SPPA-P3000 Process Optimization - Siemens Türkiye€¦ · Our solution Process Optimization...
Transcript of SPPA-P3000 Process Optimization - Siemens Türkiye€¦ · Our solution Process Optimization...
Instrumentation & Controls
SPPA-P3000Process OptimizationSolution Compendium
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 2P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Siemens Power Plant Automation
Comprehensive solutions with outstanding benefit
Industrual PowerPlants
Waste-fired CogenerationPlants
Wind Power Plants
Nuclear Power Plants
Biomass Power Plants
Coal Gasification Plants
Fossil-fired Power Plants
Combined Cycle Plants
Desalination Plants
District Heat PowerPlants
ProcessOptimization
AA!!
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 3P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Increase performance!
Can I ...
Yes you can!
... optimize plant performancewith software only?
Solutions for process optimization
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 4P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Siemens Power Plant Automation
The situation: A power plant unit needs to be operated at all times at the most profitable operating point, which calls above all for greater flexibility and higher efficiency, better availability and lower emissions.
No changes to
mechanical equipment
Process Optimization Solutions SPPA-P3000Our solution
High efficiencyHigh efficiency High flexibilityHigh flexibility
High availabilityHigh availability
Low emissionsLow emissions
AA!!
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 5P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Increase performance!Solutions for process optimization
Modern control principles are the basis for high profitability
Highrepeatability
Optimum operating behavior
Modern control principles
Prediction Intrinsic stability Decoupling
High profitabilityHigh
flexibilityHigh
efficiencyHigh
availablityLow
emissions
Highcontrol quality
Highstability
Model-basedfeedforward
Excellent control concepts are at the base of Process Optimization Solutions:
As a result, operating behavior is extremely stable, but still features flexible and fast response.
model-based, predictive feedforward structuresexploitation of inherently stable processesdecoupling of highly intermeshed subprocesses
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 6P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process Optimizationfor Steam Power Plants
Low Loss StartCombustion OptimizerSootblower Optimizer
Temperature OptimizerLow ThrottlingFuel Optimizer
Best Point
Emissions Control
Runback PlusLife Time Plus
High efficiency
High availability
High flexibility
Low emissions
Increased profitability by intelligent optimization solutions!
Fast StartFast Ramp
Frequency Control
Dispatch ControlMinimum Load Reduction
Maximum Load Plus
No changes to
mechanical equipment
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 7P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationFast Start
High flexibility
Benefit:Reduction of forced trip durationReduced fuel consumptionIncreased revenue through reproducible startup and shutdown to exploit market situation
Features:Model-based formation of setpoints for mainsteam pressure and temperature, and of firing rate
Automatic startup of boiler and turbineAutomatic differentiation between cold, warm and hot starts with bumpless transfer to coordinated power operation
Get back on the grid faster
Task: To get the unit back on the grid in the shortest possible time without thermal stresses for thick-walled components violating permissible limits.
TI
THPTM
Drains
HP-Bypass
Turbine
Start-upvalve
Fuelvalve
TI
THDTM
Furnace
Stress-measurement
Steamquality
Turbinevalve
Injections
Fast Start
Feedback from process
Effect from Fast Sart
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 8P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationFast Start
High flexibility
Increased revenues by getting back on the grid faster
References
Parish, USA565 MW, gas;startup timereduced by 50%
Simmering, Austria380 MW, gas;startup timereduced by 25%
Benefit for a standard unit
300 MW lignite Unit
Start-up time to full load reduced from 4 to 2 hrs
10 starts/year
50 EUR/MWh
300 MW lignite fired unit
Start-up time to full load reduced from 4 to 2 hrs
10 starts/year
50 EUR/MWh
300 MW lignite fired unit
Start-up time to full load reduced from 4 to 2 hrs
10 starts/year
50 EUR/MWh
150,000 EUR/year
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 9P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationFast Ramp
Features: Automatic coordination of boiler and turbine
Automatic derivation of dynamic setpoints from load setpoint and load gradient
Optimization of control loops crucial to unit dynamics
High flexibility
Task: Significant improvement of load gradients free from restrictions imposed by controls and from the need for manual actions.
