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PRODUCTIONMANAGEMENT ANDMONITORING IN A

POWER PLANT

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Enerbitul. Czerniakowska 28 B

00-714 Warsaw, POLANDTel: +48 22 880 92 68

Fax: +48 22 880 92 68E-mail: [email protected] www.enerbit.com

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PRODUCTION MANAGEMENT AND MONITORING IN A POWER PLANT

CONTENTS1. Boiler Efficiency and Thermal Balance ................................................................................................................................................. 42. Laboratory Module ................................................................................................................................................................................................... 53. Fuel Handling ................................................................................................................................................................................................................. 64. Monitoring of Heat Losses .................................................................................................................................................................................. 75. Monitoring of Coal Pulverizers ........................................................................................................................................................................ 86. Turbine Efficiency and Thermal Balance ............................................................................................................................................ 97. Regeneration System ..........................................................................................................................................................................................118. District Heating ...........................................................................................................................................................................................................119. Efficiency of Auxiliaries ...................................................................................................................................................................................... 1210. Turbine Condenser and Cooling Tower ........................................................................................................................................ 1311. Generator ................................................................................................................................................................................................................... 1412. Technological and Economic Indicators ................................................................................................................................... 1413. Boiler Start-up Monitoring ............................................................................................................................................................................ 1514. Turbine Start-up Monitoring ........................................................................................................................................................................ 1615. Start-up Context Advisory Assistance ...............................................................................................................................................17

16. Start-up Loss Monitoring .................................................................................................................................................................................1717. Stress Monitoring .................................................................................................................................................................................................. 1818. Material Degradation Monitoring ....................................................................................................................................................... 1919. Program Energy Meters ................................................................................................................................................................................2020. Equipment Characteristics ........................................................................................................................................................................ 2121. Production Accounts ....................................................................................................................................................................................... 2222. Production Cost and Revenues ........................................................................................................................................................... 2323. CHP Plant Model .................................................................................................................................................................................................. 24

24. Forecasting of CHP Plant Heat Load ............................................................................................................................................... 2525. Electric Load Forecasting ........................................................................................................................................................................... 2626. Profit Optimization - the „Cogenopt” Module ........................................................................................................................ 2727. Optimal Plant Operation with Heat Accumulator - The „CogenoptA” Module .................................... 28

Appliaction Platform .................................................................................................................................................................................................. 31Reference List ................................................................................................................................................................................................................... 32

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Fluidised bed boiler efficiency screen graphics

T he boiler efficiency programme module may be applied

to boilers red pulverised coal, oil, gas, biomass, as wellas to uidised bed boilers and heat recovery steamgenerators. Te module software enables also calculations tobe performed for simultaneous combustion of several fuels.

Te module calculates thermal balance, heat loss andefficiency on the basis of current measurements that havebeen taken from a database or from the control system. Te results in each calculation cycle are made available tooperators in the form of screen graphics. Te data obtai-ned from these calculations are also recorded in the data-base and can be analysed at a later date.

Depending on the boiler size and fuel type, the calcula-tions are carried out either by the direct method or by the lossmethod. For coal red boilers, the efficiency is calculated bydetermining the main heat loss. In addition, the ue gas com-position necessary for calculations is determined by iterativeprocedures.

Te applied calculation methodology is based on therelationships described in standard PN-EN 12952-15 of2006 „Water-tube boilers and auxiliary installations. Part15: Acceptance tests.” Also other methods may be appliedfor efficiency calculations, including the method describedin the ASME standard.

Te operators are informed of the current value of heatloss, the thermal balance components, the fuel chemical

energy used for steam generation and a number of parameters,of which some are listed below.

Te fuel composition. Tis is determined on the basis

of chemical analysis of individual fuels (for simultaneouscombustion of basic fuel and additional fuels). In addition,the current composition of the fuel composite burned isdetermined on the basis of the measurements taken of theoutlet ue gas composition.

he dependency of the boiler flue gas loss on theexcess combustion air and the flue gas temperature. Tisdependency is calculated based on the current conditions,i.e., for the current ue gas composition, the oxygen con-tent in the ue gas and the ue gas temperature at theboiler outlet.

he dependency due to unburned carbon losson the combustion conditions. he unburned parts infly ash and slag are systematically estimated with neuralmodels. he current loss value, and its dependency onthe factor that currently has the strongest influence onthis loss are then determined. A simpler solution is whenthe fuel composition laboratory analysis result is usedinstead of the neural model.

he operators, having quanti tat ive information onthe influence of individual parameters on the boilerefficiency, are then able to individually take

cost-effective measures during the boiler operation.

