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• Powerplant• Edition1.1/04-11-2014

Reference projectsPower plants

PlaceApplicationDate

KNG power plant Rostock

Rostock/GermanyCoal-firedpowerplant1996-2011

Project description

TheRostockpowerplantisahard-coal-firedcommunitypo-werplantinthenorth-eastofGermanywhoseoperatingcompany,Kraftwerks-undNetzgesellschaftmbH(KNG)wasfoundedin1990direct-lyaftertheWallcamedown.Cons-tructionworkbeganin1991,andinMarch1994thefirstcoaldeliveryarrivedattheplant.Inthefollowingmonth,thefirstpowercouldbesup-pliedfromthenewly-builtpo-werplantbeforeitofficiallytookupitscommercialoperationon1October1994.

Thepowerplant’sgrosselec-tricityoutputis553MW(netoutput509MW).Additionally,amaximumdistrictheatoutputof300MWcanbesuppliedfromcogenerationofwhich150MWhavebeenrealisedsofar.Withthisoutput,theRostockpowerplant,whichisalsoopentovisitors,iscurrentlyproducingover50%ofMecklenburgWe-sternPomerania’selectricpower,onefifthofRostock’sdistrictheatandfeedsalmost3TWhperyearintothepowergrid.Itscurrentefficiencyis42,3%andatfullheatsupplyfromcogenerationcouldbeincreasedtoamaximumof62%.

Thepowerplantfunctionsasamedium-loadandpeak-loadpowerplantandisequipped

VAG EKN® Butterfly Valves, VAG EKO®plus Gate Valves and VAG SKR slanted seat tilting disk check valves in the pumping station of the fire-fighting system

VAG CEREX® 300 Butterfly Valves and VAG SKR slanted seat tilting disk check valves in the associated intake structure

Products 10xVAGCEREX®300ButterflyValvesDN500>40xVAGEKN®ButterflyValveswithelectricactuatoruptoDN800>30xVAGBETA®/EKO®plusGateValvesuptoDN300>10xVAGSKRslantedseattiltingdiskcheckvalvesuptoDN600>10xVAGhydrantsDN100

witha141.5mhighcoolingtower(diameteratthefoot100mand60matthetop)whichisalsousedasanexhauststack.Theturbinesystemcompri-sesaone-shaft,four-cylindercondenserturbineconsis-tingofonehigh-pressure-,onemedium-pressureandtwolow-pressureturbines.

Between1996and2011VAGsuppliedover100differentval-vestotheRostockpowerplant.Thesevalvesincludedinparti-cularbutterflyvalves,gateval-ves,non-returnvalvesaswellashydrantswhichwereusedtoequipthefire-extinguishing-andcooling-watersystemoftheRostockplantandintheassociatedintakestructureatMarkgrafenheide.InsomeplacesalsoairvalvessuchastheVAGDUOJET®AutomaticAirValvewereinstalled.

AccordingtoKNG,thevalvesmadebyVAGhavebeenwor-kingtrouble-freeinthepowerplantformanyyears.

VAG BETA® 200 Gate Valve

VAG RETO-STOP Non-Return Valve, VAG BETA® 200 Gate Valve and VAG SKR Slated-Seat Tilting-Disk Check Valve in the booster station of

the fire-fighting system

PlaceApplicationDate

Project description

Intheyear2000,E.ONac-quiredastate-ownedenergycompanyintheRotterdam/TheHaguearea,thuslayingthefoundationsforE.ONBenelux.Duetothisacquisition,alsofivegas-andtwocoal-firedplantswithatotaloutputcapacityof1,052megawatts(MW)chan-gedhands.Fiveyearslater,E.ONBeneluxtakesoverano-thercompanywhichsuppliespowerto250,000consumersintheEindhovenregion.

In2008,E.ONbeganwiththeconstructionworksforthenewplantwhichwasputintoservicein2013.Thecoal-firedpowerplantwithagrossoutputcapacityof1,100MWisknownbythenameofMaasvlaktePo-werPlant3(MPP3).Thecom-panycommissionedE.ONNewBuild&TechnolgyGmbHbasedinGelsenkirchen,Germany,withtheengineeringworksandthustheselectionofvalves.

