Herbert Leopold Gabryś
ELECTRIC POWER IN POLAND 2024 from the results and challenges
selected in the context of changes in the structure of electricity production, power and loads
The energy-intensive of GDP is decreasing, and the increase in consumption will be filled by growing renewable generation. Electricity from domestic generation is supplemented by imports, but in crisis situations it is greater than domestic consumption and in the balance of foreign exchange with a surplus of exports stabilizes the needs of neighbors (in 2021 - 1.6 GWh).
Electricity from domestic generation, from solid fuels is invariably important for the needs of the national energy system and is necessary until new system capacities are acquired (at least until the 2040s on the path of reduction).
Generation of electricity from fossil fuels in Poland is in an increasingly wide range of extreme values and this will remain in an upward trend primarily due to weather-dependent renewable generation conditions.
The range of extreme generation from 2019 to 2023 in months is significantly deepening (with the extreme year 2021), mainly due to the expansion of regulatory functions in short-term distributions. In the structure of JWCD (centrally managed production units), coal-fired units in the range of 200 - 300 MW of installed capacity constitute a decisive part of the regulatory capabilities (for August 2024 a total of 27,079 MW, including 10,462 to 47 units between 120 MW and 300 MW).
Between 2014 and 2023, the achievable capacity increased by 65.38%, the available capacity by 17.86%, and the JWCD capacity by 18.34%. These are units technologically adapted for continuous operation and not adapted to strictly regulatory functions in view of the expectations and practices of recent months, and for the duration of service until the forties requiring due care in terms of maintenance expenditures.
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Paweł Woszczyk – Towarzystwo Gospodarcze Polskie Elektrownie
POSSIBILITIES OF USING 200MW CLASS UNITS DURING THE TRANSFORMATION OF THE NATIONAL POWER SYSTEM
The development of renewable energy sources places new, difficult demands on power plants and the entire energy system. In order for the entire system to function properly, the currently operating power plants, mostly with 200 MWe power units, must completely change their operating regimes and "make them more flexible". Currently, there are 45 200 MW class units left in the KSE (National Energy System), 6 of which are powered by lignite. All of the units have already seen their best days, but they still support the KSE. Many of them have undergone major renovations and modernizations in order to adapt to BAT requirements. The rising costs of CO2 emissions, the increase in variable costs and falling energy production, due to the RES market, make the operation of 200 MW class coal units economically unprofitable. This is confirmed, among others, by the report of the President of the Energy Regulatory Office "Information on investment plans in new generation capacities in the years 2020-2034" or the report of the Ministry of Climate "Report on the results of monitoring the security of electricity supply" - both of these documents predict that in the coming years there will be gaps in the KSE power. Solutions that can help in the efficient use of 200 MW class blocks, as well as preventing the power gap itself, may be the conversion of coal boilers to gas, biomass, implementation of the results of the "BLOKI 200+" program, possible introduction of CCU/S or development of a strategic reserve mechanism, which will be discussed in the presentation.
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Jerzy Trzeszczyński, Wojciech Murzynowski, Radosław Stanek – Pro Novum sp. z o.o.
DIAGNOSTICS SUPPORTING THE FLEXIBLE OPERATION OF POWER UNITS
In the foreseeable future, coal-fired power plants will be an important part of the Polish power system. Its security will depend on the availability of the units involved in its stabilization, also in the operational reserve mode. Operating time will be, to an even lesser extent than before, a criterion for determining the safe horizon of their operation based on research. Retrospection to determine the scope of research should also be based on the analysis of history and working conditions, not only in the last period between stand-stills. Ongoing diagnostic supervision should become an important part of diagnostics, which should be organized in a systemic manner using modern, proven analytical, digital and IT technologies, simultaneously based on knowledge and experience that are the result of the rich history of the Polish power industry, also in terms of know-how.
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Ollivier Hugues - International Nuclear Development, EDF
FLEXIBLE OPERATION OF FRENCH NUCLEAR POWER PLANTS – TECHNICAL, OPERATIONAL, MAINTENANCE AND SYSTEM ASPECTS
The presentation will present:
- Enablers for sustainable flexible operation: adapted reactor technology, operational experience and offer/demand balance management.
