CPS Creative Power Solutions

Transcription

1 CPS Creative Power Solutions Company profile Power Generation Services Page 1

2 CPS Creative Power Solutions Our Mission Our Customer Services Expert Resources Technology Innovation References and Selected Projects CPS office locations: A. USA, Phoenix, Tel: , Fax: B. Switzerland, Baden, Tel: , Fax: C. Libya, Tripoli, Tel: D. United Arab Emirates, Abu Dhabi, Tel: , Fax: Page 2

3 Our Mission Creative Power Solutions is an engineering company in the sector of Power generation and Energy utilization. Our mission is to provide advanced, efficient and customized technology solutions to clients ranging from Original Equipment Manufacturers (OEMs) to Plant operators and Energy consumers. We base our services to our customers on: Expertise in power generation technology and energy efficiency Decades of experience in advanced product development A long track record in technological innovation Unique engineering capabilities and state of the art tools CPS provides customized solutions to its clients. Page 3

4 Our Customer Services Product development Advanced product development for Turbo machinery and Steam boilers and components around the thermal block. Customized solutions Customized solutions for operators of power plants targeting cost efficiency and operational flexibility. Performance improvements Engineering for efficiency improvements and emission reductions in existing generation units down to component and part level. Operation & Maintenance Strategies for reduced operation & maintenance costs based on critical part lifetime management and advanced engineering. Additional Services Technical Training Tendering consulting Management consulting General engineering consulting Page 4

5 Our Customer Services Product development CPS has a senior engineering team of professionals with extensive experience in advanced product development in the field of power generation. The CPS core competence builds upon achievements and successes from key technology development programs within several leading OEM companies such as ABB, Alstom, General Electric and Siemens. CPS is dedicated to innovation as a means to strategic advantage and can help its customers to develop technology in a number of areas: Gas turbines Steam turbines Utility boilers, Packaged boilers, Waste incineration Condensers Generators Auxiliary systems CPS is specialized in advanced power generation technology. Page 5

6 Our Customer Services Customized Solutions Many operators of power plants are forced to compromise when doing business with the large OEM companies in order to fit in with their standard product portfolios. Creative Power Solutions differentiates itself by providing solutions fitted to the customers particular needs. The advantages for the client are plenty: optimized scope of supply, reduced cost and increased operational flexibility. CPS offers its utility clients alternative solutions at a fraction of the OEM cost in several areas: Firing system retrofits and upgrades. Fuel flexibility. Fuel and ignition system modifications for improved reliability. Component redesign for lifetime extension and reduced cost. Plant controls, instrumentation and data acquisition. CPS provides customized solutions to its clients. Page 6

7 Our Customer Services Performance improvements The recent decade has seen a strong volatility in fuel prices and an accompanying trend towards higher operational costs. In addition plant operators are continuously confronted with stricter emission limits and CO 2 emission credits. CPS offers engineering for efficiency improvements and emission reductions in existing generation units: Optimization of combustion processes for higher exit average temperature and reduced temperature peaks. Emission reductions and resolution of challenging combustion problems in all types of power plants and heat processes. Redesign of performance limiting components and parts that restrict the plant to reach its full potential. CPS offers technical training for establishment of efficient plant operation and maintenance procedures to plant O&M teams. CPS provides solutions for improved plant performance. Page 7

8 Our Customer Services Operation and Maintenance Power plant owners are frequently obliged to follow any recommendations regarding O&M issued by the OEM due to the technical complexity of the equipment. CPS has the capability to provide an independent analysis of the technical maintenance required and to suggest alternative procedures. CPS is able assist its clients with different strategies that target cost savings of considerable monetary value: Part replacement procedures. Refurbishment practices. Operation concepts for extended lifetime. Component redesign for extended lifetime. Negotiations of O&M contracts (commercial & technical). CPS supports its clients in reducing O&M costs. Page 8

9 Our Customer Services Additional Services Technical Training CPS provides technical training courses to strengthen your plant s O&M team for improved performance and efficiency. The course content is tailored to fit your needs. Tendering consulting CPS can assist you in negotiations with OEM companies and critically analyze technical offers as well as commercial contracts. With the participation of CPS you will be able to argue on a detailed technical level to your advantage. Management consulting Benefit from the experience of OEM top managers (ABB, Alstom, General Electric) at a consulting basis. CPS provides support in due diligence processes as well as organizational restructuring programs. General engineering consulting CPS has the advanced technical capabilities to develop solutions for a wide range of industries. Our expertise includes combustion and chemical processes, mechanical design, cooling & heat transfer processes as well as energy utilization in buildings and industry. Page 9