Itisparticularlyinsea-waterconveyingwatercircuitsthatspecialcorrosionprotectionisvitalforallpartsofavalvecomingintocontactwiththemedium.AsE.ONNewBuild&TechnologyGmbHhadhadpositiveexperiencewithVAGinpreviousprojects,theyde-cidedtopurchasethesystemvalvestobeinstalledintheprimaryandsecondarycoolingwatercircuitsfromVAG.The

Maasvlakte/TheNetherlandsCoal-firedpowerplant2008-2013

Sea water valves for the Maasvlakte power plant

The coal-fired Maasvlakte Power Plant 3 (MPP3)by day and night

Employees of E.ON New Build & Technology duringthe acceptance of a VAG EKN® Butterfly Valve

Products 19xsea-waterresistantVAGEKN®ButterflyValvesDN500–DN2200withUVVsafetyinterlock2xVAGSKRSlanted-SeatTilting-DiskCheckValvesDN250

ordercomprised19sea-waterresistantVAGEKN®ButterflyValveswithnominaldiametersofDN500,700,1200,2000and2200.AsthepowerplantislocatedontheNorthSea,thepipelineshavetobeaccessibleatalltimestocleantheplantfrommolluscs.Toavoidhavingtoinstallasecondvalveaccor-dingtotheaccidentpreventi-onregulations,VAGinstalledVAGEKN®ButterflyValveswithTÜV-approvedUVVsafetyinterlock.

E.ONNewBuild&TechnologyalsodecidedtoinstallVAGSKRSlanted-SeatTilting-DiskCheckValves.TheycompliedwiththerequirementsoftheE.ONspe-cificationandreliablypreventleaks.Asneitherthelevernortheweightarelocatedonthevalve,thevalveremainscom-pletelysteadyinthevolumetricflowevenwhenitisfullyopen–andthatataminimumflowof1.5m/sec.Whenthepumpswitchesoff,ahydraulicdam-perpreventspressuresurgesandatthesametimesecuresthepumpagainstrunningback-wardatflowreversal.

Thecustomerwashighlysa-tisfiedanddescribedVAGasa“veryreliablepartner”thatensuressafetyandtrouble-freeoperationofthepowerplantwithitspremium-qualitypro-ducts.

VAG EKN® Butterfly Valve suitable for seawaterapplications (with rubber lining)

VAG SKR Slanted Seat Tilting Disk Check Valve suitable for seawaterapplications with a hydraulic damper controlled by its own medium

PlaceApplicationDate

Project description

Inpowerplants,theprimaryandsecondarycoolingwatersystemsarefrequentlycon-nectedtoeachother.Intheeventofaunitdowntime,manyofthelargepipelineshavetobeman-accessibleforinspection–althoughthepipelinesectionononesideoftheshut-offvalvesisstillpressurised.

Toensurenobodyisinjuredintheeventofafailureoftheshut-offvalves,suchsystemshavetobesafelylockedaccor-dingtotheVGBGuidelineR107:

“(32) Valves in man-accessible pipelines equipped with energy storage devices, drop weights or other quick-closing devices have to be provided with safety devices to ensure that mainte-nance staff is not exposed to any dangers. Lockable pins can serve as safety devices.”

Inthesecases,aVAGEKN®ButterflyValvecombinedwithaUVVsafetyinterlockisasui-tabledevice.IntheVattenfallpowerplantinJänschwalde,32VAGEKN®ButterflyValveswithone-sided

UVVsafetyinterlock(DN2000)andelevenbutterflyvalveswithdouble-sidedUVVsafetyinter-lock(DN2000)wereused.

