Use of Software for Improving the Performance of Thermal Power Plants

Transcription

1 Use of Software for Improving the Performance of Thermal Power Plants Lalatendu Pattanayak (STEAG Energy Services (India) Pvt. Ltd. ),

2 Taking in view that the power plant performance can be evaluated not only based on thermodynamic related indexes, such as heatrate, Thermal Power Plant Performance Analysis focuses on the presentation of reliability-based tools used to define performance of complex systems and introduces the basic concepts of reliability, maintainability and risk analysis aiming at their application as tools for power plant performance improvement, including: selection of critical equipment and components, definition of maintenance plans, mainly for auxiliary systems, and execution of decision analysis based on risk concepts Dr. Gilberto Francisco Martha de Souza 2

3 Why to use the Software tools? DCS also has the required informations to perform the calculation of efficiencies & heat rates what are the limitations? 1. DCS does not give the system wise efficiencies so you do not know where the losses occur 2. Data from I/O points e.g. Temperature, pressure mass flow could be wrong because of sensor errors, bad connectors etc. That makes calculation erroneous. 3. DCS does not give advice on what to do 3

4 Leverage to Energy Efficiency Improvement Post Engineering: Turbine Boiler I&C retrofit IT-Tools: Operation management Optimization systems Analytics Equipment Tools O&M Practices Capacity Building: Raising awareness Changing behaviour Optimizing procedures 4

5 Comprehensive Approach towards Energy Efficiency Analyse the gap Identify Potential Define Measures Ensure sustainability Experts Walk Down (low hanging fruits) Analysis of performance data (turbine heat rate, boiler efficiency, fuel consumption etc.) Assessment on O&M routines Mapping modeling Deviations between design and operation parameters Techno-economical assessment Short / medium term approach - Optimization of operation (processes, habits) - Minor engineering modifications Medium / long term approach - Optimization by implementation of monitoring systems - Optimization of maintenance Long term approach - Major boiler / turbine / flue gas treatment retrofits Verification of project success vs. target Recurrent auditing by efficiency cell 5

6 EBSILON Professional as Diagnostic and Optimization Tools EBSILON Professional Solutions for the Design, Analysis and Operation of Power Plant & any thermodynamic Processes Identification of improvement potential regarding efficiency and availability Continuous supply of important characteristics for immediate response Easy and reliable organization of the obligations of operation management Fully flexible system convenient graphical user interface Interfaces for data exchange and programming Easy to handle design and off design calculation in single model Inbuilt different Fluid Library 6

7 Concepts of application Conceptual design Comparison of locations, boundary conditions, technologies, different design options Examination of project proposals (due diligence) Simulation of part load calculations Detailed design of a plant Mapping of all components Providing of manufacturer-specific data Testing the design in all load cases and operation conditions Acceptance Tests Data reconciliation with qualified results (value ± confidence interval) Plausibility checks during measurement (Offline Validation) Report generation Operation optimization Comparison of different operational strategies EBSILON as calculation kernel in SR::EPOS online monitoring system 7

8 Applications Gas and Combined Cycle Plants Gas turbines: GT from OEM-GTlib GT with individual characteristics Heat recovery steam generators various pressure stages Supplementary firing GT build from compressor, combustion chamber, turbine 8

9 Applications CHP-Plant (cogeneration) piston engine fired with diesel / natural gas CSP - Solar thermal plants Standard solar field component detailed model with EbsSolar parabolic trough, linear fresnel type, solar tower storage systems 9

10 Applications Conventional coal-fired plants detailed water-steam cycle and flue gas path calculation ORC Processes organic working fluid by Refprop Geothermal Energy (e.g. Kalina Process) NH3 / Water mixture Integrated coal gasification with carbon capture (IGCC) Absorption Refrigiration Water / LiBr and Ammonia / Water mixture Desalination Programmable components 10

11 EBSILON Professional & Modules VTU GT-Lib GT models based on OEM data EbsSolar Detailed design of solar fields EbsBoiler EbsValidate EBSILON Professional EbsHTML Presentation of cycles in web browser EbsScript Script language and interface EbsOptimize Parameter optimization 11

