ADVANCED SOFTWARE TOOLS FOR OPTIMIZATION OF
POWER PLANT PERFORMANCE”
ARC Tenth India Forum, Hyderabad 5-7 July, 2012
Transforming Industry and Infrastructure through New
Processes and Technologies
Debasish Patra
Addl. General Manager
Steag Energy Services (India) Pvt Ltd d.patra@steag.in
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First Step: low hanging fruits
Improve efficiency by improving operation and maintenance
Next Steps:
Audit or „map “ the plant using off line modelling tool e.g. Ebsilon
Online optimization tool PADO
Online fault detection system using
SPC and Fault trees
Online life time monitoring SR1 for better planning of inspections and maintenance
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• Power Plant Design for new Power Plant
• Mapping and Performance Analysis of existing Power Plants
• Planning for Renovations
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Topology, design-parameters, measured values
Data collection
Topology, design-parameters, measured values
Feeding into software
Stationary simulation of certain scenarios
Analysis and reporting
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The software that shall be used for this demo is called
“Ebsilon©Professional”
(it stands for “Energy Balance and Simulation in Open
Networks”)
• It has a history of approximately 20 years
• It is used by more than 120 companies (manufacturers, utility companies, engineering companies) and 20 universities worldwide
• In more than 20 countries
• Altogether more than 700 licenses sold
• Up to now approximately 45 online-systems running in power-plants
• The software is under continuous development
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• User friendliness by intuitive handling
(100 % Windows compliant)
• No programming skills required
• Graphical objects for components and pipes
(component library and fluid library)
• Complete observance of physical laws
(mass-balance, energy balance, …)
• Design and off-design calculation possible
• Extension by self-defined macros and by DLL s possible
• Large number of different fluids
• Fast diagnosis of topology and specification errors
• High stability of convergence of solution
• Different unit systems
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With the calculation tool the following thermal power cycles can be mapped :
• Fossile power plants (hard coal fired, lignite fired, oil fired, gas turbine)
• Nuclear power plants (NPP)
• Combined cycle power plants (CCPP)
• Combined heat and power plants (CHP)
• Regenerative energy (Solar thermal, Geothermal,
Biomass…)
• Additional working fluids (ORC, certain binary mixtures)
• Desalination processes (MFD)
• Refrigeration cycles
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• Create the topology
(from component library and fluid library)
• Specify the design values
(values of the 100 % plant condition at default ambient condition)
• Do a design calculation
(simulate the 100 % plant condition)
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• Identify components
(i.e. adjust nominal values and part load performance characteristics of components from default values to “real” values.
Derive the “real” values from manufacturers design data, heat-balance diagrams or from measurements)
• Do off-design calculation
(i.e. calculate values for different loadcases)
• Do What-If scenarios
(i.e. investigate the behaviour of the model under different conditions)
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Study case: Detailed mapping of Water Steam Cycle of a 210 MW power plant
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Signing of Framework Agreement
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PADO in India
72 units order for PADO have been placed on STEAG mostly through its framework agreement with BHEL
23 units successfully commissioned till date
National Thermal Power Corporation (NTPC) has standardised specification based on STEAG supplied PADO for all future units including Super-Critical
Units.
Bharat Heavy Electricals Limited (BHEL)
The largest supplier of power equipment with 70% of current installed market of Thermal Power Plants has a Framework Agreement with
STEAG for installation of PADO.
