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Of
ets
several materials
Operations that typically reduce costs include steadystate baseload operation at or below the design rating.
This is generally achieved by derating units some 3 to
5% of rated power. Carefully increasing the time
between major overhauls when there are no major
impediments to increasing these overhauls can also
reduce costs.
sese
I
The fourth cost element in Equation 1 is system longterm generation capacity costs. These costs include both
the need for short-termpurchase of replacement capacity
due to higher plant outages and acceleration of the need
for cost expenditures to build new capacity due to
shortened life of the units being cycled.
Cost-Of-Cycling Equation
The sixth cost element is the capital cost of cyclingrelated improvements. These improvements would
include turbine bypass systems, stress analyzers, and
equipment to upgrade automatic operation such as
References
1. Lefton, Steve, "A Methodology to Measure the
Impact of Cycling Operational and Power Derations
on Plant Life and Reliability," EPRI Fossil Power
Plant Conference 1992.
2. "Metals Handbook - Tenth Edition, Volume 1 Properties and Selection: Irons, Steels, and HighPerformance Alloys,'' ASM Intemational.
Conclusion
The true cost of cycling units that were originally
dosigned for baseload operation is greater than most
ubjhties have estimaled and accounted for in their system
&patch programs. 'The true cost of cycling for each unit
type should be carefully assessed by utility management
199
ACC
Fatigue Cracking of:
- Boiler Tubes in Furnace Corners
- Tube to Buckstay/Tension Bar
- Tube to Header
- Tube to Burner
-Membrane to Tube
- Economizer Inlet Header
- Header Ligament
Superheater/Reheater
Burner Refractory
Impingement and Sho
Table 2
Steam
Seals/Packing WearllSestruction
200
Table 3
CHEMISTRY EFFECTS DUE TO CYCLING
Grooving of CondenserFeedwater Heater Tubes at
Support Plates
w Corrosion Fatigue
OxygenPitting
w Increased Need for Chemical Cleaning
w Corrosion Transport to Boiler and Condenser
Attack
NH, Countermeasures)
Table 4
ELECTRICAL AND CONTROL SYSTEM EFFECTS DUE TO CYCLING
WiringFatigue
m Breaker Fatigue
Starts/Stops
201
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.
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OL
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77"
600 MW Baseloaded
600 MW Cycling and Upgraded for Cycling
600 MW Cycling - No Upgrades for Cycling
600 MW Cycling and Designed for Cycling
600 MW Cycling Arrows Show Infusion of Capital
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Cycling'Beg ins
Figure 1- Schematic of Typical EFORs and Capital Infusion Effects for Large, Aging, Coal-Fired
Units Designed or Upgraded for Cycling.
.c
Figure 2 - Overall System Costs Versus Average Cycles Per Year for Utility Power Plants.
203
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205
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Figure 7 -Boiler Waterwall Tube Strain Gages and Heat Flux Monitors.
207