12 EBSILON Professional as diagnostic tool It helps the Power Plants to identify poor performance of plant components, sub-systems or the plant as a whole. Finds the gap between the operating condition and achieved parameters of the plant based on the design and operating model with the subsystem analysis. In addition, Ebsilon application also brings out inefficiencies /inconsistencies in operation and maintenance procedures and help in deciding remedial measures. Input Values act ACTUAL Performance according to standard calculations Calculated Values Input Values Simulation exp EXPECTED Performance according to standard calculations Thermodynamic Model with Mass & Energy Balance Calculation of current Key Performance Indicators Boiler efficiency Fouling Factor Heat Rate Calculation of expected efficiencies p 1 p 2 12

13 Optimization: Process Operation Boiler Diagnostics Mass & energy balance around the boiler Calculates boiler efficiency Calculation of Heat Transfer Coefficients Determination of Soot blowing criteria Monitoring of Heat Exchanger Surfaces Determination of Soot blowing effect Monitoring of different coal types and their fouling effect Determination of Soot blowing crtieria per coal type Calculation of Flue gas temperature profile Minimizing engineering Efforts by one Graphic for Simulation Validation Optimization

14 Ebsilon as Predictive Tool Ebsilon as a predictive tool is adopted in the form of What if. What if analysis includes the following items, which can be modified by the user to see the effects on plant generation, heat rate and boiler efficiency: - Throttle pressure. Throttle temperature. Reheat temperature. Condenser backpressure, cleanliness factor Superheat spray flow. Reheat spray flow. Final feed water temperature. Boiler excess air. Flue gas exit temperature. Heater bypass Fuel composition and HHV Ambient air condition. Easy What-If Analysis direct in P&I Diagrams without additional Layout Engineering 14

15 Ebsilon as a whole Diagnositc study is undertaken by performing the following steps: Verification/ calculation of base level data (design input & output and operating input & output). Calculation and study of sectionwise heat rate deviation. Undertaking what-if scenarios for identifing and determining required parameters changes for heat rate improvement. Ebsilon software also help in : Evaluation of technoeconomic options for improvement. Planning of appropriate actions to improve the efficiency 15

16 Ebsilon Software Application of Ebsilon in PAT Scheme Steps in PAT Implementation Establishing Base line parameters Target Setting for improvement in Heat Rate Diagnostic study of the Plant Identification of Energy Efficiency Areas & Measures Measurement and Verification of achievement

17 Advantages of Applicable Ebsilon in PAT Scheme PAT Steps Establishing Base line parameters Diagnostic study of the Plant Advantages Quickens the process of arriving at /validation of baseline data Shortens time for diagnostic study. Reduces number of manpower for arriving at energy efficiency measures Support activities of Energy Auditors Eliminates the need for large number of special instruments and manpower needed for each subsystem analysis Identification of Energy Efficiency Areas & Measures Measurement and Verification of achievement eliminates the possibility of making recommendations without identifying the impact on the other subsystems Ensures reliability of data/outputs Shorten time for determining energy efficiency measures; allowing more time for implementation can compute the actual CO2 generation Can serve as an accurate M&V tool for ensuring transparency in the process of issue of ECerts

18 Ebsilon in Indian Power Sector STEAG have Provided 65 Ebsilon Licenses to the State Generating Units Trained more than 150 engineers in application of Ebsilon software Assisted State Generating Units in mapping their power plants to assess and quantify energy efficiency potential and determine energy efficiency measures Assisted State Generating Units in developing proposals for energy efficiency improvement short term and long term. Supporting State Generating Units in introduction / implementation of energy efficiency measures Technical Audit study using modeling technique 18

19 Benefits Operation Get Hints for Improvements of Operation (e.g. on/off of pumps) Diminished Outage Time or prevents Outage by guided Identification of Origin of Disturbances even they are not measured by Sensors Costs even for Co-Generation of heat and electrical Power by always closed and validated Balances Automatic Adaptation to current Operation Characteristics without expensive Calibration Procedures Maintenance Recognition of creeping Deviations (Fouling Factors) Improved Judgment of faulty Measurement or Degradation of Components 19

20 Activities Undertaken by STEAG, India in PAT & Energy Audit Mandatory Energy Audit studies PAT M&V support service and study Thermodynamic study based on Modeling technique Performance Testing 20

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