10 Expert Resources Know how CPS was founded by engineers with leading roles in large organizations such as ABB, Alstom, Rolls Royce and General Electric. The company is able to form project teams with strong component engineering skills. Know why CPS is specialized in tackling advanced research & product development challenges. The resources include specialists with unique skills and expertise in power generation and energy utilization. Experience CPS has senior professionals with an extensive history (more than 40 years) in leading international power generation equipment and energy companies. Qualifications To be able to develop leading technologies CPS continuously invests in people with advanced analytical skills. More than a third of the CPS staff is qualified with Ph.D. degrees. Page 10

11 Technology Innovation CPS stands for innovation and creativity. To date the staff has been involved in the creation of more than 80 patents related to advanced technology. CPS is continuously developing new ideas for internal as well as external development projects for a wide range of applications: Turbo machinery technology Gas turbine design (40 patents) Gas turbine operation (11 patents) Steam & gas turbine design (10 patents) Steam boiler technology Steam plant design (5 patents) Steam plant operation (5 patents) Steam plant processes (10 patents) CPS has been involved in the creation of more than 80 patents. Page 11

12 References from our customers CPS has executed a large number of challenging projects in power generation and energy efficiency services. We dedicate ourselves to deliver high quality and innovative solutions based on our advanced technical skills and capabilities. Meeting and exceeding the expectations of our customers is a top priority as illustrated by a recent testament from one of our clients: We are impressed with your team s collective knowledge, analysis tools, and capabilities in applying fundamentals as a foundation for a solution, regardless of the complexity. We have challenged CPS with projects involving very fluid scope and schedule, i.e. significant changes in objectives and milestones. CPS met this challenge on every occasion with great professionalism, expediency and understanding. We were able to maintain a very open level of communication with the CPS team, from both a project management and a technical level. This provided opportunity for learning and resulted in a more refined understanding of the technical challenges we face. This level of open communication is rare in the industry, if not unique, and is truly refreshing. Dennis del Grosso, Arizona Public Services Electricity, Power, Energy Services, USA. Page 12

13 Selected projects Product development A major original equipment manufacturing client wanted to reduce costs and improve the performance of a gas turbine engine by modifying the turbine design. CPS was asked to provide a concept that would meet the cost, performance and life requirements of the client: CPS proposed a re design of the first stage vane to lower the manufacturing cost of the turbine and to reduce the amount of cooling air for improved engine performance. Based on the extensive experience in mechanical design and integrity as well as cooling and heat transfer CPS could propose a design suitable for an implementation into the engine. The vane re design was created with the aid of advanced engineering analysis tools such as Computational Fluid Dynamics (CFD) and 3D Finite Element Modeling (FEM). Turbine vane component and new design FEM model simulation results. Page 13

14 Selected projects Gas turbine reliability A large utility client experienced reliability issues and start up problems of a gas turbine plant that prohibited scheduled operation. The start up phase was frequently interrupted by a number of errors and warnings: failed ignition, flame out, large turbine outlet temperature spread and more. Several teams from the OEM were sent to the site without being able to provide a reliable solution. CPS proposed a systematic and in depth root cause analysis including evaluation of the ignition system and ignition fuel (propane), the main fuel (light diesel oil), fuel distribution system, operation conditions, engine settings and more. The outcome of the analysis pointed towards a need for optimizing the ignition system based on the particular conditions of the engine. A short test campaign was made to confirm the results of a detailed flame analysis (ignition flame strength, momentum and temperature as well as main fuel evaporation rate). After validating the results the solution was finally implemented into the engines. All engines successfully started on the first attempt and the plant has since then increased its start up reliability to 100%. Gas turbine plant Ignition system optimization Page 14

15 Selected projects Boiler firing system retrofit An oil fired steam plant with severe emission problems called for an urgent solution. The utility client had been recommended a complete combustion system replacement by several OEMs. With CPS a route towards a much more cost effective solution has been made possible: By advanced simulations and engineering analysis the original combustion system was examined to identify the reason behind the poor performance of the combustion process. CPS was able to determine the aerodynamic mechanisms associated with the original burner system responsible for the high emissions. CPS proposed a cost effective and elegant modification of the burners. With the burner modification the emission targets were achieved and black stack from plant was completely eliminated. The implementation was made at a fraction of the cost proposed by the OEMs. Old burners Baseline Modified design CPS design Steam power plant and comparison of burner system design. Page 15

16 Selected projects Boiler performance A desalination plant with steam boilers running on heavy fuel oil experienced frequent problems to achieve maximum rated capacity due to excessive smoke and particle formation. CPS proposed an in depth analysis to identify the root cause behind the operational problems: CPS concluded that the firing system delivered by a major OEM was not able to cope with the varying fuel compositions of the plant due to the boiler design parameters applied. Based on detailed simulations of the combustion process CPS could propose burner modifications that significantly improved the combustion efficiency as well as the flame stability in the boilers. After implementation the emission problem was eliminated allowing the plant to increase its capacity and also to reduce fuel consumption by 4% at a relative load of 80%. Elimination of emission problem and performance improvement. Page 16

