ENGINE & TURBINE TECHNOLOGY
ABOVE AND RIGHT: Two 50% capacity pumps were installed by Sulzer to improve the resilience of the cooling system at the CCGT plant
EDF Energy’s combined-cycle gas turbine (CCGT) power plant at
Bouchain in Northern France is one of the most energy-effi cient in the world, achieving an overall effi ciency level of 62.22%
T e scope of Sulzer’s work at Bouchain
went far beyond the mere supply of the pumps themselves. Drawing on its experience of similar installations elsewhere in the world, the company was awarded a turnkey project for the circulation system. T is included the design of the suction intake where the pumps are installed and the control strategies used to ensure optimum performance through every phase of the plant’s operation from start-up to shut down. Sulzer’s collaboration with EDF began
very early in the project, during the concept and design phase. Sulzer experts from France and Switzerland worked to propose a solution that met EDF’s technical requirements, then conducted a series of detailed studies to create an optimum solution that would achieve the best combination of price, performance and reliability. T at work involved advanced thermal analysis as well as fl ow simulations using computational fl uid dynamics (CFD) software to build a complete picture of the performance of the cooling system. T e pumps selected for the Bouchain plant are two of Sulzer’s latest generation
of high-effi ciency vertical circulation water pumps; a proven design that was optimised to suit perfectly the technical requirements of the installation. Each pump draws approximately 1.3MW of power, and in normal operation they run in parallel to supply the required cooling capacity. Two 50% capacity pumps were installed to improve the resilience of the cooling system; if one pump has to be taken out of service for maintenance, the power plant can continue to operate until the pump is back in service.
PUMP DATA MONITORING Once the design of the pumps and their associated control and monitoring systems was agreed, the two units were manufactured at Sulzer’s production facility in France. EDF’s specifi cations for the pumps included the installation of extensive instrumentation and data collection equipment to monitor temperatures and vibration levels in the pump bearings and other key components during operation. Both pumps also underwent extensive factory testing prior to their installation at the plant. Sulzer’s involvement with the Bouchain
project goes on to this day, four years after the successful commissioning of the cooling system. T e company continues to monitor the performance of the pumps in service
and works closely with EDF’s operations and maintenance teams at the site to ensure optimal performance and advise on the most appropriate maintenance strategies for these important items of equipment. “When we work with EDF, we
know that we are expected to adhere to demanding specifi cations. Sulzer can meet these and off er a specifi c comprehensive solution to EDF,” says Nicolas Amalric, head of mechanical design at Sulzer Pumps France, who was the technical manager for the Bouchain pump project. “It’s a real feeling of pride to be part of a project like this, knowing that it is one of the most energy-effi cient in the world.” “We are very satisfi ed with both
the reliability of the pumps and their mechanical behaviour, which we regularly monitor through vibration analysis. T e performance is always stable and exactly what is expected,” says Phillippe Lambin, EDF’s manager of the maintenance department at the Bouchain CCGT plant. “Sulzer has always supported us with its engineering and maintenance expertise. T e team is always there to help us maintain the levels of performance and quality that are essential for generating electricity.”
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