- Technical aspects and examples of flexible operation on reactor level. Operational skills. Impacts of flexible operation on reactor safety and maintenance.
- French experience of nuclear fleet flexibility – rationale, operational issues, coordination between nuclear and renewable assets.
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Tomasz Sojka, Stanisław Noworyta – TAURON Wytwarzanie SA
FAILURES OF POWER PLANT ASSETS EQUIPMENT DUE TO FLEXIBLE OPERATION
Flexible operation of power units is not indifferent to the technical condition of the power plant equipment. Frequent changes in power, a large number of shutdowns/start-ups and operation at a technical minimum negatively affect the durability of these elements. The presentation focuses on examples of damage caused by the above mentioned factors. Damage occurs throughout the entire area of the power unit on the pressure parts of the boiler, fans, supply pumps, steam turbine elements and electrical devices.
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Jerzy Król - ENEA Elektrownia Połaniec SA
Jerzy Trzeszczyński – Pro Novum sp. z o.o.
MODERNIZATION OF POWER UNITS IN ENEA ELEKTROWNIA POŁANIEC SA IN ORDER TO MEET LEGAL REQUIREMENTS AND NEW OPERATING REGIMES
Modernization of 200MW class units is aimed at extending their operation, increasing flexibility and reducing emissions, especially CO2 to the level of 550g/kWh. This is accompanied by actions to ensure safety and availability. ENEA Elektrownia Połaniec SA is considering the use of solutions that would allow for the identification of threats related to flexible work and adaptation of units to the new operating mode.
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Jan Skórski– Polenergia Elektrociepłownia Nowa Sarzyna Sp. z o.o.
AVAILABILITY, RELIABILITY AND FLEXIBILITY AS THE BASIS FOR THE OPERATION OF THE COGENERATION UNIT IN CURRENT MARKET CONDITIONS.25 YEARS OF EXPERIENCE IN THE OPERATION OF BGP POLENERGIA ELEKTROCIEPŁOWNI NOWA SARZYNA Sp. z o. o.
The aim of the paper is to present the functioning of the ENS gas and steam unit from the perspective of 25 years of operational experience, and in particular to present the challenges and experiences related to the energy transformation that has taken place on the energy market in the last 5 years in connection with the dynamic development of renewable energy sources.
The speaker will present the operation of the gas-steam unit with full or partial load during the first two decades of operation of the combined heat and power plant, and then the challenges and tasks that were performed to adapt the unit to flexible operation, including reserve shutdowns, start-ups and peak operation of the gas-steam unit. The most important procedures and methods of stand-by maintenance of the gas and steam unit will also be presented, as well as methods of protecting generating units against freezing during winter.
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Paweł Gawron, Wojciech Murzynowski, Radosław Stanek – Pro Novum sp. z o.o.
IDENTIFICATION OF PLACES EXPOSED TO CORROSION DAMAGE ON POWER UNITS OPERATED UNDER INTENSIVE REGULATION AND POSSIBILITIES OF PREVENTING THEM
Corrosion problems are inherent in the operation of power units, regardless of the mode of their operation. Corrosion phenomena, known and controlled to a sufficient degree, on power units operating in the normal mode, in the case of units operating in the mode of intensive regulation and increased flexibility, take on a new dimension. In addition to the typical destruction mechanisms, there are factors characteristic of the flexible mode of operation of blocks, important from the point of view of intensifying the processes of corrosion destruction. Flexible operating conditions of production equipment generate a new range of corrosive phenomena. A systemic approach to information processing, including diagnostic data, gives a chance to take preventive measures adequate to the risk and maintain good technical condition of power plant
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Andre de Bache – Kurita Polska GmbH.
MODERN METHODS OF CHEMICAL TREATMENT OF THE CIRCULATION FLUID IN ENERGY UNITS OPERATING
IN INTENSIVE REGULATION CONDITIONS - CETAMINE CORRECTION ON HRSG BLOCKS IN SPAIN
This year, Kurita celebrates its 75th anniversary. The experience gained over the years means that we are able not only to solve problems in the field of water treatment, but at the same time offer the benefits of this solution.
