Power Plant Thermodynamic Performance Monitoring National Energy Efficiency Conference September 2012
Agenda • Performance Monitoring Objective • Performance Monitoring Methodology • Examples of Issues Identified • Case Studies • Experience Establishing a PM Program • Alignment to ISO 50001 EMS
Introduction of Tuas Power Installed capacity - 2,670 MW • 2 x 600 MW oil fired • 2 x 367.5 MW gas fired • 2 x 367.5 MW gas fired steam plants, Unit 1 & combined cycle plants, combined cycle plants, 2 CCP 1 & 2 CCP 3 & 4 • Mar & Dec 99 • Nov 01 & Jan 02 • Jul 05 & Sep 05
Performance Monitoring Objective • Facilitate Operational Adjustments and Corrective Maintenance to ensure plant operates at optimum thermal efficiency • As fuel is a substantial part of power generation cost, small gains in thermal efficiency could achieve significant fuel savings • Enable advance maintenance planning to restore degraded performance of plant components
Performance Monitoring Objective Singapore 2009 Primary Fuel and Electricity Consumption 16000 Others Domestic 14000 Commerce Industry 12000 Transport Kilo Tons Oil Equivalent 10000 Industry, Commerce, Households Power Plants 8000 6000 4000 2000 0 Primary HC Fuel Electricity Cons
Performance Monitoring Objective • Proactively identifying the plant sections that have degraded performance • Quantifying the degradations in terms of effect on overall plant efficiency • Enabling a condition based predictive maintenance program to set and prioritize maintenance activities that will minimize degradation and hence maximize efficiency
Performance Monitoring Objective GT Compr Actual and Potential Efficiency Improvement Cold Wash 50.800% 50.600% 50.400% 50.200% 50.000% 49.800% 49.600% Nov 06 Dec 06 Jan 07 Feb 07 Mar 07 0.051% 0.150% 0.320% 0.423% 0.030% GT Compressor Fouling 0.012% 0.020% 0.025% 0.026% 0.026% BFP Inefficiency 0.300% 0.320% 0.288% 0.310% 0.310% LP Bypass HP Bypass 0.150% 0.150% 0.150% 0.150% 0.150% 0.085% 0.092% 0.224% 0.225% 0.225% Condenser Fouling 0.005% 0.022% 0.033% 0.054% 0.054% IAF Pressure Drop 50.300% 50.100% 49.800% 49.700% 50.040% Actual Efficiency Note : Figures in this chart are fictitious to maintain data confidentiality
Performance Monitoring Methodology Modeling Application To make a Complete Heat and Mass Balance Establishing current performance level of individual components and total system Establishing the benchmark for the individual component and for total system Set targets for improvement/maintenance
Performance Monitoring Methodology HRSG HRSG Effectiveness Duty of individual heat transfer components GT Steam Turbine GT Power Generation HP Turbine Power GT Comp Eff. IP Turbine Power GT Turbine Eff LP Turbine Power GT Heat rate HP/IP/LP Turbine Eff IAF performance CCP Power Station Condenser Distribution Condenser Water Flow Valve passing Condenser Duty Line Loss Condenser effectiveness Auxiliaries CWP Performance BFP Performance CEP Performance
Performance Monitoring Methodology HPBFW2 HPBFW1 LPDEAR GLNSTM DEAER 109848 BFWSPP SP5 ST Power kW HPBFW SP3 S59 IPST LPST SP6 S37 BFWHDR DFW S50 HPBFWP S38 HPSTOT S55 HPBYPS IPBFW S26 S48 S51 V1 S52 M6 HPST LPSTOT IPBFWP PI3 CONDSR CWS S40 S60 M3 S39 V2 CWR LPBFWP S47 S54 MAKEUP PI1 S57 S58 HPBPSS S43 S45 S44 S46 GLNDCN SP4 PUMP1 S53 PI2 M4 M5 LPBFW S49 HPSDSH HPS LPS S31 COND S30 IPS S23 S35 S36 S24 S22 S29 S27 RHDSH S1 S3 S25 S33 S32 S28 S13 S15 HPECO1 S34 RHTRS HPSH2 S5 S9 S10 S11 S12 S17 S18 S19 S20 S21 S6 S7 S8 STACK S4 M1 SP2 SP1 M2 S14 S16 RHTR1 HPSH1 HPEVAP HPECO2 IPSHTR LPSHTR IPEVAP LPEVAP HPECO0 IPECO1 LPECO FWPRHT S2 S56 RHTR2 IPECO2 GTEXH 278.91 DUCT1 169298 FUELGS GT Power kW GTCOMB Gross Generator Output MW CMPDSC TURBIN S41 GTCOMP GTTURB COMPIN AIR S42 SSGEN INLFLT
Performance Monitoring Methodology • Complete quantification of all streams in a power plant eg flue gas, cooling water, steam and fuel flows • Establish the present performance level of the individual equipment eg efficiency, heat transfer coefficients, leakages • Enables data validation – Measured values can be compared against the heat balance output for validating the accuracy of measurement.
