SPPA-P3000 Process Optimization Solution Compendium. Instrumentation & Controls
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1 SPPA-P3000 Process Optimization Solution Compendium Instrumentation & Controls
2 Siemens Power Plant Automation Comprehensive solutions with outstanding benefit Waste-fired Cogeneration Plants Fossil-fired Power Plants Wind Power Plants Combined Cycle Plants Nuclear Power Plants Desalination Plants Industrual PowerPlants Process Optimization Coal Gasification Plants Power Generation Instrumentation & Controls 2
3 Increase performance! Solutions for process optimization Can I..... optimize plant performance with software only? Yes you can! Power Generation Instrumentation & Controls 3
4 Siemens Power Plant Automation The situation: A power plant unit needs to be operated at all times at the most profitable operating point, which calls above all for greater flexibility and higher efficiency, better availability and lower emissions. High availability High efficiency High flexibility Our solution Low emissions No changes to mechanical equipment Process Optimization Solutions SPPA-P3000 Power Generation Instrumentation & Controls 4
5 Increase performance! Solutions for process optimization Modern control principles are the basis for high profitability Excellent control concepts are at the base of Process Optimization Solutions: model-based, predictive feedforward structures exploitation of inherently stable processes decoupling of highly intermeshed subprocesses High flexibility High stability High profitability High efficiency Optimum operating behavior High repeatability High availablity Low emissions High control quality As a result, operating behavior is extremely stable, but still features flexible and fast response. Model-based feedforward Modern control principles Prediction Intrinsic stability Decoupling Power Generation Instrumentation & Controls 5
6 for Steam Power Plants Increased profitability by intelligent optimization solutions! Runback Plus Life Time Plus High availability No changes to mechanical equipment Low Loss Start Combustion Optimizer Sootblower Optimizer High efficiency Temperature Optimizer Low Throttling Fuel Optimizer Best Point Fast Start Fast Ramp Frequency Control High flexibility Dispatch Control Minimum Load Reduction Maximum Load Plus Low emissions Emissions Control Power Generation Instrumentation & Controls 6
7 gh flexibility Fast Start Get back on the grid faster Task: To get the unit back on the grid in the shortest possible time without thermal stresses for thickwalled components violating permissible limits. Stressmeasurement Steam quality Start-up valve Turbine valve Fast Start Features: Model-based formation of setpoints for main steam pressure and temperature, and of firing rate Automatic startup of boiler and turbine Automatic differentiation between cold, warm and hot starts with bumpless transfer to coordinated power operation Fuel valve T M T I Injections T HP HD Drains Furnace HP- Bypass Feedback from process Effect from Fast Sart Turbine Benefit: Reduction of forced trip duration Reduced fuel consumption Increased revenue through reproducible startup and shutdown to exploit market situation Power Generation Instrumentation & Controls 7
8 gh flexibility Fast Start Increased revenues by getting back on the grid faster References Benefit for a standard unit Parish, USA 565, gas; startup time reduced by 50% lignite lignite fired fired Unit unit unit Start-up Start-up time time time to to to full full full reduced reduced from from from to to to hrs hrs hrs starts/year starts/year EUR/h EUR/h Simmering, Austria 380, gas; startup time reduced by 25% 150,000 EUR/year Power Generation Instrumentation & Controls 8
9 gh flexibility Fast Ramp Respond reliably and fast to market requirements Task: Significant improvement of gradients free from restrictions imposed by controls and from the need for manual actions. Features: Automatic coordination of boiler and turbine Automatic derivation of dynamic setpoints from setpoint and gradient Optimization of control loops crucial to unit dynamics power % MCR SPPA-P3000 Fast ramp Faster reaction on demands Old Load ramp Benefit: Increased revenues thanks to Fast and repeatable response to changed demands High ranking of the plant with grid dispatcher 60 t Power Generation Instrumentation & Controls 9
10 gh flexibility Fast Ramp Increased revenues by flexible response to market requirements References Benefit for a standard unit Vales Point, Australia 660, coal Load gradients doubled to 6%/min Velsen 24, Holland 460, Natural and industrial waste gas. Load gradients tripled to 4%/min hard hard coal coal fired fired unit unit Load Load gradients gradients increased increased from from 2 2 to to 2.5%/min 2.5%/min,, extending extending the the range range from from to to after after 5 5 min min period period Revenue Revenue (+)*: (+)*: EUR/kW/a EUR/kW/a Revenue Revenue (-)* (-)* : : EUR/kW/a EUR/kW/a 940,000 EUR/year for ± 7.5 * Actual average values from EnBW,, E.ON, RWE, Vattenfall Power Generation Instrumentation & Controls 10
