BU Power Generation Energy efficiency presentation PSPG Services

Transcription

1 BU Power Generation Energy efficiency presentation PSPG Services

2 World primary energy demand in reference scenario Demand and related emissions rise 40% Source: IEA World Energy Outlook 2009 World energy demand (in million tonnes of oil equivalent, Mtoe) +40% Energy-related CO 2 emissions (in gigatonnes) +40% 12,013 13,488 16, ABB 11 November 2014 Slide 2

3 Only 20% of primary energy generates economic value The rest is lost to conversion processes, transportation and operational inefficiencies Primary energy Transport Generation T&D Industrial processes Industrial production Available energy 80% of energy is lost November 11, 2014 Slide 3

4 Power and water plant operations The economic principle main characteristics Minimum Principle: Achieve target using a minimum of resources Maximum Principle: Use available resources to achieve maximum output Optimum Principle: Define optimal relation of deployed resources and intended target by yield optimization Power Plant: Use less primary energy to reach targeted power production Power Plant: Produce more power with a given amount of primary energy Power Plant: Maximise power production with minimised energy usage to reach a point of maximum financial return Key principles guiding investments, operations & maintenance Different principles provide for different objectives Monitoring and optimization measures key to implement principles November 11, 2014 Slide 4

5 Power and water plant operations The economic principle Follow structured concept and process to achieve objected economic principle Plan: Establish objectives, processes / measures Do: Implement processes/measures Check: Measure and benchmark, identify deviations Act: Analyze differences to determine cause Actions and measures should reflect productivity rules Effectiveness: Doing the right things Efficiency: Doing the things right Key questions: How to evaluate and assess power and water plant operations? How to derive optimization potentials? How to implement and track measures? November 11, 2014 Slide 5

6 Power generation services Improve plant energy output November 11, 2014 Slide 6 ABB energy efficiency solutions have a proven and well-documented ability to Improve the energy efficiency of power plants. Raise the plant s electrical output by correcting process inefficiencies Generate more energy from less fuel by lowering the plant s fuel consumption Increase plant revenues by selling more energy and reducing fuel wastage Extend the operating life of the plant by optimizing asset performance Improve operational flexibility by maximizing process efficiency Reduce greenhouse gas emissions by minimizing the plant s carbon footprint

7 Power generation services Energy efficiency audits ABB s energy efficiency experts run an on-site assessment to identify potential savings for energy consumption Based on this audit customer representatives of management and engineering and ABB review the energy efficiency potential and define and implementation plan for implementing measures. Main focus is on a short pay-back period Saving potential per plant usually lies between 5 to 20 per cent of the actual energy consumption means up to 8% of overall plant efficiency. November 11, 2014 Slide 7

8 Power generation services ABB Power Generation Energy Efficiency Assessment November 11, 2014 Slide 8

9 Plant target areas Observed parasitic load profile Parasitic Load Profile Average parasitic electricity consumption by major plant area. Boiler Island Water Systems Turbine Island Materials Handling Compressed Air Flue Gas Treatment Balance 0% 5% 10% 15% 20% 25% 30% 35% 40% Percentage of Total Parasitic Load (%) November 11, 2014 Slide 9

10 ABB 11 November 2014 Slide 10

11 Industrial Energy Efficiency (IEE) implementation Plant efficiency improvement up to 8% November 11, 2014 Slide 11 TYPICAL FOCUS AREAS Optimisation of coal handling Improvement of ID and FD fan flow control Improvement of boiler feed water pump control Implementation of high efficiency motors and drives Optimised turbine controls Advanced steam temperature control Stabilisation of firing rate and combustion optimisation Excess oxygen reduction for boiler combustion Improved feed water pressure and level control Electric power system improvement (GSU s and auxiliary transformers) Reduction of leakages Reduction of thermal losses Thermal optimisation of chiller operations

12 Industrial Energy Efficiency (IEE) Value creation Energy Cost Current Plant Energy Cost Lost Energy Costs Industrial Energy Efficiency Benefit Quick Wins Industrial Energy Efficiency identifies zero or low capital investment projects to save energy that can be implemented immediately as quick wins. Projects Theoretical Energy Intensity Reduction in Energy Costs With IEE Following the identification of energy saving projects and development of the Master Plan, projects are implemented according to a prioritised plan. Opportunity Identification Master Plan Implementation November 11, 2014 Slide 12

13 Example 500 MW coal fired power plant, 25 years old Original fuel consumption per Year: 1,5 Mio. Tons Additional energy to grid: MW Energy saved per year: 22.5 Mio. kwh CO2 emission reduction per year: 260,000 Tons Equivalent to additional alternative fuel: Tons November 11, 2014 Slide 13

14 Example 500 MW coal fired power plant, 25 years old 8 % improvement of plant efficiency means 150 million kg of additional fuel available to produce more electrical energy 850 cars may run one additional year, just with the savings of only one 500 MW power block Additional green house gases are also to be expected to reduce significantly tons of CO2 reduction expected ABB 11 November 2014 Slide 14

15 Industrial Energy Efficiency (IEE) Deliverables and results Industrial Energy Efficiency delivers 5% to 20% of your customer s energy bill in savings. Chart based upon an example energy price of US$ 90/MWh. November 11, 2014 Slide 15

16 Industrial Energy Efficiency (IEE) Power Generation - energy efficiency examples STEAM GENERATION Optimised boiler operating air-to-fuel ratios & blowdown rates Variable speed drives for pumps & fans Heat Recovery through air pre-heaters and economisers Optimised boiler load profiles versus demand Improved feed water treatment Installation of efficient burners Performance pre-treatment of fuels Optimised boiler soot-blowing frequencies Optimised materials handling coal grinding, conveyor performance, electrical drives November 11, 2014 Slide 16