Performance Monitoring Methodology Modeling Application To make a Complete Heat and Mass Balance Establishing current performance level of individual components and total system Establishing the benchmark for the individual component and for total system Set targets for improvement/maintenance
Performance Monitoring Methodology Each piece of equipment modeled separately to match guaranteed data, then read by overall model COND matches HEI/condenser ST model matches ST vendor S10 CONDEN CONDST MAKEUP S15 CNDMIX S14 S9 S12 HRSG matches S3 CNDPMP S11 DEAER HRSG vendor S8 S13 S5 S6 HPPUMP S1 S2 S4 EXH S7 DUCT HPSHT HPEVAP HPECON GT GT uses curves or spreadsheet data
Performance Monitoring Methodology • Construct software models of the plant components tuned to design performance • New & Clean performance is the benchmark Inputs Benchmark Gas Turbine Ambient Temp, Press, Heatrate Load HRSG GT Exh Flow, Temp HP, IP, LP steam Stack Temp Steam Turbine HPS Flow, Temp, Press, HP, IP, LP section sliding IPS Flow, Temp, Press, Press, Power, Efficiency Condenser Press Condenser LPST Exh Flow, Enthalpy, Vacuum Cooling Water Flow, Temp
Examples of Issues Identified • Lost of efficiency after MI due to IGV reprogramming • Boiler Feed Pump minimum flow recycle valve passing • Identification of Passing HPST Bypass Valve • FW Preheater Bypass Valve passing • Selection of Optimum Inlet Air Filter • Condenser Cooling Water Optimization • Condenser Cooling Water Debris Filter Choke • HPST Bypass Spray Valve Passing • HRSG HP and RH Spray Valve Passing • Condenser Air Ingress • Condenser Tube Fouling
Case Study : FW Preheater Bypass Bypass Condensate Valve Preheated Water Extraction Pump To Deaerator V-1 E-3 Passing Valve Feed water Preheater Flue Gas Inlet Flue Gas to Stack
Case Study : FW Preheater Bypass 0.90 0.90 0.95 0.95 1.00 1.00 1.05 1.05 1.10 1.10 1-Jan-05 15-Jan-05 29-Jan-05 12-Feb-05 (Actual) / (New and Clean Performance) 26-Feb-05 Stack temp Vs Feedwater Preheater Temperature Stack temp Vs Feedwater Preheater Temperature 12-Mar-05 26-Mar-05 Feedwater Preheater T Stack T 9-Apr-05 23-Apr-05 7-May-05 21-May-05 4-Jun-05 18-Jun-05 2-Jul-05 16-Jul-05 30-Jul-05 13-Aug-05 27-Aug-05 10-Sep-05 24-Sep-05 Valve Repaired 8-Oct-05 22-Oct-05 5-Nov-05 19-Nov-05 3-Dec-05 17-Dec-05 31-Dec-05
Case Study : Cond Debris Filter Choke LPST Exhaust (steam water mixture) Debris Cooling Water A Side Filter Cooling Water Out Cooling Water B Side Condenser Cooling Water B Side Debris Filter Choke Condensate (saturated water)
Case Study : Cond Debris Filter Choke • Condenser cooling water flow dropped in June 2011 and it is because B side water path was choked. • Transmission shaft gear of debris filter was replaced with a new one during July 2011 shutdown. Condenser cooling water flow resumed back. Condenser Cooling Water Flow (T/H) Debris Filter Repaired
Case Study : Condenser Air Ingress • Condenser performance was very poor in Q1 and Q2 2007 (Condenser Pressure ACT/NC is very high). It was then found out that the vacuum pump sealing strainer was clogged and the pump was running with less sealing water. After it is rectified, the Condenser performance has improved significantly. Condenser Press ACT/NC Condenser Air Ingress Solved
Experience Establishing a PM Program • 2003 engaged ACTSYS for thermodynamic analysis of MHI GT performance • 2004 – Present, annual Performance Monitoring contract with ACTSYS on all CCPs • Quarterly reporting and presentations, review performance gaps and required corrective actions • Involvement of Maintenance, Equipment specialists, Instrumentation, Operations • Close working relationship where ACTSYS engineers track plant performance and correlates findings to operational and maintenance events
Experience Establishing a PM Program Plant Info System Plant Plant Data Data Data Reconciliation Heat Balances Performance Models Theoretical Analysis & Interpretation Reports Decision Operations & Discussion Points Support Maintenance Presentation & Discussion of Results
Alignment to ISO 50001 EMS ISO 50001 EMS Implemented PM System TP Mgmt provides the framework for setting and reviewing energy objectives and targets Allocating resources and setting up of a methodology for analyzing energy usage Operating and maintaining systems and equipment, in accordance with operational criteria For all Energy Performance Indicators review non- conformities => check Actual versus “New & Clean” Quarterly Performance Review Meetings Determining and implementing the appropriate action needed
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