11 gh flexibility Frequency Control Increase range for frequency control Task: Upgrade of the unit to provide primary frequency control and spinning reserve. Due to the fast ramps that this service requires, it places very high demands on the dynamic control response of a power plant unit. Features: Throttling of turbine valves or Activation of condensate throttling to mobilize energy storage Frequency control time Application of control for frequency deviations. Frequency control, the first stage of ancillary services. Benefit: Increased revenues for primary frequency control and spinning reserve services Avoidance of fiscal penalties for non-provision of contractually agreed primary frequency control and spinning reserve services. Power Generation Instrumentation & Controls 11
12 gh flexibility Frequency Control Lucrative services through frequency control References Benefit for a standard unit Völklingen, Germany 2 x 230, hard coal Frequency control range extended to 7.5% hard hard coal coal fired fired unit unit Frequency Frequency control control using using turbine turbine valve valve throttling throttling in in the the range range of of ± ± Revenue Revenue (+)*: (+)*: EUR/kW/a EUR/kW/a Maor David, Israel 2 x 575, hard coal Frequency control range extended to 7.0% 800,000 EUR/a for ± ,700 t/a CO 2 (due to reduced efficiency) * Actual average values from EnBW,, E.ON, RWE, Vattenfall Power Generation Instrumentation & Controls 12
13 gh flexibility Dispatch Control Increase window for dispatcher control Task: Upgrade of the unit to provide increased secondary frequency control capability (AGC). Implementing faster change rates will open up a larger window for high-return secondary frequency control services. Features: Automatic coordination of boiler and turbine Automatic derivation of dynamic setpoints from setpoint and gradient Optimization of control loops crucial to unit dynamics Dispatch control time Application of control for frequency deviations. Dispatch control, the second stage of ancillary services. Benefit: Increased revenue through sale of secondary frequency control services Avoidance of fiscal penalties for non-provision of contractually agreed secondary frequency control services. Power Generation Instrumentation & Controls 13
14 gh flexibility Dispatch Control Lucrative services through dispatcher control References Benefit for a standard unit Vales Point, Australia 660, coal. Load gradients doubled to 6%/min Velsen 24, Holland 460, Natural and industrial waste gas. Load gradients tripled to 4%/min hard hard coal coal fired fired unit unit Increased Increased gradients gradients rate rate from from 2 2 to to 2.5%/min 2.5%/min,, extending extending the the range range from from to to after after 5 5 min min period period Revenue Revenue (+)*: (+)*: EUR/kW/a EUR/kW/a Revenue Revenue (-)* (-)* : : EUR/kW/a EUR/kW/a 940,000 EUR/year for ± 7.5 * Actual average values from EnBW,, E.ON, RWE, Vattenfall Power Generation Instrumentation & Controls 14
15 gh flexibility Minimum Load Reduction Reduce minimum level Task: Reduction of minimum level imposed by process parameters Despite the reduction of minimum level, fast and low-stress increase capability on demand to meet market requirements. Lower minimum operating Old minimum sustainable Features : Adaptation, optimization and setting of lower-level controls for new minimum level If necessary, supplementing of plant valves and sensors Savings SPPA-P3000 NEW minimum sustainable time Benefit: Reduced commercial losses during off-peak periods Faster response to increased demands Avoidance of unnecessary start-ups and shut-downs Potential for reducing the minimum level through I&C optimization. Additional potential can be tapped by mechanical optimization. Power Generation Instrumentation & Controls 15
16 gh flexibility Minimum Load Reduction Cost savings through reducing minimum level References Benefit for a standard unit Parish, USA 565, Benson gas; Minimum reduced from 22% to 9% Manzanillo, Mexico 350, drum boiler; diesel, heavy fuel oil; Minimum stable output reduced from 30% to 20% gas gas fired fired unit unit Reduction Reduction of of minimum minimum from from to to (30% (30% to to 20%) 20%) Difference Difference between between production production costs costs and and electricity electricity price price during during minimum minimum time: time: EUR/h EUR/h Duration Duration of of minimum minimum operation: operation: h/a h/a 150,000 EUR/year Power Generation Instrumentation & Controls 16
