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250 Mw Unused Oil-fired Steam Power Plant A.

Steam Generation System

The steam generator is a Mitsubishi Heavy Industries Ltd single reheat drum type natural circulation, balanced draught, tangentially oil fired unit. Located in the gas convection pass is a three stage radiant and convection type superheater, a single stage reheater section and a two bank extended fin economiser. Included with the unit are four Oraka Blower Mtg Co Ltd, igniter fans, two each Mitsubishi Electric Company gas recirculating, forced draught and induced draught fans, two steam air heaters, two Gadelius KK air preheaters and a Mitsubishi Vulcan soot blower system. Designed for a maximum continuous rating of 825,000 kg of steam per hour continuously at 139.7 kg/cm absolute at 541C and combustion air at 69 C . An average superheater and reheater outlet temperature of 541C is maintained at all loads from 492,000 kg to 825,000 kg of steam per hour. The steam generator is designed for operation on residual fuel oil. Component specifications are as follows:1. Boiler Plant Manufacturer Type

: :

Mitsubishi Heavy Industries Ltd, Japan Mitsubishi CE natural Circulation boiler Radiant, Reheat, Balance Draft and Indoor 1 820,000 kg/h (overload 825,000 kg/h) 132.6 kg/cm (G), @ 541C

type Number of Unit : Maximum Continuous : Evaporation Steam Conditions :

2. Boiler & Furnace The steam drum is 1775 mm internal diameter furnished with four Dresser Industrial Valve and Instrument Divisions safety valves, and two Diamond Power Speciality Corporations bi-colour water level gauges. One gauge is equipped with a liquid cooled camera and remote mounted monitor for closed circuit televiewing of the drum level. The boiler is 11.5 metres wide, 14 metres deep and approximately 44.5 metres high.

The three stage radiant and convection type superheater, a single stage reheater section and a two bank extended fin economiser are located in the gas convection pass.

Seal air is provided for observation doors, sootblowers, flame scanners and other fittings requirement cooling because of exposure to hot combustion gases. B. Turbine Generator And Station Auxiliary Plant

The unit is a Mitsubishi Heavy Industries Ltd, three casing, tandem-compound, double flow, condensing, single reheat steam turbine operating at 3000 rpm. The unit is directly coupled to a two-pole, three phase, 50 Hz, 19,000 volts, hydrogen cooled generator. Field excitation for the generator is supplied by a Mitsubishi Electric Company brushless excitation system, driven from the main generator rotor and rated at 1500 kW, 420 Vdc, 3000 rpm. Design steam conditions are 124 bar gauge and 538 C at the turbine stop valves. Reheat temperature is 538 C and the design exhaust pressure is 74 m absolute. The nominal rating of the unit is 250,000 kW at guaranteed steam flow rate of 748,000 kg/h through the stop valves are 124 bar gauge main steam pressure and 76 m absolute back pressure. 1. Steam Turbine Plant : : Mitsubishi Heavy Industries Ltd, Japan Three casing, tandem compound,

Maker Type double

flow, condensing, single reheat. Speed : 3000 rpm Nominal Rating : 250,000 kW Steam Conditions at Turbine Valves Pressure : 124 barg Temperature : 538 C Steam Flow (max) : 748,660 kg/h (786,093 kg/h design) Number of Extractions : Six (6) Number of Stages : Fifty-five (55) Overall length of Unit : 34 metres Overall Width of Unit : 8.5 metres Height of unit above Floor line: 5.0 metres