Respond reliably and fast to market requirements
power % MCR
60
65
70
75
80
85
90
95 Faster reaction on demands
SPPA-P3000Fast rampSPPA-P3000Fast ramp
OldLoad rampOldLoad ramp
tBenefit:Increased revenues thanks to
Fast and repeatable response to changed load demands High ranking of the plant with grid dispatcher
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 10P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationFast Ramp
High flexibility
Increased revenues by flexible response to market requirements
Velsen 24, Holland460 MW, Natural and industrialwaste gas. Loadgradients tripled to 4%/min
Vales Point, Australia660 MW, coalLoad gradientsdoubled to 6%/min
References
300 MW hard coal fired unitLoad gradients increased from 2 to 2.5%/min , extending the load range from 30 MW to 37.5 MW after 5 min periodRevenue (+)*: 90 EUR/kW/aRevenue (-)* : 35 EUR/kW/a
300 MW hard coal fired unitLoad gradients increased from 2 to 2.5%/min , extending the load range from 30 MW to 37.5 MW after 5 min periodRevenue (+)*: 90 EUR/kW/aRevenue (-)* : 35 EUR/kW/a
* Actual average values fromActual average values fromEnBWEnBW, E.ON, RWE, , E.ON, RWE, VattenfallVattenfall
940,000 EUR/year for ± 7.5 MW
Benefit for a standard unit
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 11P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Frequency control
SPPA-P3000 Process OptimizationFrequency Control
Task:
Upgrade of the unit to provide primary frequency control and spinning reserve. Due to the fast load ramps that this service requires, it places very high demands on the dynamic control response of a power plant unit.
High flexibilityIncrease range for frequency control
Features:Throttling of turbine valves
or
Activation of condensate throttling to mobilize energy storage
Benefit:
Increased revenues for primary frequency control and spinning reserve services
Avoidance of fiscal penalties for non-provision of contractually agreed primary frequency control and spinning reserve services.
load
time
Application of load control for frequency deviations. “Frequency control”, the first stage of ancillary
services.
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 12P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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High flexibility
Lucrative services through frequency control
300 MW hard coal fired unit
Frequency control using turbine valve throttling in the range of ± 7.5 MW
Revenue (+)*: 115 EUR/kW/a
300 MW hard coal fired unit
Frequency control using turbine valve throttling in the range of ± 7.5 MW
Revenue (+)*: 115 EUR/kW/a
SPPA-P3000 Process OptimizationFrequency Control
Völklingen, Germany2 x 230 MW, hard coalFrequency control range extended to 7.5%
Maor David, Israel2 x 575 MW, hard coalFrequency control range extended to 7.0%
* Actual average values fromActual average values fromEnBWEnBW, E.ON, RWE, , E.ON, RWE, VattenfallVattenfall
800,000 EUR/a for ± 7.5 MW
+ 3,700 t/a CO2 (due to reduced efficiency)
References Benefit for a standard unit
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 13P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Dispatch control
SPPA-P3000 Process OptimizationDispatch Control
Features:
Automatic coordination of boiler and turbine
Automatic derivation of dynamic setpoints from load setpoint and load gradient
Optimization of control loops crucial to unit dynamics
High flexibility
Increase window for dispatcher control
Task:
Upgrade of the unit to provide increased secondary frequency control capability (AGC). Implementing faster load change rates will open up a larger window for high-return secondary frequency control services.
Benefit:Increased revenue through sale of secondary frequency control services
Avoidance of fiscal penalties for non-provision of contractually agreed secondary frequency control services.
load
time
Application of load control for frequency deviations. “Dispatch
control”, the second stage of ancillary services.
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 14P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationDispatch Control
High flexibility
Velsen 24, Holland460 MW, Natural and industrial waste gas. Load gradients tripled to 4%/min
Vales Point, Australia660 MW, coal.Load gradientsdoubled to 6%/min
300 MW hard coal fired unit
Increased gradients rate from 2 to 2.5%/min , extending the load range from 30 MW to 37.5 MW after 5 min period
Revenue (+)*: 90 EUR/kW/a
Revenue (-)* : 35 EUR/kW/a
300 MW hard coal fired unit
Increased gradients rate from 2 to 2.5%/min , extending the load range from 30 MW to 37.5 MW after 5 min period
Revenue (+)*: 90 EUR/kW/a
Revenue (-)* : 35 EUR/kW/a
940,000 EUR/year for ± 7.5 MW
* ActualActual averageaverage valuesvalues fromfromEnBWEnBW, E.ON, RWE, Vattenfall, E.ON, RWE, Vattenfall
References Benefit for a standard unit
Lucrative services through dispatcher control
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 15P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationMinimum Load Reduction
Task: Reduction of minimum load level imposed by process parameters
Despite the reduction of minimum load level, fast and low-stress load increase capability on demand to meet market requirements.