17 Industrial Energy Efficiency (IEE) Power Generation - energy efficiency examples STEAM DISTRIBUTION Optimised system distribution system Identified and minimised system leaks Introduction of steam trap and downcomer predictive maintenance programmes Minimised steam let downs Optimum additional metering specific to advised monitoring & targeting programme Improved condensate return system Optimum de-aerator performance Improved insulation and piping lagging November 11, 2014 Slide 17

18 Industrial Energy Efficiency (IEE) Power Generation - energy efficiency examples POWER GENERATION Thermodynamic performance Condenser performance Water chemistry optimisation Optimisation of extraction/back-pressure steam control Turbine control as individual units Turbine control of fleet for optimum heat rates Performance deterioration Predictive maintenance programmes for turbine and condenser November 11, 2014 Slide 18

19 Industrial Energy Efficiency (IEE) Power Generation - energy efficiency examples MONITORING & TARGETING Baseline thermal performance Industry benchmark performance Confirmation of energy saving opportunities Benefits verification methodology Integration with energy management policy, strategy and vision Automated performance monitoring On-line real-time optimisation ABB Optimax / cpm+ Energy Manager November 11, 2014 Slide 19

20 Industrial Energy Efficiency (IEE) Power Generation - energy efficiency examples AUXILLIARY & BALANCE OF PLANT Transformers Switchgear Field devices (instrumentation & analytics) Compressed Air System Leakage reduction programme Optimised compressor operation Reduced header pressure Cooling water system optimisation VSDs for cooling water pumps and fans Data acquisition system Alarm systems November 11, 2014 Slide 20

21 ABB s implementation view Heat rate Power output Live and reheat temperatures Basic control loops Automation (sensors and actuators) ABB 11 November 2014 Slide 21

22 Customer s financial benefit view Heat rate Power output Live and reheat temperatures Basic control loops Automation (sensors and actuators) ABB 11 November 2014 Slide 22

23 Power generation services Energy efficiency Contact Person Speaker name: Speaker title: Responsibilities: Yulius Christiady Power Generation Service Manager Power Generation Indonesia Location: WM 1 10 th floor Jakarta Indonesia Phone ABB 11 November 2014 Slide 23

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26 TAPCO: An ABB PGEE assessment (Al Taweelah, UAE) Energy efficiency opportunity identification (Nov, 2011) November 11, 2014 Slide 26 Site: New B Extension Location: Abu Dhabi, UAE Units: CCPP (3*240 MW GT + 1*340 MW ST) MSF Desalination 28 MGPD Commercial operation: Since 2008 Energy Savings: 380,000 MWh thermal per year Customer needs Ongoing interest in improving plant performance Plant efficiency decreases during low load condition Dispatcher requires unbalanced supply of power and water leading to low plant efficiency Fuel Demand Model as implemented partly recommends lower fuel consumption then possible ABB s response 32 Opportunities to improve efficiency & demand coverage were identified potential savings of up to 10 M US$/year Up to 380,000 MWh thermal energy can be saved Gas turbine air inlet cooling by absorption chilling would provide largest absolute efficiency improvement Performance Monitoring and Optimization System would be low cost investment with large improvement potential Variable Speed Drives in Brine Recirculation and Cooling System would improve efficiency in part load condition Customer benefits Quick wins would cover ¼ of all saving potential, without any significant investment Maximisation of bonus operation time and minimisation of penalties for low efficiency operation

27 Tuas South Incineration Plant, Singapore Energy efficiency case study Insert a picture here Site/project: Tuas South Incineration Plant, Energy Audit Service Agreement Location: Singapore Units: 2 x 66 MW Steam Turbine Commercial operation: 2000 Customer need To carry out an energy audit on the power generation capability and efficiency of the Plant. ABB s response Perform an energy audit on the plant to provide recommendations for energy efficiency and resulting electricity production improvements that could be achieved through: (a) Operational Adjustments (b) Corrective Maintenance (c) Retrofit or plant improvement measures Customer benefits Help the customer to identify and quantify the energy losses that can be recovered. It improve the return on investment for customers by reducing the total cost of ownership, which is the complete cost from purchase to disposal, including environmental impact. November 11, 2014 Slide 27

28 TAURON: An ABB PGEE assessment (Jaworzno, PL) Energy efficiency opportunity identification November 11, 2014 Slide 28 Site: Unit 4, Jaworzno 3 Plant Location: Jaworzno, Poland Units: 1345 MW ( 5x ) Commercial operation: Energy Savings: 125,000 MWh thermal and 21,000 MWh electrical per year Customer needs Ongoing interest in improving plant performance Difficulty reaching full output on peak demand days Carbon in Ash reduces sale value of fly ash FD fans maxed out, considering larger equipment ABB s response 43 Opportunities to improve efficiency & reliability were identified potential savings of up to 10M PLN/year Recommended coal flow monitoring plus CIA instrumentation, with closed-loop combustion controls Located FD intake screens which were about 60% fouled and recommended periodic cleaning to improve FD flow Recommendation to re-calculate heat balance diagrams for each unit thus adding a real time thermal performance model for the plant operators Customer benefits Quick wins identified which can pay for further improvement Common solutions for all six units many recommendations apply to common processes, and utilities such as fuel oil, compressed air, and water treatment Program allows for further efficiency improvements on short and medium term