Location and Access The station is sited on 22 hectares of land in a beach front situation, approximately 40 metres inland from the high water line. The site is serviced by good asphalt surfaced local feeder roads and is only 6 km from the main inter-city highway. The nearest port is approximately 5 km from the site. The nearest airport is approximately 43 km and 40 minutes drive away, however this airport is served only by domestic services. The International Airport is approximately 2 hours drive from the site. Scope of Supply Steam generator and auxiliaries including a single reheat, drum type natural circulation, balanced draught, tangentially fired steam generator designed for a maximum continuous rating of 825,000 kg/h steam at 137 bar (abs.) and 541C at the superheater outlet, and 811,400 kg/h steam at 37.2 bar (abs.) and 541C at the reheater outlet. The steam generator is designed to burn residual (No. 6) fuel oil. Tilting burners, gas recirculation and spray desuperheating are provided for temperature control. Other plant items include seal air system, oil burners, igniters, FD and ID fans, sootblowers steam air heaters, Ljungstrom regenerative air reheaters, gas recirculation fans, hydrostatic test pump, continuous blowdown flash tank, atmospheric blow-off tank and burner cleaning station. Steam turbine generator and auxiliaries including a single reheat, tandem compound, double flow, condensing steam turbine generator operating at 3000 rpm and directly coupled to a two pole, 3 phase, 50 hertz, 19 kV hydrogen cooled generator. Brushless field excitation is driven from the main generator rotor. The normal rating of the unit is 250,000 kW. Other plant items include oil pumps, lube oil reservoir, lube oil conditioner, lube oil coolers, hydrogen seal oil coolers and seal oil system. Condensate system including single pressure, single pass radial flow, vertically divided, rectangular bonnet, sea water cooled condenser, steam jet air ejector, inter and after condenser, first, second and third stage low pressure regenerative feedwater heaters, deaerator, deaerator storage tank, boiler fill pump and demineralised water storage tank. Boiler feedwater system including fourth and fifth stage high pressure regenerative feedwater heaters and three half capacity electrically driven boiler feedwater pumps.

Fuel oil system including main oil storage tanks light oil tank, serpentine heating coils, fuel tank suction heaters, primary fuel oil pumps, secondary fuel oil heaters, secondary fuel oil pumps, jet steam atomised oil guns for the main steam generators, fuel oil transfer pump, primary and secondary fuel oil sump pump sets, and light oil pumps. Circulating water systems including intake structure recirculating water gates, straight-through, band type, travelling screens with wash water system, screen wash pumps, intake structure sump pumps, cooling water pumps, closed cooling water heat exchangers, auxiliary cooling water pump, auxiliary cooling water heat exchanger, circulating water pumps, condensed water box vacuum pump, and sodium hypochlorite generator system. Auxiliary steam system including a two drum D type water tube packaged boiler complete with superheater section, trim, combustion and flame safeguard system, FD fan, sootblower, auxiliary deaerating heater, fuel oil pump, feed pumps, condensate pumps, reboiler heat exchanger and reboiler drain pump.
AUXILIARY BOILER : DATA SHEET General Description Two Drum D-Type Water Tube, Packaged Boiler complete with Super-heater Section Trim, Combustion Controls and Flame Safe guard System. Performance Data - Boiler Maxlmum Design Pressure Maximum Operating Pressure Normal Continuous Output Type of Fuel Burned Efficiency at NCO (Based upon firing No. 6 oil) Furnace Heat Liberation Minimum Steaming Rate Physical Data - Boiler Manufacturer Type Total Heating Surface Furnace Volume Weight (Shipped) Weight (Flooded) Tube Size: Outside Diameter Drum Size: Steam/ Lower (Nominal Dia) Lower Drum Steam Coil: Size / Material / Type
2

26.4KG / CM 2 21.0 KG / CM 34,636 KG / HR API No. 6 (residual) API No. 2 (distillate) 81.7% 1,906,700 KJ / HR / M 6,930 KG / HR
3

Babcock & Wilcox Canada Ltd. FM 13-79 2 633 M (ABMA) 2 787 M (Full Circulation) 3 59. 5 M 57,600 KG 76,600 KG 2-.inch 1.07 metres / 0.6 metres 1 -Inch / steel / U-tube

Super-heater Data - Boiler Type Design Pressure Operating Pressure Outlet Temperature at N.C.O. Tube Size: Outside Diameter Reader Size: Inlet / Outlet (inches nominal)