Features :Adaptation, optimization and setting of lower-level controls for new minimum load level
If necessary, supplementing of plant valves and sensors
High flexibility
Potential for reducing the minimum load level through I&C optimization.
Additional potential can be tapped by mechanical optimization.
Benefit:Reduced commercial losses during off-peak periodsFaster response to increased load demandsAvoidance of unnecessary start-ups and shut-downs
Reduce minimum load level
Savings
Old minimumsustainable load
SPPA-P3000NEW minimumsustainable load
Lower minimum operating loadload
time
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 16P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationMinimum Load Reduction
300 MW gas fired unit
Reduction of minimum load from 90 MW to 60 MW (30% to 20%)
Difference between production costs and electricity price during minimum load time: 10 EUR/MWh
Duration of minimum load operation: 500 h/a
300 MW gas fired unit
Reduction of minimum load from 90 MW to 60 MW (30% to 20%)
Difference between production costs and electricity price during minimum load time: 10 EUR/MWh
Duration of minimum load operation: 500 h/a
150,000 EUR/year
Parish, USA565 MW, Benson gas;Minimum load reduced from 22% to 9%
Benefit for a standard unit
High flexibility
Cost savings through reducing minimum load level
Manzanillo, Mexico350 MW, drum boiler;diesel, heavy fuel oil;Minimum stable output reduced from 30% to 20%
References
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 17P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationMaximum Load Plus
Features:Upgrade of unit control to allow
Valves wide open (VWO) operation of unit
and / or
Automatic coordination of shutdown of HP feedwater heaters and increase in firing rate
Benefit:Additional profits, particularly at times of high power prices without the need for upgrading of process equipment.
High flexibility
Increase electrical output to above 100%
Task: Fast and low-stress increase in output to above 100% on demand to meet market requirements
(1) Unit setpoint increased to 100 % (mod. variable pressure operation)(2) HP feedwater heater 7 is shut off by this module(3) Unit setpoint increased to 110 %, HP feedwater heater 6 shut off fully(4) 110 % output achieved (spinning reserve is maintained)
0 60
(3)
(2) Overload operation110%
HP heater 7
0 %
100 %
Throttling ofHP heaters
Electricaloperation
80 %
120 %
Time [min]
(4)
100 %(1)
HP heater 6
(1) Unit setpoint increased to 100 % (mod. variable pressure operation)(2) HP feedwater heater 7 is shut off by this module(3) Unit setpoint increased to 110 %, HP feedwater heater 6 shut off fully(4) 110 % output achieved (spinning reserve is maintained)
0 60
(3)
(2) Overload operation110%
HP heater 7
0 %
100 %
Throttling ofHP heaters
Electricaloperation
80 %
120 %
Time [min]
(4)
100 %(1)
HP heater 6
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 18P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationMaximum Load Plus
High flexibility
Additional revenues by increased electrical output
Callide, Australia420 MW, BensonMax. load + 10%1400 h/a max. load
Enstedvaerket, Denmark650 MW, BensonMax. load +7%district heat extraction
300 MW hard coal fired unit
Maximum load + 7%, i.e. 320 MW
Electricity price for max. load 60 EUR/MWh
Duration of max. load operation 500 h/a
300 MW hard coal fired unit
Maximum load + 7%, i.e. 320 MW
Electricity price for max. load 60 EUR/MWh
Duration of max. load operation 500 h/a
References
380,000 EUR/a
+ 13,200 t/a CO2 (due to reduced efficiency)
Benefit for a standard unit
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 19P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationLow Loss Start
Task:
Reduction of startup fuel consumption and ensuring reproducible startups.