Jänschwalde/GermanyThermalpowerplant1992-2013

Power plant Jänschwalde

VAG EKN® Butterfly Valve with double-sided UVV safety interlock as unit isolation valve DN 2000

VAG EKN® Butterfly Valve with one-sided UVV safety interlock

Products 32xVAGEKN®ButterflyValvesDN2000withUVVsafetyinterlockononeside11xVAGEKN®ButterflyValvesDN2000withUVVinterlockonbothsides

Intheyear2008thepowerplantoperatorconfirmedthattheyweresatisfiedwiththeVAGvalvesinstalled:

“Inourcompany,hydrants,checkvalves,gatevalvesandairvalvesmadebyyourcom-panyareinusebesidesthenumerousVAGEKN®ButterflyValves,andallofthemperformtheirtaskscompletelytrouble-free.TheVAGbutterflyvalveshavebeeninoperationinourplantsuccessfullyformanyyears.Wedecidedinfavourofyourproductduetoitsexcel-lentquality.(…)Particularlyinourpowerplants(…)VAGEKN®ButterflyValvesmeetalltherequirements.Inthepastfewyears,wehavepurchasedvariousvalvesfromyouwhichperformessentialfunctionsintheoperationofourplants.Sin-ce1992,youhavesupplied(…)EKN®ButterflyValveswithUVVsafetyinterlockforourplants.”

VAG EKN® Butterfly Valve with double-sided UVV safety interlock ready for installation into the pipeline system

VAG EKN® Butterfly Valve with double-sided UVV safety interlock as unit isolation valve DN 2000

PlaceApplicationDate

Project description

InBoxberg,acommunityinGermany’sstateofSaxony,thelignite-firedUnitRofthepowerplantwithanelectricpoweroutputof675MWwascommissionedinOctober2012.

ForthisnewlybuiltunitVAGsuppliedanumberofvalvesincludingVAGEKN®andVAGCEREX®ButterflyValves,VAGRIKO®PlungerValves,VAGSKRSlantedSeatTiltingDiskCheckValvesaswellasVAGEKO®plusGateValves.

Toprotectthemaincoolingwaterpumpfromcoolingwaterpressuresurgesduringcontrolledshut-downbutalsointheeventofaquickshutdown,twoVAGEKN®ButterflyValvesDN2000withahydraulicbrake-and-liftunitwereinstalleddownstreamofthispump.

Thedesignofthebutterflyvalvehasbeenadaptedtothepressuresurgecalculationsofthemaincoolingwatersystemtobeabletoresistallcondi-tionspresentinthesystem.

TheVAGEKN®ButterflyValvemustbeabletoshutoffmassflowratesof10.28m³/sduringacontrolledclosingprocedure.

Bywayofatwo-stepclosingcharacteristic,thediskofthe

Boxberg/GermanyCoal-firedpowerplant2009-2012

Boxberg power plant

Construction site of the lignite-fired Unit R

VAG EKN® Butterfly Valve with hydraulic brake-and-lift unit during customer acceptance for the pressure test in the year 2009

Products 2xVAGEKN®ButterflyValvesDN2000PN61xVAGhydraulicbrake-and-liftunit(aspumpprotectiondeviceinthemaincoolingwatersystem)+safetyinterlockaccordingtoUVV

butterflyvalveismovedfroma90°openingtoa20°openinginnineseconds.Ittakesanother30secondsuntilthevalveisfullyclosed.Theopeningtimeforthisunitis45seconds.

Thekineticenergyneededtoclosethebutterflyvalveisstoredinthethree-tonnedropweight.

Installation of a VAG EKN® Butterfly Valve with double-sided UVV safety interlock, ready for