Drainable - 3 pass - 4 loop - 13 element 2 26.4 KG / CM 21.0 KG / CM2 0 324 C 2-inch 10 / 10

Accessories - Boiler Drum & Superheater Relief VaIves: Site / Manufacturer Set Pressure Main Steam outlet stop Check. Size / Manufacturer Feed-water Stop Check & Regulator Size / Manufacturer

Main Steam Backpressure valve Size / Manufacturer Continuous Blow-down Valve Size / Manufacturer Lower Drum Blow-off Valves Size / Manufacturer Materials - Boiler Boiler Pressure & Casing Parts Steam and Water Valves; - Boiler Pressure Steam Valve - Reduced Pressure Oil Valves Forced Draught Fan Number of Units Spec. Number General Description

(2) 2" Figure 706 Hopkinson (1) 1 " Figure 706 Hopkinson 22.8 KG / CM2 Gauge (1) 8" Figure 2193 Hopkinson (1) 8" Figure 6003 Hopkinson (1) 3" Figure 3773 Hopkinson (2) 3" Figure 2193 Hopkinson Feed-water Control Valve supplied with Combustion Controls (1) 8" Mark I / Valtek with Bailey, Positioner (2) 1 " Figure 8736 / Hopklnson (1) 1 " Figure 2576/ Hopklnson

Steel Cast or Forged Steel Steel

1 11021 - M - 227 Single Width, Horizontal Shaft Centrifugal Fan, Direct Connected Motor with Inlet Damper, Pedestal Mounted.

Fan Data Manufacturer model Number Fan Size Fan Speed Rated Capacity Static Pressure Rated Temperature Barometric Pressure Fan Power Requirement

Taylors Limited (NZ.) 730 CP 142 CM 1480 RPM 11,400 Iitres / sec. 2.73 KPA 0 32 c 760 MM HG 39 KW

Fan Motor Data Rating Rated Speed Voltage Phase Frequency Type of Enclosure Insulation Class Bearings Lubrication

1480 RPM 45 KW 400 3 50 HZ TEFC B Ball Grease

Burners - Boiler Number of units Manufacturer spec. Number General Description Performance Data - Oil Burner Oil Pressure: Maximum Oil Pressure: Minimum Oil Viscosity (Maximum) Atomising Steam Pressure Atomising; Air Pressure Ignition Power Supply Burner Throat Diameter Ignition - Burner Carbon Arc lgnitor with Air Cylinder Stroke Mechanism lgnltor Manufacturer

1 Babcock & Wilcox Canada Limited 11021 - M - 227 Venturi Throat, Forced Draught Type for Oil Firing. 17.6 KG / CM 2 10.5 KG / CM 135 SSU 2 8.75 KG / CM 7.70 KG / CM 110 VOLT 50 HZ 457 MM
2 2

254mm Travel Electronic Corp. of AmerIca (E.C.A.)

Atomisers - Burner Number Manufacturer Sprayer Plates Soot Blower - Boiler Number Manufacturer Spec. Number General Description:

2 Racer 305 MM Dia.

1 Babcock & Wilcox Canada Limited 11021 - M - 227 Valve-in-Head. Chain Wheel Operated, Retractable, Telescoping Type Rotary Soot Blower In Convection Section of Boiler. Super-heated Steam Boiler Main steam Outlet