Features:Automatic run-up of boiler to requisite parameters for turbine start
Automatic differentiation between cold, warm and hot starts
Automatic and bumpless transfer to coordinated power operation
Benefit:
Savings through reduced fuel consumption
Increased revenue through reproducible startup and shutdown
High efficiency
Start-up with minimum losses
TI
THPTM
Drains
HP-Bypass
Turbine
Start-upvalve
Fuelvalve
TI
THDTM
Furnace
Stress-measurement
Steamquality
Turbinevalve
Injections
Low Loss Start
Feedback from process
Effect from Low Loss Start
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 20P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationLow Loss Start
Parish, USA565 MW, BensongasStartup costs reduced by 66%
Mandalay, USA 215 MW, DrumgasStartup costs reduced by 70%
100 starts per year
4,000 EUR / start
50% reduction
100 starts per year
4,000 EUR / start
50% reduction
References
200,000 EUR/year
Benefit for a standard unit
High efficiency
Lower costs for start-ups
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 21P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationCombustion Optimizer
Task: Reducing unburned carbon in ash (‘LOI’ - loss on ignition), NOx, CO and achievement of optimum efficiency through improved combustion.
High efficiency
Increase efficiency, lower emissions
Features:Optimized burner operating point with the aid of:
On-line measurement of coal flow to individual burners using the ECT method Burner-specific matching of air and pulverized coal flow Burner-specific matching of air flow
Benefit:
Higher efficiency
Lower emissions (NOx / CO) and compliance with LOI limit for fly ash
--
Pulverizors
Air Damper
Combustion air• Distribution• Trim
Combustion air• Distribution• Trim
Air Damper
---------
Dataacquisition
------
Coal Flow(electrostatic measurement)
Furnace
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 22P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationSootblower Optimizer
Task:
Condition-based soot blowing integrated into unit DCS
High efficiency
Optimize operation of sootblowers
Features:Use of existing temperature measurements to determine the degree of fouling
Automatic cost-benefit analysis
Activation of soot blowers, either automatically or by the operator
Benefit:
Lower fuel costs due to optimal operation of sootblowers
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 23P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationTemperature Optimizer
Features:Use of dynamic models with predictionIdentification of heat input variations using an observer structureWhere needed, use of entire control range including injection into saturated steamUse on start-up and over the entire load rangeUse of flue gas recirculation, biflux, triflux or burner tilt to control reheat steam temperature to increase the efficiency
High efficiency
Task: Stable control of steam temperature with setpoint close to material limits
Increase temperatures close to limits
-- HP temperature-- Material limit-- set point
Conventional Control
ϑFD low => η low
SPPA-P3000 Control
ϑFD high => η high
-- HP temperature-- Material limit-- set point
Conventional Control
ϑFD low => η low
SPPA-P3000 Control
ϑFD high => η high
Benefit:Increased efficiency thanks to
Higher steam temperaturesReduced reheat injection flow
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 24P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationTemperature Optimizer
High efficiency
Increased revenues or lower costs by increasing efficiency
Velsen, Netherlands360 MW, Natural and industrial waste gas. SH and RH-temp. increased by 5K
300 MW hard coal fired unit
SH and RH-temperature increased by 5K
Coal price 50 EUR/t
300 MW hard coal fired unit
SH and RH-temperature increased by 5K
Coal price 50 EUR/t
Simmering, Austria380 MW, GasSH and RH-temp. increased by 5K
References
60,000 EUR/a- 3,700 t/a CO2
Benefit for a standard unit
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 25P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationLow Throttling
Task: Minimization of throttling losses without any negative impact on load flexibility.
High efficiency
Reduce throttling losses
Features:Setting of optimum degree of throttling for turbine valves, feedwater control valves and fan vanes for forced- and induced-draft fans on basis of a steady-state process model.
Benefit:High efficiency thanks to minimum throttling losses
Turbine
FurnaceAir
flaps
Turbine
Furnace Feedwatercontrol valve
Turbinecontrol valve
Low Thrrottling
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 26P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Karlsruhe, Germany550 MW, Bensonhard coal,efficiency increased by 0.5%
300 MW hard coal fired unit
5,000 h/a operation
Coal price 50 EUR/t
Efficiency increased by 0.33%
300 MW hard coal fired unit
5,000 h/a operation
Coal price 50 EUR/t
Efficiency increased by 0.33%
SPPA-P3000 Process OptimizationLow Throttling
Reference
80,000 EUR/a- 4,800 t/a CO2
Benefit for a standard unit
High efficiency
Increased revenues or lower costs by higher efficiency
Wilhelmshaven, Germany820 MW, hard coal,provision of 20 MW for frequency control without reduced efficiency
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 27P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationFuel Optimizer
Task: Ensuring safe and stable unit operation despite firing of low-cost supplementary fuels and fuels with widely fluctuating properties.