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49 units where PADO is commissioned or under commissioning
NTPC Simhadri 2x500 MW
NTPC Ramagundam 1x500 MW
NTPC Rihand 2x500 MW
NTPC Talcher 4x500 MW
NTPC Kahalgaon 3x500 MW
NTPC Sipat 2x500 MW
NTPC Vindhyachal 2x500 MW
NTPC Korba 1x500 MW
NTPC Dadri 2x500 MW
NTPC Farakka 1x500 MW
Mahagenco Khaparkheda 1x500 MW
Mahagenco Bhusawal 2x500 MW
NTPC Simhadri (stage II) 2x500 MW
NTPC Jhajjar 3x500 MW
KPCL Bellary (KPCL) 1x500 MW
RVUNL Stage 1 and 2 Chhabra 3 x 250 MW
Shree cement Ltd. RAS
DVC Maithan 2x500 MW
GEB Ukai 2x500 MW
NTPC Korba Extn 1x500 MW
NTPC Bongaigaon 3x250 MW
TNEB North Chennai 2x600 MW
CSEB Marwa 2x500 MW
CSEB Korba 1x500 MW
L&T Rajpura 2x700 MW
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● Improving the quality of measurements by data validation
● Evaluation of boiler, turbines, condenser and other components
● Optimization of unit operation (sootblowing, setpoints)
● Calculation of what-if scenarios
● Generation of daily and monthly reports
● Enhance the efficiency of the power plant !
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Modules of PADO System
Data
Visualizer
Soot
Blowing
Optimizer
Data
Validation
Boiler
Setpoint
Optimizer
Statistical
Process
Control
Fault
Tree
Data
Management
System
Ebsilon
Model
Base Modules
Fault Detection
Optimization
Physical Condition
Performance Analysis
Lifetime
Monitoring
Metal
Performance
Monitoring
What-If
Analysis
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SR::x is the central data management in the
SR product family featuring:
– “state-of-the-art“ visualization
– Long-term storage of measured and computed values in time-oriented archives;
– Automatic aggregation of data to higher time classes such as 5‘, quarterly, hourly, daily, monthly- or yearly- values
– Integrated mathematical formula editor
– Excel-Add-In and HTML-List Generator allow the generation of extensive reporting systems
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SR::x is the central data management with “state-of-the-art” visualization
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Data Validation to replace data errors due to defective sensor or cable problems:
Incorrect Data – Wrong results
No data – No results
Validation – A 3 tier Process
1) Plausibility Check using Neural
Networks
2) Plausibility Check based on range of Values
3) Data validation / reconciliation based on “First Principle
Thermodynamic” model
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based on Neural Network…
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based on “First Principle Thermodynamics”…
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check the quality of measurements …
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Compares the actual values of critical parameters with the best achievable under current operating conditions.
Shows monetary loss against each sub optimal operating parameter , defining the scope of improvement.
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Fouling/Slagging: Results from thermodynamic model - SR::EPOS
Time intervals
- Minimum frequency of soot blowing
- Minimum-pauses
Configurable priorities for each criterion
Soot-blowing costs
Process-engineering criteria, plant-specific
- Reheat spray flow
- Flue gas temperature before air preheater
- Furnace exit gas temperature
- RH Metal Temperature
- Mills Combination
- Coal mass flow
- NOx-emissions
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Shows the optimal against current set points and improvement in heat rate.
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Shows the temperature profile of individual tubes of various heating surfaces of boiler and identifies the Hot spots .
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SR1 module aims to calculate the remaining life of thick walled components in boiler the consumed life of an equipment could be different from the actual age of the equipment
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Fault Prediction in Power Plant using statistical methods to corelate deterioration of key performance indicators.
Air ingress false alarms
07.09.2006
plausible alarm air ingress
07.09.2006
plausible alarm air ingress
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Measured vibration bearing temperature oil temperature power consumption
… calculated heatrate
Component quality factor efficiency
…
Key measurements in power plants usually depend on
- load,
- operation mode
- fuel quality
- ambient conditions and are superposed by noise
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• Models and analyzes faults in the process.
• Composed of logic diagrams that display the state of the system and the states of the components
• Constructed using Drag & Drop technique
• Does not need programming expertise for building such trees.
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PADO helps to optimize process parameters so that plant operates at optimum level of efficiency
STEAG also offer other two software systems for plant optimization:
• Simulator- to improve the skills of the operators by giving training on Simulator
• SI- Computer based Maintenance Management system to improve the maintenance activity
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Thank You for your attention!!
For live demo or more questions on all the above software solutions, kindly visit STEAG Stall
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