SERVICE OFFERINGS FOR POWER PLANT FINGERPRINT

Transcription

1 SERVICE OFFERINGS FOR POWER PLANT FINGERPRINT Page

2 INTRODUCTION 3 PROJECTPHASESDELIVERABLES 5 Pre-project plant data collection 5 Site Visit 5 Energy Assessment and report generation 5 TYPICALSCOPEOFDELIVERY 7 Page

3 Introduction Power Plant FingerPrint is a service that aims to assess the performance of a power plant, including all major sections like boiler island, turbine island, power island etc. to identify process and energy efficiency improvement opportunities. For this purpose, the historical plant data is collected to study the process operating performance. The KPIs and process models, derived based on best practices and known standards in the industry, are evaluated. The current plant performance is compared against benchmarks to identify gaps and potential energy efficiency improvement opportunities. Multiple what-if scenarios are used to perform cost-benefit analysis and the results/recommendations are reported in an opportunity identification report. Picture 1 - PowerPlant Fingerprint Value Proposition The main tasks in the investigation are as follows Page

4 Discussions with process engineers Collection and analysis of plant operating data Evaluation of key performance metrics and performance bechmakring. What-if analysis and cost-benefits analysis Recommendations and reporting Depending upon the plant performance status, the potential benefits would be achieved by implementing some or all of the following: Information Management System for long term tracking and monitoring of plant KPIs, equipment performance to identify the deviations and improvement opportunities. Application of additional measurements such as carbon in ash, coal flow monitor. Variable Speed Drives for specific applications Reduction of heat losses with the flue gas Application of auxiliary power consumption reduction measures Reduction in blow-down losses and application of blow-down heat recovery systems (if not available) Reduction in losses through PRDS or replacement of PRDS with turbine. Advanced process control for boiler for reducing variations in %O 2 in flue gas and main steam temperature. Application of soot blowing advisory, boiler life monitoring, turbine life monitoring tools. Resizing/Redesign of equipment such as Fans, Pumps, Drives and Motors. PID loops tuning services and continuous loop monitoring systems to maintain optimum performance. The following questions are to be addressed during the project Which opportunities exist to improve energy efficiency and environmental impact? Which technologies can deliver these goals? Which financial impact can be expected? Page

5 ProjectPhasesDeliverables Pre-projectplantdatacollection During this preliminary part of the project ABB would qualitatively assess the plant performance by interviewing plant personnel remotely or sending the questionnaire in order to understand Plant layout, technology etc Current general status of equipment/plant operation i.e. the current level of instrumentation, monitoring, maintenance and operating practices and application of control and optimization techniques in plant. Major problems and bottlenecks as seen by plant staff This phase allows ABB to better prepare for the project execution and perform quantitative energy audit. SiteVisit This step would involve a qualitative audit. It may or may not involve site visit depending upon the cooperation with the end customer. It would involve the following tasks Gather overview of the process through telecon and/or visit to site. Collect process operating data and DCS graphics/pfds Perform energy assessment remotely Conduct interviews with process engineers and plant operators on phone wherever additional information is required to be sought. Presentation and submission of report The duration of the visit depends on the project scope, but roughly it is 5 days for two ABB engineer participating in the energy assessment of a power plant involving single boiler and associated units. If multiple boilers are to be analyzed then total time for assessment would be more. During the site visit ABB requires access to the following Process engineers/operators for interviews/discussion Access to plant and control room to observe operations Access to historian and other relevant design data EnergyAssessmentandreportgeneration This phase happens at ABB facilities and contains the following steps. Analysis of historical data and its preparation for the tool Page

6 Energy assessment involving tool configuration and calculations Analysis of results, proposals for improvements with paybacks Report generation and compilation of work done Submission and discussion with customer Page

7 TypicalScopeofDelivery Item No. 1. Description Power Plant Fingerprint services will have following in its scope Performance assessment of all major equipment in the plant by evaluation of key metrics like efficiency, losses, energy distribution for all major equipment in the plant. This includes: Boilers Turbines Preheaters Pumps Fans Heaters/condensers/heat exchangers Coal Mills Cooling tower etc. Performance assessment and reporting can be done based on weather condition and day wise operation Assessment for operation practices and opportunity mapping for improvement. This produces a list of recommendations/applicable hardware and software solutions/products/services in power plants. Identification of opportunities for improvement and benefit estimation from Waste heat recovery potential Boiler blow-down heat recovery Compressed Air and Steam throttling losses calculations APC applications like tighter temperature and oxygen control etc. Application of variable frequency drives Efficiency map of plant Breakup of auxiliary power consumption Energy distribution in major equipment Boiler load distribution profile KPIs trending Page