Power Plant Standardization Reduces Project Schedule and Plant Costs

摘要

During recent years, the trend in the combined cycle power industry has continuously called for shorter cycles, earlier Commercial Operation Dates (CODs), lower Cost Of Electricity (COE) and increased availability and reliability. GE has responded to this trend by developing a standard power plant offering. The Standard Plant Offering is based on a highly pre-engineered modular plant concept and is the evolution of GE's reference plant concept, which was applied successfully during the last decade. The GE Standard Plant has its roots in the highly successful, reliable and daily start/stop capable 109FA Single-Shaft STAG Power Train, with more than 24 trains in operation globally and 12 more trains in construction across Europe and Asia. In order to satisfy the demand for accelerated plant construction cycles, the degree of pre-engineering in this pre-designed Power Island is 95% compared to 15% in the reference plant concept. GE embarked on this initiative two years ago in conjunction with the latest technology GE Power Train. The first standard plant was developed for the 50 Hz market and is under construction in Spain. To create this high efficiency combined-cycle STAG 109FB Single-Shaft (SS) Standard Power Plant, GE drew upon a company-wide pool of experts from equipment, power plant design, and operation and maintenance teams, as well as specialists from the Global Research Center. Using a Six Sigma approach, customer Critical-to-Quality (CTQ) attributes were identified. Through the use of Quality Function Deployment (QFD) analysis, these CTQs were translated into actions that prioritized customer requirements and expectations to create an effective balance of design and processes. GE also performed a Failure Mode and Effects Analysis (FMEA) in order to identify and mitigate potential risks. A detailed evaluation of site ambient conditions and options was undertaken in order to develop a power plant with a "design envelope" to fit the majority of potential site applications with the flexibility to adapt to various site conditions and customer options. The most significant challenge was determining the optimum balance between "standardization of elements" vs. "cost of elements". The power plant design team worked closely with the GE equipment design team as well as construction and commissioning teams to determine which features and accessories to incorporate in the Standard Power Plant. These team efforts resulted in the reduction of the gas turbine inlet ducting angle from 30 degrees to 10 degrees, which optimized the turbine building height. Also, through the use of a large database of plant design, construction, commissioning and maintenance cycles, it was determined that all of these cycles could be improved by including a second maintenance crane in the Turbine Building.