Operating Media Source

Compressed air system including two rotary screw compressors, two air dryers and two air receivers. Water treatment system including demineralising plant. Chemical feed system including pumps, tanks and agitators. Sampling system. Fire protection system including a diesel driven emergency fire pump. Service water system. Cranes and hoists including 45/10 tonne turbine bay bridge crane. Generator 19 kV system including isolated phase bus duct, load break switch, voltage transformer and generator neutral earthing transformer. 220 and 110 kV systems including one main 305 MVA 19 kV/220 kV generator transformer, one 15/20 MVA 6.6 kV/110 kV reserve transformer, 220 kV surge diverters and 110 kV surge diverters. Auxiliary power system including one 15/20 MVA 19 kV/6.6 kV auxiliary power transformer, 6.6 kV switchgear, 415 volt substations and DC switchgear. Control and instrumentation systems including combustion control system, automatic burner control system, turbine generator controls, control room equipment and annunciator systems and protection and metering panels. Piping including interconnecting main steam, reheat, feedwater condensate, cooling water, service water, compressed air and miscellaneous services. Power, instrumentation and control cabling. Structural steelwork including turbine and boiler support structures, turbine and boiler buildings, access galleries and stairways. Chimney flue liner 4.27 m diameter Corten B steel, insulate with 50 mm fibreglass.

Yard tanks including service water tanks and a demineralised water storage tank. The data processing computer and one of the 240 V DC battery banks, which have been removed for use at other sites, are not available for sale.

Concrete structures including the turbine, building and chimney foundations, chimney windshield and intake structure. Buried fixtures including concrete circulating water pipework, cable ducting and site drainage. While the plant has been in long term storage, some plant items have been used to maintain the stored condition and for operation and storage of the adjacent Power Station. Specific plant in regular use and therefore not in near new condition, includes the following. Consideration of this equipment for sale would be by negotiation. Auxiliary transformer - used for providing power to services such as lighting and batteries. Air compressors - used for supplying dry air to both stations, for storage purposes. The circulating water system hypochlorinator - used for the dosing of the adjacent stations circulating water pipelines on a regular basis. The DC battery system. The power station has been in long term storage since construction was stopped in 1979. It was initially envisaged that the storage period would be for a maximum of 10 years, and that the situation would be reviewed and procedures possibly amended if the period was to be extended. The original storage philosophy, based on a 10 year storage period, was that the equipment should be stored and maintained in as near operating condition as possible. Storage procedures incorporated a combination of methods but mainly comprised dry air for internal, closed volumes, such as boiler and pipework and various coatings for other surfaces. Radiant heaters in the boiler furnace have ensured an elevated temperature in this space. Outdoor plant which could be readily moved has been moved to indoor storage. Such plant includes most motors and pumps, with the motors being stored with anti-condensation heaters connected and energised.

Not commissioning the station prior to storage and the fully enclosed design of the boiler and turbine buildings have greatly aided the long term storage process. This has resulted in minimal corrosion within the generally dry, warm atmosphere within the buildings.

The proximity of the station to the coast means that outdoor plant suffers from the harsh corrosive atmosphere, especially where equipment is not regularly washed by rain to remove salt deposits. For certain minor structural steelwork, small-bore pipework and valves located outdoors, no particular storage procedures have been followed, as replacement prior to commissioning was seen as the most appropriate action. From the time the long term storage procedures were instigated, the station has continued to be maintained by staff from the adjacent power station. The scope of maintenance work has generally ensured that the plant is kept in excellent condition. This has been confirmed by several plant reviews in the period 1987 to 1993 by independent consultants. In addition to the scope of maintenance work required by the long term storage procedures, the following has been carried out in recent years: External boiler ductwork has had its cladding and thermal insulation removed and the underlying steelwork surfaces have been cleaned and painted to arrest corrosion. The main and reserve transformers have been refurbished and repainted allowing the removal of most of their cooling fans to indoor storage. The service water tank anchor bolts and supports have been modified and upgraded. Duct support steelwork has been sandblasted and painted. Bottom sections of the chimney have been sandblasted and painted.

Summary of Option Reviews and Investigations The owner has carried out numerous reviews, studies and investigations of options for utilising the power station in the local power system. In 1980, the year following the decision to place the situation in long term storage, the then Electricity Division to the Ministry of Energy engaged the original designer of the power station, to carry out a feasibility study on using alternative fuels for the station. They studied four options: fuel oil as designed,

replacement coal fired boiler, coal-oil mixture firing and coal gasification. The study concluded that a new coal fired boiler was the best option.