RAM Development for Gasification Plants

Transcription

1 RAM Development for Gasification Plants Project Sponsor Siemens Energy / Gasification-IGCC Service Development Wolfgang Streer Director Project Manager Siemens Energy / Gasification-IGCC Service Development Dr. Christoph Kiener Service Manager Project Implementation R&D Project / Siemens Energy Service / Corporate Technology Dr. Ariane Sutor Program Manager Reliability & Availability

2 Siemens Answers for Energy Supply Energy Products and Solutions - in 6 Divisions Oil & Gas Fossil Power Generation Renewable Energy Energy Service Power Transmission Power Distribution Page 2

3 Gasification Service Programs Available Project Development Project Service Projects Operation Increasing Scope / Mutual Benefit Gasification Process Support Feed Studies & RAM Analysis Feasibility Studies Siemens Gasifier Parts and Service O&M (Operations and Maintenance) on Gasification Plant or Power Island Long Term Programs on Gasifier and Power Island Siemens Power Island Parts and Service Total Gasification & IGCC O&M The types of Service Programs for Gasification Projects range from Feasibility and FEED Studies to complete Gasification O&M and vary in content, timeframe, risk and rewards among others Increasing Project Stage / Progress Solutions customized to the unique requirements of each project and customer Page 3

4 Siemens Service R&D Total Plant Approach Service R&D investment on the entire plant to support project development and O&M R&D investment on the gasifier island for diagnostics, sensor development and repair technology One successful R&D Program is evaluating RAM - availability, reliability, output for gasification plants Objectives of RAM R&D project Develop a modeling and computational approach to predict the availability and reliability of IGCC and Gasification plants Allow the flexibility to address many different plant configurations RAM = Key Focus on Customer Economic Drivers Page 4

5 Expected Availability of the Plant Through RAM (Reliability, Availability and Maintainability) Determine Expected Values Reliability factor RF [%] = MTBF / (MTBF+MDT) System is running at start of period System is running at the end of period MTBF: Mean time between failures MDT: Mean down time after forced outage Availability: Reliability plus Planned Maintenance System failure MTBF MDT System returned to operation Distribution of Probability Monte Carlo simulation of probability distribution Uncertainty due to: Limited observation periods Inaccurate input data 100 % Probability 0 % 100 % Observation Period The probability to reach at least 92 % reliability is over 90 % Reliability 80 % Page 5

6 RAM Optimization Reliability Sensitivities Assess components with high / low sensitivities Sensitivity: component i with respect to the system [drf/rf]/[drfi/rfi] RF: Reliability Factor Availability Optimization through: Maintenance schedule coordination across all systems Spare parts stocking and repair planning Value of Spare Parts 100,000 $ Optimization Zone Total Cost Loss of Revenue = f(availability) 99.8% 99.7% 99.6% 99.5% 99.4% 99.3% 99.2% 99.1% Availability Increasing Availability Determined by Customer Spare Parts Cost = f(availability) Sensitivities and Optimization: Reliability versus Cost Page 6

7 Gasification / IGCC: Overview of RAM Modules Input Gasification & Controls Syngas Treatment Downstream Process Shift SNG COS Hydrolysis Methanol / MTG, MTP Coal Milling and Drying Liquid Fuels Gasification Siemens Fuel Gasification Acid Gas Removal Claus Plant Ammonia / Urea Fischer-Tropsch CO 2 Removal Air Separation Controls Siemens Digital Process Control System DCS PSA IGCC Siemens Energy Solutions Page 7

8 Reliability and Availability Analysis: Modeling of System Structure Identification of possible failures with impact on reliability and availability ZUSIM - Siemens Tool for Fault Tree Analysis and Markov Chains Failure modes and effects analysis (FMEA) for single faults Fault tree analysis (FTA) for failure correlations Markov models to describe consecutive failures Page 8

9 Evaluation of Reliability Models Evaluation of field experience on system level Comparison with calculated values for system and subsystems Calculation of system reliability: MTBF, MDT RF Top Down Bottom Up Evaluation of reliability structure model Input in reliability model Assessment of component reliability Calculation of component reliability: MTBF, MDT RF Dual Approach Results in More Accurate Models Page 9

10 Calculation of RAM Values for Gasification / IGCC Basic Configuration - No Redundancy BWS BWS 1x100% Sour Shift Acid Gas Removal Claus Plant 4x25 % 1x 100% 1x 100% 1x100% LOx 24h 1x100% Air Separation Unit CO 2 Compression 2x50% Coal Mill 4 hours capacity Silo MIN 1x100% Methanation Coal Mill Silo System Output Page 10

11 Calculation of RAM Values for Gasification / IGCC Redundancy on Mills BWS BWS 1x100% Sour Shift Acid Gas Removal Claus Plant 4x25 % 1x 100% 1x 100% 1x100% LOx 24h 1x100% Air Separation Unit CO 2 Compression 3x60% Coal Mill 8 hours capacity Silo MIN 1x100% Methanation Coal Mill Coal Mill Silo System Output Page 11

12 Calculation of RAM Values for Gasification / IGCC Enhanced Configuration - Redundancy on all Systems except Gasification BWS BWS 2x75% Sour Shift Sour Shift Acid Gas Removal Acid Gas Removal Claus Plant Claus Plant 2x100% 2x75% LOx 24h Air Separation Unit 4x25 % 2x75% 2x75% CO 2 Compression Air Separation Unit 3x60% 8 hours capacity MIN CO 2 Compression 2x75% Methanation Coal Mill Silo Methanation Coal Mill System Output Coal Mill Silo Page 12

13 Example Results Equivalent Output of Plant 120% 100% 80% 60% 40% 20% 0% Hours Basic Configuration Module Basic-RF Gasification 96.16% Milling 98.59% ASU 98.76% CO2 Compression 99.80% Shift 99.04% Methanation 97.28% Acid Gas Removal 99,40% Claus Plant 98.83% Redundant Mills 3x60% Module RF-Gain Basic-RF Gasification n.a % Milling % 99.61% ASU n.a % CO2 Compression n.a % Shift n.a % Methanation n.a % Acid Gas Removal n.a % Claus Plant n.a % Enhanced Configuration Module RF-Gain Basic-RF Gasification n.a % Milling n.a % ASU % 99.37% CO2 Compression % 99.90% Shift % 99.52% Methanation % 98.61% Acid Gas Removal % 99.70% Claus Plant % 99.99% Page 13 Effects of design and configuration options become accessible take the right decisions for customer specific needs!

14 Conclusions on Example Calculations Alternative Comparison Basic configuration typical arrangement In the redundant configuration the gasification is held constant whereas other modules comprise spare capacity Results The redundant configuration shows better total expected output for redundant modules The results show how the Siemens RAM model can assist in the feasibility stages to easily evaluate the availability effects of different plant configurations Page 14

15 Conclusions for Siemens Service RAM R&D Development Program The RAM Tool: Is an accurate tool for predicting Plant Equivalent Availability and Reliability Is particularly valuable during feasibility studies Is applicable for any plant configuration The Modular RAM Approach: Is flexible for many applications Offers wide and expandable configuration options Calculates sensitivities to pinpoint highest reliability impacts The RAM Tool allows to evaluate project alternatives to optimize performance and project financial returns Page 15

16 RAM Development for Gasification and IGCC Plants Project Sponsor Siemens Energy / Gasification-IGCC Service Development Wolfgang Streer Director Project Manager Siemens Energy / Gasification-IGCC Service Development Dr. Christoph Kiener Service Manager Project Implementation R&D Project / Siemens Energy Service / Corporate Technology Dr. Ariane Sutor Program Manager Reliability & Availability