Operate efficient and reliable despite firing of different fuels
Features:
Model-based determination of necessary fuel and air flows
Modulating of flow for selected fuels for load controlAutomatic heating value correctionAutomatic correction of air flowAdjustment of control loops, e.g. flue gas recirculation
Benefit:Maximum use of low-cost fuels, i.e. reduced fuel costs
High efficiency
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 28P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationFuel Optimizer
References Benefit for a standard unit
High efficiency
Cost reduction by firing of supplementary fuels
Velsen 24, Netherlands360 MW, firing of natural gas for load control and blast furnace gas as base fuel
Völklingen MKV, Germany230 MW, 210 MW heat extr., firing of hard coal for base load and load control, and methane / converter gas as supplementary fuel
300 MW hard coal fired unit
5,000 h/a operation
Coal price 50 EUR/tCosts of supplementary fuel 50% of coal costs per specific energy contentReplacement of 1% hard coal by supplementary fuel
300 MW hard coal fired unit
5,000 h/a operation
Coal price 50 EUR/tCosts of supplementary fuel 50% of coal costs per specific energy contentReplacement of 1% hard coal by supplementary fuel
130,000 EUR/a
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 29P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationBest Point
Features:On-line calculation of key process data on the basis of a thermodynamic process modelData reconciliation / validation of measured actual process situationInteractive process analysis for “what if?“ scenarios: Optimized operation and investment decisionsWeb-oriented visualization for office LANs
High efficiency
Operate plant at optimum operating point
Benefit:Early detection of malfunctions and deviations from optimum operation Reduced maintenance costs through problem analysis Reduced generation costs
Task: Automatic analysis of the overall process and of key components, fast provision of information about deviations from optimum operation, calculation of consequential costs for detection of improvement potentials.
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 30P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process Optimization Best Point
Heilbronn, Germany760 MW, heat extraction,hard coal; detailed boiler model, data reconciliation, what-if simulation
Benefit for a standard unitReference
High efficiency
Reduced costs by operation at optimum operating point
Taishan, People's Republic of China2 x 600 MW, hard coal, Data reconciliation, what-if simulation
• Early detection of malfunctions, deviations from optimum operation and slowly drifting values
• Determination of cleanliness of boiler heating surfaces
Improved operation and maintenance
Support of operating staff for routine tasks and fast analysis of problems
50,000 - 150,000 EUR/year
• Easy analysis of actual and historic data • Process analysis available at engineer’s office • Cyclic report generation
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 31P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Features:Assignment of dedicated load capability levels and runback rates for the different major components Consideration of fuel-related restrictions on the loadLoad reduction at the necessary rate with coincident changeover of turbine to stable initial pressure control mode.
Task:
Automatic runback of the unit on loss of major components and transition to the new safe operating mode.
High availability
Ride out loss of major components
Benefit:Reduced number of unit outages
Extended service life
SPPA-P3000 Process OptimizationRunback Plus
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 32P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationRunback Plus
References Benefit for a standard unit
High availability
Increased income by reduced outage
Setubal, Portugal250 MW, oil fired,Reliable runback to 50% load
Nikola Tesla, Serbia & Montenegro305 MW, lignite fired, Reliable runback to 50% load
300 MW hard coal-fired unit,
Avoidance of 5 trips and 5 start-ups per year
Instead: operation at 50% load for 5 x 3 h/a
Startup costs 5,000 EUR
Difference between electricity price and production costs: 30 EUR/MWh
300 MW hard coal-fired unit,
Avoidance of 5 trips and 5 start-ups per year
Instead: operation at 50% load for 5 x 3 h/a
Startup costs 5,000 EUR
Difference between electricity price and production costs: 30 EUR/MWh
93,000 EUR/a
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 33P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process Optimization Life Time Plus
Features:
Model-based control process with prediction
Automatic online adaptation of control parameters
Benefit:Extended service life thanks to avoidance of life-consuming plant trips and inadmissible operating conditions
Reduced repair costs thanks to low-stress operation of final control elements
High availability
Task: Regardless of the demands for fast load changes and fast start-up, components must still be operated below specified stress limits so as to assure long-term availability
Increase availability through low-stress operation
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 34P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process OptimizationEmissions Control
Task:
Compliance with requirements of environmental legislation at as low as possible cost.