installation into the pipeline system

PlaceApplicationDate

Project description

Whatisgeothermalenergy?ThetermoriginatesfromGreek“geo”,meaningEarth,and“thermos”,whichtranslatesashot,i.e.thermalenergygene-ratedandstoredintheEarth.GeothermalenergyisreferredtoasarenewablesourceofenergywhichcanbegainedfromtheEarth’scrustthathasathicknessofabout40km.ThisenergyisconductedbyacontinuousflowofheatfromtheEarth’sliquidcore,whosetemperatureisestimatedtobe5,000to9,000°C,intotheEarth’scrust.Insomecases,thisheatevenreachesthesurface–intheformofvolca-noesorgeysers.Icelandhasanunusuallyhighnumberofactivevolcanicsystemsandisknownforitsgeysersandhotsprings.ItthereforecomesasnosurprisethatgeothermalenergyisIceland’smostim-portantsourceofenergy.TheaveragetemperatureclosetotheEarth’ssurfaceisabout10°Candincreasestowardsthecorebyabout3°Cper100mofdepth.Inadepthof3,000m,thisamountstoabout85°C–whichisenoughtouseitforheating.

UseofgeothermalenergyinPullachButalsoinGermany–ormorepreciselyinSouthernBava-ria–thegeologicalconditionsareoptimalfortheextraction

Pullach/GermanyThermalpowerplant2011

Geothermal energy in Pullach

Each valve installed in the pipeline as a fully isolated VAG RIKO® Plunger Valve

Products 2xVAGRIKO®PlungerValvesDN150PN25

ofheatfromtheEarth.Since2005,thecommunityofPullachimIsartal,locatedinthesouthoftheadministrativedistrictofMunich,hasbeenoperatingageothermalCHPplantrunbyInnovativeEnergiefürPullachGmbH(IEPGmbH).Twobore-holesareneeded,aso-calleddoublet.Throughthefirstbore-hole,theextractionborehole,hotwaterwithatemperatureof102°Cto107°Cisconductedtothesurfacefromadepthofabout3,500mandfedintoaheatexchanger.Afterrunningthroughtheheatexchanger,theheatedwaterissupplieddirect-lytotheconsumers,andthecooledthermalwaterextractedbeforeisreinjectedintotheearthviathesecondborehole(=principleofsustainability).

VAGequippedthegeothermalenergyplantwithtwoVAGRIKO®PlungerValvesDN150PN25.ThesetwovalveswereinstalledbetweenthewellheadsandtheheatexchangerandanotherVAGRIKO®PlungerValveDN200PN25wasin-stalledupstreamoftherein-jectionborehole.Thecontrolvalvesarecustom-madeplun-gervalves,madecompletelyofspecialsteelcasting,andareresistanttotemperaturesofupto150°C.Themediumtobecontrolledbythevalvescon-tainshighconcentrationsofso-lublegasessuchasmethane,nitrogenorcarbondioxideandhasanoperatingtemperature

of107°C.Thevalves’taskistokeepthesystempressureataconstantlevelsothatalldissolvedgasesremaindissolvedtopreventdeposits.

Duetothespecialconditionsoftheplant,specialsteelcas-tingwaschosen.Thismaterialfeatureslong-termresistancetothedifficultconditionsofthermalwater.In2009,PullachwasgivenanawardasclimateprotectionprojectbyDeutscheUmwelthilfe,anenvironmentalprotectionorganisation,andasearlyas2011Pullach’sdistrictheatingnetworkhadgrownto25km.

Almostallpublicbuildingssuchasthetownhall,municipalhall,swimmingpoolandschools,butalsochurchinstitutions,commercialenterprisesandofcoursemanyprivatecustomersaresuppliedwithheatgeneratedintheplant.Sincetheirinitialset-up,theplungervalveshavebeenperformingtheircontroltasksreliablyandtrouble-free.

PlaceApplicationDate

Project description

Thecontinuouscoolingofthecondenserwithinaverynar-rowtemperaturerangeisoneoftheessentialprerequisitesforkeepingthepressureintheturbineataconstantlevelandisthusdecisivefortheeffici-encyofapowerplant.Inregi-onswherewaterisabundant,once-throughcoolingorawetcoolingtowerisnormallyused.

Inareaswithecologicallysen-sitivebodiesofwaterorlimitedwateravailability,watercon-sumptionmustberestricted.Thisiswhyindirectdrycoolingtowersareusedintheseregi-onsasarule.

