approach is presented on the example of two overhauls carried out recently by ZRE Katowice with the participation of Pro Novum.
Keywords: diagnostics supporting the repairs, remote diagnostics, ZRE Katowice SA, Pro Novum Sp. z o.o.
Marcin Kijowski, Bartosz Borcz, Mateusz Nowak
Feedwater pipelines – an ugly duckling of conventional energy
The feedwater pipelines of the power unit are divided into two functional parts: the suction part and the discharge part. Pipelines, despite multiple demands, are not covered by the technical supervision of the Office of Technical Inspection, although they are the most dangerous device in the entire power unit. Failure, especially in the pressure part, is a disaster on the scale of the entire power plant (heat and power plant and power plant), more tragic in consequences than the explosion of hydrogen cooling the generator, because it concerns only one unit, sometimes adjacent, and not the entire engine room. The paper discusses typical pipeline structures and the resulting risks, both of design and operational origin. Based on many years of Pro Novum experience, basic diagnostic recommendations are presented with reference to the types of non-destructive testing. The most commonly used fixing systems are described, along with their advantages and disadvantages. The summary presents the power unit feedwater pipeline diagnostics program developed and used in Pro Novum.
Keywords: feedwater pipelines of the power unit, diagnostisc, design and operational risk
Marcin Kijowski, Radosław Stanek, Mateusz Nowak
Diagnostic supervision of steam pipelines in the remote mode in order to optimize the scope, time and costs of diagnostics
Ensuring the safety of pipeline installations operating in creep conditions at acceptable costs should distinguish two groups of installations significantly different from each other: long-operated pipelines and new or relatively new pipelines, often operated with high, supercritical parameters made of steel and according to technologies for which we have less practical experiences. The paper presents an approach that has recently been gaining more and more popularity, ensuring a rational consensus between diagnostics costs and an acceptable level of risk minimization. Such an approach is remote diagnostic supervision, which integrates classic as well as ongoing analysis of the history and working conditions. In this mode, you can both verify the lifetime forecast and update the assessment using AutoPipe modeling or, in the most advanced version, using digital twins. In the latter, advanced version, the service in the LTSA mode can and should be performed for both new and long-operated installations, repeatedly modernized in order to extend the operation and/or change its conditions. The paper presents examples of different versions of remote diagnostics implemented by Pro Novum.
Keywords: diagnostic supervision, stream pipelines, remote diagnostics