Benefit:Compliance with air pollution control laws and regulations, avoidance of fines and even mandatory shutdown for non-compliance
Increased revenue from emission credit trading
Low emissions
Lower emissions
Features:
Continuous emissions monitoring for NOx, CO, SO2, O2 and particulates
Measurement of pulverized coal flow per burner to optimize fuel and air control for each separate burner
Reduction of NOx and CO at the origin
Selected process optimization solutions to increase the plant efficiency Reduction of emissions at the origin
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 35P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000 Process Optimizationfor Steam Power Plants
Low Loss StartCombustion OptimizerSootblower Optimizer
Temperature OptimizerLow ThrottlingFuel Optimizer
Best Point
Emissions Control
Runback PlusLife Time Plus
High efficiency
High availability
High flexibility
Low emissions
Increased profitability by intelligent optimization solutions!
Fast StartFast Ramp
Frequency Control
Dispatch ControlMinimum Load Reduction
Maximum Load Plus
No changes to
mechanical equipment
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 36P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Modernization with customized execution of SPAA-P3000 solutions
Optimization add-on forthird party I&C
Third party basic automation
Concepts - from small to comprehensive - whatever fits your situation!
SPPA-P3000
Third party HMI
Partial modernizationincl. optimization
Third party basic automation
Third party HMI
Siemensautomation
Siemens HMI
SPPA-P3000
Comprehensivemodernization
Siemensautomation
Siemens HMI
Plus Electrical, Field, Maintenance &Management solutions
SPPA-P3000
AA!!
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 37P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-T3000 architectureUserinterfaces
Powerservices
Processinterfaces
SPPA-T3000 Application
Server
SPPA-T3000 Automation
Servers
SPPA-P3000 ProcessOptimizationSolutions
One common platform: SPPA-P3000 fully embedded in SPPA-T3000
Consistent engineering and HMI for basic automation and optimization!
AA!!
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 38P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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SPPA-P3000Execution process
On-site analysis
Presentation and
decision
Implemen-tation and fine-tuning
Optimizedoperation
AA!!
Five joint steps to success!
Discussion ofsituation
Contract
• Engineeringbased on com-prehensive power plant know-how
• Start of installa-tion while plant is still in operation
• Outage and connection to plant I&C
• Commissioning / fine-tuning
• Handover to customer
• Operating experience
• Targets• Options for
optimization• Result:
Which solutions are feasible for this unit?
• Establish, localize and quantify existing potential
• Examine and evaluate archives and control schematics
• Plant tests and limits
Enhanced performance and higher profitability are guaranteed:• Flexibility • Efficiency• Emissions• Availability
• Result: Evaluation of examined solutions
• Proposal:Scope of modernization,different variants?
• Benefits?• Profitability
(return on investment)?
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 39P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Process engineering expertise
+
Automation expertise
+
Siemens Power Plant Automation Combination of strength
Project managementexpertise
600 GW installed fleet 10 GW O&M
Shortest outage timesShortest execution times
2000 systems installed throughout the world
100 years of powerplant experience
World market leader in automation systems
Benchmark in project management
A sound basis for your profitability
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 40P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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Selected referenceswith SPPA-P3000 solutions
Parish, USALow Loss StartMinimum Load ReductionFast Ramp
ValesPoint, AustraliaFast RampTemperature OptimizerMinimum Load ReductionLow Throttling
Callide, AustraliaFast RampMaximum Load PlusTemperature OptimizerDispatch Control
Niederaussem, GermanyFast RampFrequency ControlDispatch Control
Lippendorf, GermanyFast RampTemperature OptimizerFrequency Control
Karlsruhe, GermanyFast RampFast StartFrequency ControlDispatch Control
Simmering, AustriaLow Loss StartTemperature OptimizerLife Time PlusDispatch Control
Plomin, CroatiaFast StartTemperature OptimizerFast RampFrequency Control
Profitable, reliable and flexible process optimization - worldwide
SPPA-P3000 Process Optimization Power Generation · Instrumentation & Controls 41P3000 solution compendium / Dr. Meerbeck / L52 / V 2.116 Pa
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ReferencesPowering the worldProfitable, reliable and flexible power generation - worldwide
More than 2000 power plants worldwide in operationwith Siemens electrical systems, I&C and IT
Source: http://visibleearth.nasa.gov/