The operation of power units in flexible/regulatory mode entails many operational challenges, including proper protection of the water and steam circuit during operation, but also, and perhaps above all, during unplanned shutdowns. A challenge that is technically difficult to achieve for traditional correction systems can be achieved in systems based on modern correction measures.
One of Kurita's technologies is CETAMINE Technology. This is the 4th Generation of products based on film-forming amines. CETAMINE FB, Dropwise Technology, securing the boiler system during shutdowns, alkaline boiling out are just some of the solutions Kurita has in their portfolio.
The advantage of CETAMINE compared to standard boiler water treatments is that it does not increase the salinity of make-up water, is resistant to pH fluctuations, and maintains a protective layer in the system during unplanned, forced shutdowns. Kurita offers safe technology with procedures for carrying out the process and easy measurement methods.
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Tomasz Sygnarski – Elektrociepłownia Stalowa Wola SA
EXPERIENCE IN THE OPERATION OF ELECTRICITY AND HEAT GENERATING EQUIPMENT AT THE STALOWA WOLA HEAT AND POWER PLANT
The presentation provides information on the basic nominal parameters of the generation units that are part of Elektrociepłownia Stalowa Wola S.A. (ECSW), including a combined cycle power plant with an electrical capacity of 450 MW and a backup heat source, the gas boiler plant (RZC), with a thermal capacity of 132 MW. It also presents the ownership structure, the current business environment, and production data for 2023. Based on the collected experience, the most important defects identified during the commissioning process and the initial period of operation, referred to as the investment familiarization phase, will be highlighted. The defects are categorized by the area of occurrence, such as the boiler, turbine, etc.
The presentation includes load charts of the combined cycle unit, broken down by week and day, allowing for the illustration of the block’s operational flexibility from minimum to maximum power. The charts are based on the unit’s performance in 2023. Subsequently, the key tasks performed in the past year will be discussed. ECSW is not only about the power block but also includes the backup boiler plant – a summary of operation will also be presented.
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Marcin Centkowski - Zakład CCGT Włocławek, Obszar Energetyki ORLEN S.A.
THE ROLE AND IMPORTANCE OF THE LTSA (LONG-TERM SERVICE AGREEMENT)/CSA (CONTRACTUAL SERVICE AGREEMENT) ON THE EXAMPLE OF THE CCGT WŁOCŁAWEK PLANT
During the presentation a description of CCGT technology and an outline of the LTSA (Long-Term Service Agreement) program implemented at the CCGT Plant in Włocławek, with a particular focus on LTSA as a diagnostic tool, will be presented. Issues related to the service agreement will be discussed, as well as the importance of the contract for the plant, including, among others, operational risk mitigation, optimization of Maintenance Services, support from the M&D Center, and TIL (Technical Information Letter). Based on the advantages and disadvantages of the implemented LTSA service, a technical evaluation of the contract in the context of CCGT Włocławek will be discussed. Additionally, CSA (Contractual Service Agreement) will be presented as an alternative to LTSA contracts.
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Oliver Then – vgbe energy e.V.
THE VALUE OF FLEXIBILITY IN THE FUTURE ENERGY SYSTEM – AND ITS CONSEQUENCES
The ongoing decarbonization of the energy system is largely based on the deployment of volatile renewable energy sources like wind and solar. Their production is fluctuating in different time scales – from seconds to seasons. Therefore, increasing flexibility options are needed in the future energy system. In particular for the large scale and long-term provision of electricity to cover unavailability of renewable sources, dispatchable generation is the matter of choice for the mid to long-term perspective. Depending on political and geological preconditions, different generation technologies are available. High operational flexibility is a key requirement for choosing the right options, as well as considering consequences of highly flexible operations on the O&M and the lifetime consumption of the equipment. The presentation will highlight key aspects of the said developments as well as experiences from vgbe’s experience.
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Paweł Gawron – Pro Novum sp. z o.o.
PREPARATION AND SUPERVISION OF THE TECHNICAL CONDITION OF POWER UNITS REMAINING IN OPERATIONAL RESERVE
The need to support power has arisen in connection with the rapid development of subsidized renewable sources, especially wind turbines and photovoltaics, which are replacing conventional power plants from the market.