17 Selected projects Gas turbine performance & life The gas turbine fleet operating on fuel oil had a long record of high O&M costs due to performance degradation and a shortfall in component life. The client hired CPS to do an engineering analysis as to develop a strategy for a solution to the problems: CPS carried out a detailed analysis including simulations of the combustion system to identify the root cause of the overheating problems and eventual part failure. The analysis showed that the existing combustion process produces a inhomogeneous turbine inlet temperature pattern which is the main driver behind the engine failure. A A Gas turbine engine combustion system and simulation model. Page 17

18 Selected projects Coal fired furnace operation The utility company operating a pulverized coal steam plant was having difficulties with a 170 MW unit. Due to heavy slagging and deposits the unit had to be ramped down frequently and was also not able to operate at full load due to excessive steam temperatures. CPS was hired to come up with a solution where several OEM companies had failed: CPS conducted a root cause analysis which identified several weaknesses related to the burner design and its operation conditions. The in depth analysis with detailed simulations of the aerodynamics gave insight into the mechanisms causing uneven temperature and oxygen levels at the furnace exit. A straightforward and inexpensive burner redesign was proposed that stabilizes the combustion process aerodynamics resulting in significantly more uniform furnace exit conditions and reduced slagging. Coal fired steam plant furnace and simulation results. Page 18

19 Selected projects Steam boiler controls A utility with an aged steam boiler plant was struggling with the availability due to a malfunctioning controls system. Due to the significant age of the plant the management was reluctant to replacing the system with a new OEM system for a high cost. CPS was asked to provide a customized solution. CPS evaluated the functionality of the existing plant controls system and quickly identified the critical issues. The CPS team generated a plan for retrofitting the existing controls system including addition of new functionalities and improved human machine interface design for easier operation for the plant. The customized CPS controls system is associated with a significantly lower cost as compared to replacing the existing design with a new OEM application. Plant Controls systems Page 19

20 Selected projects Gas turbine fleet O&M A large company in power generation wanted to reduce the operation and maintenance expenditures for its gas turbine fleet. CPS was consulted to provide a suitable strategy for cutting the O&M spending and strengthening the company in negotiations with the OEM companies. CPS carried out a benchmark analysis of the clients O&M expenditures to set the cost reduction targets of the project. CPS could identify a significant cost reduction potential in the procedures for replacement of hot gas parts as well as refurbishment of the same. The evaluation by CPS included a set of recommendations on how to strengthen the position of the client in the O&M contract negotiations in a short as well as a long term perspective. Operation & Maintenance Page 20

21 Selected projects Gas turbine plant design A utility company had planned for expansion of its power generation capacity during a period of very high market prices for OEM equipment. In order to minimize the capital investment cost CPS was consulted. CPS was able to engineer, procure and install a customized solution based on a conversion of 60 Hz engines to the 50 Hz electricity grid. The conversion of the machines and subsequent adaption of the plant allowed to client to achieve significant first cost savings. Gas turbine plant and converted engine units. Page 21

22 Selected projects Conversion to external firing A manufacturer of small gas turbines wanted to convert an existing engine design into an externally fired turbine generator. CPS was contacted to develop a conceptual design in competition with other engineering firms. With the delivery of a compelling design CPS was chosen to develop the concept into a detailed design for the engine. The detailed design included a redesign of the engine casing and implementation of a hot air delivery system. In addition to the new hardware the scope included development of operation as well as controls concepts for the engine. Conceptual design proposals for externally fired gas turbine. Page 22

23 Selected projects Enhanced ACC performance A utility company planned a new layout for the placement of the air cooled condensers (ACC) in their power plant. The influence that upstream cooling tower exhaust could potentially play on the ACC performance was a concern of the utility. CPS was hired to perform an analysis to evaluate the proposed location with regards to the performance. CPS conducted simulations with varying crosswinds to determine the overall affect of the cooling tower exhaust on the ACC units. An in depth analysis was performed on the wind interaction with surrounding structures and the recirculation zones created throughout the plant. CPS was able to advice the client on an optimized location and improved overall site layout with regards to the performance of the ACC units. Power plant site model and simulation results. Page 23

24 Other projects CPS has carried out numerous product development projects with large OEM companies leading to improved performance, increased quality and reduced costs. In the interests of our clients and with respect to the confidentiality agreements in place we can only publish general information of our product development activities: Development of new burner technology for reduced emissions and reduced cost for gas turbines and steam boilers. Development of sealing technology for high pressure combustion systems for reduced emissions. Development of gas turbine hot gas parts with reduced cooling demand for improved engine performance. Development of a new gasification process for solid fuels leading to significantly reduced carbon emissions and reduced cost. Development of auxiliary systems for gas turbine power plants for improved engine emissions. CPS develops new technology for improved performance. Page 24