IntheYangchengpowerplant(2x600MW),theworld’stwolargestdrycoolingtowersareoperated.Throughtheuseofthesetowers,waterconsump-tioncouldbereducedtothreecubicmetresperday.ThesecoolingtowerswereerectedbyGEAEGIin2007.

Toensurethesafeoperationofthisplantovermanyyears,itisessentialtousemodernandpremium-qualityvalves.Thefailureofevenasmallcoolingwatervalvemayhavedisastrousconsequencesfortheentiresystemandhaveanadverseeffectontheoutputofthepowerplant.

Yangcheng/ChinaCoal-firedpowerplant2007-2009

Yangcheng Coal-Fired Power Plant

Dry cooling towers at the Yangcheng coal-fired power plant

Machinery room; Hydraulics area

Products VAGDUOJET®AutomaticAirValveVAGEKO®plusGateValveVAGSKRSlantedSeatTiltingDiskCheckValveVAGEKN®ButterflyValvewithVAGHYsecHydraulicBrakeandLiftUnit

Thisiswhy,besideshighquali-tystandards,modernsolutionsfordemandingtasksareaskedfor.Whentheambienttempe-raturedrops,thesystemmustbequicklydrainedtopreventdamagecausedbyfreezingcoolingwater.Ithastobedonefast,reliablyand,ifnecessary,evenwithoutelectricalenergy.Toensurethis,GEAEGIdeci-dedinfavourofVAGbutterflyvalvescombinedwithhydraulicbrakeandliftunits.

EGI’sconstructionsitemana-ger,MrBorosJeno,hasbeenattheYangchengpowerplantsiteforalmosttwoyearsnow.Tohimthefailureofevenasmallvalvemeansadisasterfortheentiresystem.HeishighlysatisfiedwithVAG’svalvesastheyareoftopquality,easytocontrolandpracticallymainte-nance-free,allofwhichsetshisheartatrest.

VAG EKN® Butterfly Valve with VAG HYsec Hydraulic Brake and Lift Unit in open position

VAG EKO®plus Gate Valve

PlaceApplicationDate

Project description

TheSchwarzePumpepowerplantoperatedbyVattenfallwasbuiltbetween1993and1998,and,inJune1998,officiallytookupcommercialoperationafterunitAhadcomeonlineinMay1997andunitBinOctober1997.Thedoubleunitplanthasatotalgrosselectricityoutputof1600MWwitheachunithavinganoutputof800MW.Thebrown-coalfiredpowerplantislocatedonthesiteoftheSchwarzePumpeindustrialestatewhichhasservedasapowerplantlocationsincethe1950s.Beforethat,thepowerplantsSchwarzePumpeWest,MitteandOstwerelocatedthe-rewhichhavemeanwhilebeendecommissionedandpulleddown.Withanoutputbetween25and100MW,theygenera-tedbothelectricalenergyandprocesssteam.Thenewpo-werplantfollowsthistraditionandbesideselectricalenergyitalsogeneratesprocesssteamforthecompanieslocatedinthenearbyindustrialestateSchwarzePumpe.Additionally,oneofthemostimportanttasksofthispowerplantisthesupplyofdistrictheattothevillageofSchwarzePumpeandthecitiesofSprembergandHoyerswer-da.

The172mhighexhauststackoftheauxiliaryboilerplantandtwonaturaldraughtwetcoolingtowersriseabovethepower

Spremberg/GermanyCoal-firedpowerplant1996-2011

The Schwarze Pumpe power plant

VAGSKRSchrägsitz-Kipp-RückschlagklappeDN600PN10inderWasseraufbereitung

VAG EKN® Butterfly Valves DN 800 PN 10 in the condenser section

VAG SKR slanted seat tilting disk check valveDN 600 PN 10 in water treatment

Products 4xVAGEKN®ButterflyValvesDN2000withelectricactuatorandUVVsafetyinterlockononeside>50xVAGEKN®ButterflyValveswithelectricactuatoruptoDN1000>50xVAGBETA®GateValvesuptoDN300>10xVAGSKRSlantedSeatTiltingDiskCheckValvesuptoDN600>10xVAGhydrantsDN100variousaccessories