17 gh flexibility Maximum Load Plus Increase electrical output to above 100% Task: Fast and low-stress increase in output to above 100% on demand to meet market requirements Features: Upgrade of unit control to allow Valves wide open (VWO) operation of unit and / or Automatic coordination of shutdown of HP feedwater heaters and increase in firing rate Benefit: Additional profits, particularly at times of high power prices without the need for upgrading of process equipment. Throttling of Electrical HP heaters operation 100 % 120 % (2) Over operation (4) 110% (3) (1) 100 % HP heater 6 HP heater 7 0% 80 % 0 Time [min] 60 (1) Unit setpoint increased to 100 % (mod. variable pressure operation) (2) HP feedwater heater 7 is shut off by this module (3) Unit setpoint increased to 110 %, HP feedwater heater 6 shut off fully (4) 110 % output achieved (spinning reserve is maintained) Power Generation Instrumentation & Controls 17
18 gh flexibility Maximum Load Plus Additional revenues by increased electrical output References Benefit for a standard unit Callide, Australia 420, Benson Max. + 10% 1400 h/a max hard hard coal coal fired fired unit unit Maximum Maximum + + 7%, 7%, i.e. i.e Electricity Electricity price price for for max. max EUR/h EUR/h Duration Duration of of max. max. operation operation h/a h/a Enstedvaerket, Denmark 650, Benson Max. +7% district heat extraction 380,000 EUR/a + 13,200 t/a CO 2 (due to reduced efficiency) Power Generation Instrumentation & Controls 18
19 h efficiency Low Loss Start Start-up with minimum losses Task: Reduction of startup fuel consumption and ensuring reproducible startups. Stressmeasurement Steam quality Start-up valve Turbine valve Low Loss Start Features: Automatic run-up of boiler to requisite parameters for turbine start Automatic differentiation between cold, warm and hot starts Automatic and bumpless transfer to coordinated power operation T M T I Injections Fuel valve T HP HD Drains Furnace HP- Bypass Feedback from process Effect from Low Loss Start Turbine Benefit: Savings through reduced fuel consumption Increased revenue through reproducible startup and shutdown Power Generation Instrumentation & Controls 19
20 h efficiency Low Loss Start Lower costs for start-ups References Benefit for a standard unit Parish, USA 565, Benson gas Startup costs reduced by 66% starts starts per per year year 4,000 4,000 EUR EUR / / start start 50% 50% reduction reduction Mandalay, USA 215, Drum gas Startup costs reduced by 70% 200,000 EUR/year Power Generation Instrumentation & Controls 20
21 h efficiency Combustion Optimizer Increase efficiency, lower emissions Task: Reducing unburned carbon in ash ( LOI - loss on ignition), NOx, CO and achievement of optimum efficiency through improved combustion. Features: Optimized burner operating point with the aid of: On-line measurement of coal flow to individual burners using the ECT method Burner-specific matching of air and pulverized coal flow Burner-specific matching of air flow Combustion air Distribution Trim Air Damper Air Damper Pulverizors Data acquisition Furnace Coal Flow (electrostatic measurement) Benefit: Higher efficiency Lower emissions (NO x / CO) and compliance with LOI limit for fly ash Power Generation Instrumentation & Controls 21
22 h efficiency Sootblower Optimizer Optimize operation of sootblowers Task: Condition-based soot blowing integrated into unit DCS Features: Use of existing temperature measurements to determine the degree of fouling Automatic cost-benefit analysis Activation of soot blowers, either automatically or by the operator Benefit: Lower fuel costs due to optimal operation of sootblowers Power Generation Instrumentation & Controls 22
23 h efficiency Temperature Optimizer Increase temperatures close to limits Task: Stable control of steam temperature with setpoint close to material limits Features: Use of dynamic models with prediction Identification of heat input variations using an observer structure Where needed, use of entire control range including injection into saturated steam Use on start-up and over the entire range Use of flue gas recirculation, biflux, triflux or burner tilt to control reheat steam temperature to increase the efficiency Benefit: Increased efficiency thanks to Higher steam temperatures Reduced reheat injection flow Conventional Control ϑ FD low => η low -- HP temperature -- Material limit -- set point SPPA-P3000 Control ϑ FD high => η high Power Generation Instrumentation & Controls 23
24 h efficiency Temperature Optimizer Increased revenues or lower costs by increasing efficiency References Benefit for a standard unit Simmering, Austria 380, Gas SH and RH-temp. increased by 5K hard hard coal coal fired fired unit unit SH SH and and RH-temperature RH-temperature increased increased by by 5K 5K Coal Coal price price EUR/t EUR/t 60,000 EUR/a Velsen, Netherlands 360, Natural and industrial waste gas. SH and RH-temp. increased by 5K - 3,700 t/a CO 2 Power Generation Instrumentation & Controls 24
25 h efficiency Low Throttling Reduce throttling losses Task: Minimization of throttling losses without any negative impact on flexibility. Low Thrrottling Turbine control valve Features: Turbine Setting of optimum degree of throttling for turbine valves, feedwater control valves and fan vanes for forced- and induced-draft fans on basis of a steady-state process model. Air flaps Furnace Feedwater control valve Benefit: High efficiency thanks to minimum throttling losses Power Generation Instrumentation & Controls 25