Conventional generating units, not working the required number of hours per year, become unprofitable, but at the same time they are needed to ensure that demand is met when the wind and sun light are weak, as well as during peak demand. Economic issues related to unprofitability are one thing, technical issues related to the need to guarantee the appropriate availability and flexibility of conventional sources in "working" conditions far removed from the originally assumed are another, but very important and difficult to implement issue.
The ongoing changes in the energy market related to the growing share of renewable energy sources and their privileged position in the queue to the power grid operator with the necessary level of system security guaranteed by producers using conventional energy sources require a change in the approach to the management of production assets planned for operation within the operational reserve. The paper presents an outline of problems in the area of physico-chemical operating conditions and downtime of devices and possible solutions related to maintaining good technical condition of production devices that are in the operational reserve.
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Rafał Kobyłecki, Robert Zarzycki – Politechnika Częstochowska
SELECTED ISSUES ASSOCIATED WITH THE ADAPTATION OF POWER GENEGATION SYSTEMS
TO CO-OPERATE WITH RES
The article presents and discusses some selected and chosen results of authors' research focused on the determination and assessment of the effect of boiler operation with variable load on the operational difficulties, including: the degradation changes, work flexibility, corrosion and erosion of boiler elements. The operational difficulties and their measurable effects are the results of current work requirements caused by short-term demands and changes of loads due to the need for classical units to cooperate with renewable sources within the framework of Polish power system.
The research results obtained from several measurement campaigns at real plants are presented, as well as the results of many years of analysis and experience from the practical implementation of various selected technological solutions, including the issues associated with the operation of fluidized bed, stoker, and pulverized combustors, as well as the real effects brought about by the operation with variable loads.
The possibility of reducing the negative effects of the cooperation of power units with renewable sources was also addressed. Some positive effects could be achieved by using innovative, technical and technological solutions, such as improved flexibility, as well as energy and heat storage in some selected systems.
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Agnieszka Jojczyk, Ewa Trzeszczyńska, Paweł Galbarczyk – Pro Novum sp. z o.o
INNOVATIVE PRO NOVUM SOLUTIONS – THEIR RESULTS AND INSTRUMENT USUED
Pro Novum has been developing innovative solutions for over 30 years, has maintained the status of a R&D Centre (CBR) for over 15 years, and has been increasingly reaching for various types of instruments supporting innovative activities, including EU funds, for several years. The effect of implementing these projects is providing power plants with useful tools supporting the safety of operation and availability of power equipment, especially in the conditions of flexible operation of 200 MW class units. But not only that, because the implementation of these projects has also become an impulse for the development of Pro Novum, which in result has an impact on the company's image and increased its competitiveness on the market. The presentation will recall projects already implemented, also with the support of EU funds, discuss the effects of these implementations for both the power sector and Pro Novum, and present plans for the near future.
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Frank Biesinger, Huascar Lorini - GE Power GmbH, Mannheim, Germany
Mariusz Banaszkiewicz - GE Power Sp. z.o.o., Elbląg, Poland
REWORK AND REPAIR OF STEAM TURBINE COMPONENTS SUBJECT TO FLEXIBLE OPERATION
The increase in renewable energy penetration on the grid has accelerated the need to transition conventional fossil-based energy sources from their traditional base load operation to more flexible operational regimes. The mode of operation changed dramatically in terms of number of starts, operating hours per annum, and variation in load level. This results in greater thermal transients on operational equipment leading to an increase in low cycle fatigue damage. To ensure the continued integrity of the steam turbine components, it is essential to assess the lifetime status by applying residual lifetime analysis methods.
Depending on the amount of lifetime consumption and the extent of potential crack findings, different component repair options are possible. The rework or repair options can be divided into two main groups, namely cold and hot rework. These two options can also be carried out consecutively. All rework or repair options provide the opportunity to improve the application of a component by applying profiling with improved stress fields and even superior materials, in the case of hot rework.
The aim of the rework/reconditioning is to ensure that the steam turbine component is suitable for future operation. This ensures that plants are well placed to deliver more flexible operation in the energy industry through careful tailored refurbishments and reworks.
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Michał Górka , Roman Michał Wojciechowski – Veolia Energia Poznań S.A.
Sławomir Rajca - Pro Novum sp. z o.o.