plant.Aglazedobservationdeckcanbefoundoneachofthetwostairtowersofthesteamgenerationbuilding.Theeasterndeckisopentovisitors.ThepowerplantusedtocoverbaseloadpowerdemandissuppliedwithrawbrowncoalbythenearbyWelzow-Südstripmineandconsumesabout36,000tonnesofcoalperday.Likeallmodernpowerplants,theSchwarzePumpepowerplant,whichhasanefficiencyofalmost40%,isequippedwithamultistagefluegasclea-ningsystem.AspecialtyofthispowerplantisitspilotplantforCO2sepa-rationwhichofficiallywentintooperationinSeptember2008afterateststage.Thecarbondioxidegeneratedbycombu-stioniscompressedandlique-fiedintheplant.Inthepast15years,VAGhassuppliedover50VAGEKN®ButterflyValvestotheSchwar-zePumpepowerplant,inclu-dingfourVAGEKN®ButterflyValveswithsafetyinterlockwhichserveassafetyvalves.Additionally,agreatnumberofVAGBETA®GateValves,VAGSKRslantedseattiltingdiskcheckvalvesandVAGhydrantswereinstalledintheprimaryandauxiliarycoolingcircuitsand/orthefire-fightingsystemofthepowerplant. VAG EKO®plus Gate Valve DN 100 PN 16

Installed in the ash settling pond

VAG EKN® Butterfly Valve DN 2000 PN 6 as pump safety valve with hydraulic brake-and-lift unit installed in the pump-house

downstream of the main cooling water pump

PlaceApplicationDate

Project description

InOctober1986,theownersatthattime,PreussenElektraandHEW,starteduptheBrokdorfNuclearPowerStation(KBR)inSchleswig-Holsteinforthefirsttime.TodaytheenergygroupE.ONowns80%ofthepowerplantandtheSwedishcompa-nyVattenfall20%.

Inthe1980s,VAGinstalled,amongotherthings,VAGEKN®GateValveswithnominaldiametersofuptoDN2000,VAGSKRSlantedSeatTiltingDiskCheckValvesuptoDN700,VAGHydrantsandVAGBETA®GateValves.Thevalves,someofthemseawaterresistant,arelocatedinthemaincoolingwatersystem,inthenuclearandtheconventionalinterimcoolingsystem,inthesecuredancillarycoolingwatersystem,andinthefirefightingsystemandinvariousaidandancillarysystems.

Morethan20yearslater,themaincoolingwaterbutterflyvalvesaretobereplaced.VAGisreplacingtheringsfromitsheadquartersinMannheim.TheVAGdesignersareusingtheolddrawingstoproduceacentrallymountedsealingvalve.VAGisalsorubberliningthebodiesanddisksofsixothersealingvalvesandreplacingthesensitivehydraulicbrakeandliftcylindersoftheolder

Brokdorf/GermanyNuclearpowerplant2008-2010

E.ON Nuclear Power Station in Brokdorf

The centrally mounted disk is dismantledat the headquarters in Mannheim

Installation of a VAG AKL Butterfly Valve in a seawaterdesign for the nuclear power station in Brokdorf

Products 115xVAGAKLButterflyValves/EKN®ButterflyValvesuptoDN200013xVAGSKRSlantedSeatTiltingDiskCheckValvesuptoDN700294xVAGBETA®GateValves45xVAGHydrants

100generationwiththemodern200actuatorseries.VAGEKN®ButterflyValvesDN2000PN10withaVAGHYsechydraulicbrakeandliftunithavebeendesignedforuseinthebrackishElbewateratapressureof6barsandtemperaturesof70°C.

An extract from a reference letter from the customer shows that the VAG valves are still reliable, even after 25 years.

BETA® 136 Gate Valve

Oldhydraulicbrakeandliftcylinder

Modifiedhydraulicbrakeandliftcylinder

Notes

Notes

[email protected]

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