26 h efficiency Low Throttling Increased revenues or lower costs by higher efficiency Reference Benefit for a standard unit Karlsruhe, Germany 550, Benson hard coal, efficiency increased by 0.5% Wilhelmshaven, Germany 820, hard coal, provision of 20 for frequency control without reduced efficiency hard hard coal coal fired fired unit unit 5,000 5,000 h/a h/a operation operation Coal Coal price price EUR/t EUR/t Efficiency Efficiency increased increased by by 0.33% 0.33% 80,000 EUR/a - 4,800 t/a CO 2 Power Generation Instrumentation & Controls 26
27 h efficiency Fuel Optimizer Operate efficient and reliable despite firing of different fuels Task: Ensuring safe and stable unit operation despite firing of lowcost supplementary fuels and fuels with widely fluctuating properties. Features: Model-based determination of necessary fuel and air flows Modulating of flow for selected fuels for control Automatic heating value correction Automatic correction of air flow Adjustment of control loops, e.g. flue gas recirculation Benefit: Maximum use of low-cost fuels, i.e. reduced fuel costs Power Generation Instrumentation & Controls 27
28 h efficiency Fuel Optimizer Cost reduction by firing of supplementary fuels References Benefit for a standard unit Völklingen MKV, Germany 230, 210 heat extr., firing of hard coal for base and control, and methane / converter gas as supplementary fuel Velsen 24, Netherlands 360, firing of natural gas for control and blast furnace gas as base fuel hard hard coal coal fired fired unit unit 5,000 5,000 h/a h/a operation operation Coal Coal price price EUR/t EUR/t Costs Costs of of supplementary supplementary fuel fuel 50% 50% of of coal coal costs costs per per specific specific energy energy content content Replacement Replacement of of 1% 1% hard hard coal coal by by supplementary supplementary fuel fuel 130,000 EUR/a Power Generation Instrumentation & Controls 28
29 h efficiency Best Point Operate plant at optimum operating point Task: Automatic analysis of the overall process and of key components, fast provision of information about deviations from optimum operation, calculation of consequential costs for detection of improvement potentials. Features: On-line calculation of key process data on the basis of a thermodynamic process model Data reconciliation / validation of measured actual process situation Interactive process analysis for what if? scenarios: Optimized operation and investment decisions Web-oriented visualization for office LANs Benefit: Early detection of malfunctions and deviations from optimum operation Reduced maintenance costs through problem analysis Reduced generation costs Power Generation Instrumentation & Controls 29
30 h efficiency Best Point Reduced costs by operation at optimum operating point Reference Benefit for a standard unit Heilbronn, Germany 760, heat extraction, hard coal; detailed boiler model, data reconciliation, what-if simulation Taishan, People's Republic of China 2 x 600, hard coal, Data reconciliation, what-if simulation Improved operation and maintenance Early detection of malfunctions, deviations from optimum operation and slowly drifting values Determination of cleanliness of boiler heating surfaces Support of operating staff for routine tasks and fast analysis of problems Easy analysis of actual and historic data Process analysis available at engineer s office Cyclic report generation 50, ,000 EUR/year Power Generation Instrumentation & Controls 30
31 h availability Runback Plus Ride out loss of major components Task: Automatic runback of the unit on loss of major components and transition to the new safe operating mode. Features: Assignment of dedicated capability levels and runback rates for the different major components Consideration of fuel-related restrictions on the Load reduction at the necessary rate with coincident changeover of turbine to stable initial pressure control mode. Benefit: Reduced number of unit outages Extended service life Power Generation Instrumentation & Controls 31
32 h availability Runback Plus Increased income by reduced outage References Benefit for a standard unit Setubal, Portugal 250, oil fired, Reliable runback to 50% Nikola Tesla, Serbia & Montenegro 305, lignite fired, Reliable runback to 50% hard hard coal-fired coal-fired unit, unit, Avoidance Avoidance of of 5 5 trips trips and and 5 5 start-ups start-ups per per year year Instead: Instead: operation operation at at 50% 50% for for 5 5 x x 3 3 h/a h/a Startup Startup costs costs 5,000 5,000 EUR EUR Difference Difference between between electricity electricity price price and and production production costs: costs: EUR/h EUR/h 93,000 EUR/a Power Generation Instrumentation & Controls 32
