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With the experience
gained from operating 2 GE Frame 5, GSP decided to obtain the
license for a power plant to sell electricity to the national
grid. Besides providing electricity to the grid, the plant would
be able to provide process steam to paper mill to make GSP the
first combined cycle cogeneration plant in Malaysia.
On 6th January 1994,
GSP signed the Power Purchase Agreement (PPA) with Tenaga Nasional
Berhad to build, operate and own a 720 MW natural gas-fired
combined cycle power plant with distillate as the standby fuel in
Kuala Langat, Selangor.
The new combined
cycle block power is based on three 164 MW Alstom 13E2 gas
turbosets and a 248 MW Alstom steam turbine.
The plant was built
on a fast-track basis. With the PPA signed, GSP was able to fire
the first 13E2 in November 1994 and all three units operating in
simple cycle commercial operation by March 1995. From contract
signing to full commercial operation, the combined cycle plant was
completed in just over 24 months, 3 months ahead of schedule. GSP
first started to sell electricity from the existing 2 units of GE
Frame 5. Later, one of the GE Frame 5 machine was replaced to a GE
Frame 6.
Plant Configuration
Kuala Langat
Co-generation Plant comprises basically of 5 gas turbines, 5 Heat
Recovery Steam Generator and 1 steam turbine:
Gas Turbines
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Three Alstom 13E2
gas turbines, each capable of producing 164 MW.
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One GE Frame 5 gas
turbines, which is capable of producing 26 MW.
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One GE Frame 6 gas
turbines, which is capable of producing 42 MW.
Heat Recovery Steam Generators
Three dual-pressure
HRSGs:
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Each HRSG is
coupled to the individual 13E2 gas turbine.
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Each HRSG produces
superheated HP steam and saturated LP steam, to a common HP
header and common LP header, before directing the steam to the
steam turbine or for process steam extraction.
One single high
pressure HRSG:
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The waste heat
from GE Frame 5&6 exhaust gas is channeled to a common duct
system. Waste heat is diverted to a single high pressure HRSG to
produce superheated HP steam.
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The HP steam
generated will be coupled to the common HP header, before
directing the steam to the steam turbine.
Steam Turbine
One Alstom dual pressure condensing steam turbine with double-flow
LP cylinder.
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The superheated
high-pressure live steam, from the common HP header, is fed to
the HP steam Turbine.
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At the HP turbine
exhaust, the expanded high-pressure steam is mixed with the
saturated low-pressure steam from common LP header and fed to
the LP turbine.
Plant Operational Profile
The power plant has
the flexibility to operate as a simple cycle, combine cycle or
cogeneration plant. The gas turbines uses natural gas as fuel
input and distilate as standby fuel.
The level of power
dispatch of the facility is dictated by TNB central dispatch
station according to grid requirements. Process steam is extracted
from the steam header and the amount is dictated by the paper
plants' processes.
The power supplied
by two existing GE Frame5 & Frame6 can be used as a black start
and these machines themselves have diesel black start units. If
the grid breaks down, the plant can run in island mode.
Since this plant is
not just a combined cycle facility, its cogeneration operation
makes it one of the most energy efficient stations in Malaysia,
with an efficiency of over 50%. |