OPERATIONAL AND OVERHAUL DIAGNOSTICS OF TURBINE WORKING IN HEATING PLANT
As part of the technical dialogue within the Veolia group, a decision was made to extend the operational life of the 13UC105 turbine. The turbine was designed in the 1980s and was commissioned in 1991. New challenges in the capacity market required improving the turbine's efficiency and restoring its nominal power, as well as enabling operation under different modes. A decision was made to replace the rotor, which had been repaired several times before. The design changes and operational advantages of the new rotor were described.
The presentation shows a diagnostic analyses of the turbine with the new rotor after the deterioration of its dynamic condition was observed. The authors present possible causes of vibration changes and the repercussions for future repairs. Guidelines for the safe operation of this turbine until the planned overhaul are also provided. The scope of identified irregularities after the rotor's disassembly and two analyses of the causes of these issues are discussed: the first by the new rotor's manufacturer, and the second by a team of specialists from Pro Novum. The determination of the causes of the damage involved two turbines of this type in the Veolia group, and therefore, the process data set was also analyzed in detail.
Following the tests and analyses, the causes of the damage were identified. All the work related to the modification and repair of the rotor was carried out by its manufacturer. After the repair, the turbine has been operating reliably with good dynamic conditions. Periodic endoscopic inspections of the flow system, particularly around the Baumann stage, are performed.
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Kamil Staszałek, Wojciech Murzynowski – Pro Novum sp. z o.o.
TECHNICAL CONDITION ASSESSMENT OF STEAM BOILER DRUMS - SELECTED PROBLEMS AND METHODS OF SOLVING THEM
A large part of boilers, not only those used in 200 MW class units, are equipped with drums that have worked for approx. 300,000 hours. Unlike other elements of the pressure parts of boilers, replacing them is practically impossible or expensive. However, they can be repaired without restrictions because their damage is local and has a fatigue character. They can also be modernized to a certain extent, which means that the construction of drums used so far is rarely consistent with the design documentation. Modernizations and numerous repairs mean that the User uses an element with individual features, which should be taken into account when determining its durability reserve and safe operation conditions.
When assessing the technical condition of drums, the actual conditions of their operation should also be taken into account, especially when it is planned to operate boilers/power units in an even more regulated mode than before. This means that current methods of assessing the technical condition of steam boiler drums, in addition to potential damage zones, should take into account the actual damage zones and changes in their design, especially changes in the local geometry of the drum shell related to the repair.
The paper presents the current approach to the diagnostics of long-operated drums and presents methods, that allow during the technical condition assessment and ongoing diagnostic supervision, to take into account the individual features of the drums and ensure their safe operation.
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Jerzy Trzeszczyński, Radosław Stanek - Pro Novum sp. z o.o.
DIAGNOSTICS PERFORMED IN LTSA MODE ENSURING THE AVAILABILITY OF COAL UNITS DURING THEIR CONTINUED OPERATION
The LTSA service (Long Term Service Agreement) is an attractive solution for both the user and the equipment supplier ensuring safe operation and the expected availability over an extended, multi-year period of operation. For equipment that is operated independently by the user after the warranty has expired, especially for long-operated devices, an appealing option to ensure safety and availability of power plant equipment is the LTSA service, carried out jointly by a maintenance and diagnostics company, or the LTDSA service (Long Term Diagnostic Service Agreement), performed solely by a diagnostics company.
This is particularly important when the operating conditions of the equipment significantly differ from those for which it was originally designed, and the remaining operating time may not be precisely known. Similar to the LTSA service, a service limited to diagnostics should ideally be conducted in a full cycle, i.e., from one major overhaul to the next, or until the decommissioning of the unit/equipment or its placement in operational reserve. During this time, comprehensive diagnostic supervision is maintained, the technical condition is monitored and updated in real-time, and durability forecasts are made, along with inspections and repairs.
This type of service guarantees safety and availability by ensuring the retention of necessary diagnostic company competencies, the loss or significant limitation of which could pose a greater threat to equipment availability than the loss of durability due to operation.
Pro Novum has extensive experience in providing diagnostic services of this kind, with certified laboratories offering a full range of testing and remote diagnostics systems that integrate the knowledge and long-standing experience of specialists, as well as the current standards and guidelines.
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