33 h availability Life Time Plus Increase availability through low-stress operation Task: Regardless of the demands for fast changes and fast start-up, components must still be operated below specified stress limits so as to assure long-term availability Features: Model-based control process with prediction Automatic online adaptation of control parameters Benefit: Extended service life thanks to avoidance of life-consuming plant trips and inadmissible operating conditions Reduced repair costs thanks to low-stress operation of final control elements Power Generation Instrumentation & Controls 33
34 emissions Emissions Control Lower emissions Task: Compliance with requirements of environmental legislation at as low as possible cost. Features: Continuous emissions monitoring for NO x, CO, SO 2, O 2 and particulates Measurement of pulverized coal flow per burner to optimize fuel and air control for each separate burner Reduction of NO x and CO at the origin Selected process optimization solutions to increase the plant efficiency Reduction of emissions at the origin Benefit: Compliance with air pollution control laws and regulations, avoidance of fines and even mandatory shutdown for non-compliance Increased revenue from emission credit trading Power Generation Instrumentation & Controls 34
35 for Steam Power Plants Increased profitability by intelligent optimization solutions! Runback Plus Life Time Plus High availability No changes to mechanical equipment Low Loss Start Combustion Optimizer Sootblower Optimizer High efficiency Temperature Optimizer Low Throttling Fuel Optimizer Best Point Fast Start Fast Ramp Frequency Control High flexibility Dispatch Control Minimum Load Reduction Maximum Load Plus Low emissions Emissions Control Power Generation Instrumentation & Controls 35
36 Modernization with customized execution of SPAA-P3000 solutions Concepts - from small to comprehensive - whatever fits your situation! Optimization add-on for third party I&C Partial modernization incl. optimization Comprehensive modernization Third party HMI Third party HMI Siemens HMI Siemens HMI SPPA- P3000 SPPA- P3000 SPPA- P3000 Third party basic automation Third party basic automation Siemens automation Siemens automation Plus Electrical, Field, Maintenance & Management solutions Power Generation Instrumentation & Controls 36
37 One common platform: SPPA-P3000 fully embedded in SPPA-T3000 Consistent engineering and HMI for basic automation and optimization! User interfaces SPPA-T3000 architecture Power services SPPA-T3000 Application Server SPPA-T3000 Automation Servers SPPA-P3000 Process Optimization Solutions Process interfaces Power Generation Instrumentation & Controls 37
38 SPPA-P3000 Execution process Five joint steps to success! Discussion of situation On-site analysis Presentation and decision Implementation and fine-tuning Optimized operation Operating experience Targets Options for optimization Result: Which solutions are feasible for this unit? Establish, localize and quantify existing potential Examine and evaluate archives and control schematics Plant tests and limits Result: Evaluation of examined solutions Proposal: Scope of modernization, different variants? Benefits? Profitability (return on investment)? Engineering based on comprehensive power plant know-how Start of installation while plant is still in operation Outage and connection to plant I&C Commissioning / fine-tuning Handover to customer Enhanced performance and higher profitability are guaranteed: Flexibility Efficiency Emissions Availability Contract Power Generation Instrumentation & Controls 38
39 Siemens Power Plant Automation Combination of strength A sound basis for your profitability Process engineering expertise Automation expertise Project management expertise GW installed fleet 10 GW O&M 2000 systems installed throughout the world Shortest outage times Shortest execution times 100 years of power plant experience World market leader in automation systems Benchmark in project management Power Generation Instrumentation & Controls 39
40 Selected references with SPPA-P3000 solutions Profitable, reliable and flexible process optimization - worldwide Parish, USA Low Loss Start Minimum Load Reduction Fast Ramp ValesPoint, Australia Fast Ramp Temperature Optimizer Minimum Load Reduction Low Throttling Callide, Australia Fast Ramp Maximum Load Plus Temperature Optimizer Dispatch Control Niederaussem, Germany Fast Ramp Frequency Control Dispatch Control Lippendorf, Germany Fast Ramp Temperature Optimizer Frequency Control Karlsruhe, Germany Fast Ramp Fast Start Frequency Control Dispatch Control Simmering, Austria Low Loss Start Temperature Optimizer Life Time Plus Dispatch Control Plomin, Croatia Fast Start Temperature Optimizer Fast Ramp Frequency Control Power Generation Instrumentation & Controls 40
41 References Powering the world Profitable, reliable and flexible power generation - worldwide More than 2000 power plants worldwide in operation with Siemens electrical systems, I&C and IT Power Generation Instrumentation & Controls 41
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