1. BOILER EFFICIENCY AND THERMAL BALANCE

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Laboratory module is a database in which records are

gathered after analyses have been completed. Te data-base - along with the user interface - enables this datato be used both by the employees and by applications, whichmay automatically download this information and applythem in calculations.

For calculations as regards boiler efficiency, the results ofanalyses taken of the fuel burned are required, along withthe ash and slag. Tis data, along with their time stamps, aredownloaded by the application from the database.

As an example, the following parameters may be archivedin the database:

•Demineralised water: hardness, acidity, conductivity,silica, iron, copper

• Feed water: hardness, acidity, conductivity, silica, eliminox• Boiler water: acidity, conductivity, phosphates, p parame-

ter, m parameter• Saturated steam: conductivity, silica• Superheated steam: conductivity, silica• Condensate: hardness, acidity, conductivity, silica,

ammonia• Coal, technical analysis: caloric value, C, S, ash, moisture• Coal, elementary analysis: caloric value, C, S, N, H, O,

H2O• Flue gas, unburned parts content: in ash, in slag

• Pulverised fuel, mill 1, pulverised coal duct 1: R200, R125,

R90; pulverised coal duct 2: R200, R125, R90• Pulverised fuel, mill 2, pulverised coal duct 1: R200, R125,R90; pulverised coal duct 2: R200, R125, R90

Apart from the laboratory database, the module alsocontains two interfaces:

• Te user interface, for retrieving the recorded data• Te laboratory interface for making entries into the

database by authorised personnel

Making entries is authorised by inserting the individual’susername and password.

Users

Id Name Initials Password

1 Alexis Galwarys AG ***

5 Alicja Kubicki AK ******

12 Ann Neugebauer AN ********

4 Barbara Zeeman BZ ***

16 Dafne Coperer DK ****

2 Hana Lexwind HL ********

An example of a user interface of the laboratory module

2. LABORATORY MODULE

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A t present, in many power and CHP plants,co-combustion of two or more fuels is applied.

Unless the proportion of fuels burned is forced, thequestion as regards the best ratio will always arise. In both casesthese questions can be answered by efficiency assessment. ocalculate efficiency, one needs to know the chemical com-position of the fuel composite that is formed in the processof combustion of various fuels. Terefore the applicationsystematically deter-mines the share of the elementary com-ponents that are fed to the boiler. Te screen graphics showthis as the composition of the fuel composite.

If two known fuels are burned, it is possible to performregression analysis of the results of the afore-mentionedeconomic calculations and to obtain a simple dependencyof the boiler efficiency on the fuel ratio.

Boiler efficiency at various shares of the additional fuel

Te left-hand graph shows such a dependency for a CFBboiler that is red with coal and hydraulically fed coal slurry

of inferior quality, but is much cheaper than the basic fuel.

Optimal share of the additional fuel in combustion

Tis graph - complemented with fuel prices - enablesthe optimum proportions of fuels to be determined. Tegraph presented above indicates explicitly how much addi-tional fuel should be burned in order to ensure the highestpossible revenues from energy sales in relation to the fuelcosts.

Preparation of pulverised fuel to have it adapted forcombustion in the boiler is a separate issue. Pulver-isedcoal of adequate quality may be obtained by the monito-

ring of coal mills. Tis module is described in the section Monitoring of Coal Pulverizers .

3. FUEL HANDLING

Screen graphics showing the current composition of the fuel composite at simultaneous combustion of coal,biomass (two types) and biogas

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T he main heat losses in a boiler consist of ue gas loss,incomplete combustion loss and imperfect combustionloss, as well as convection and radiation loss.

Te latter does not depend on the operational condi-tions, and the imperfect combustion loss in modern boilers isnegligible.

Monitoring of the outlet loss is performed by trackingthe working point in a graph with independent coordi-nates (oxygen in ue gas and ue gas outlet temperature). Te graph curves are calculated accordingly to thecurrent chemical composition of ue gas and the moisturecontent. Monitoring of this biggest heat loss enables the boilerefficiency to be monitored on an ongoing basis. Te opera-tors may change the settings of the oxygen set value if it isdeemed advisable and practicable.

Te second biggest heat loss in the boiler is the incomple-te combustion loss that arises from the remains of unburnedcarbon in carbon y ash and slag. Te content of ammab-le matter in y ash is not measured by direct methods andtherefore its value is laboratory-determined. Tis is a seriousdisadvantage as the consequent delay prevents it from beingmoni-tored online.

In order to eradicate this drawback, a model has beenapplied in which characteristics are determined with anarticial neural network. As a result, we can obtain a graphof the ammable matter content in y ash with a timeresolution of 10 seconds. An example of the graph is presen-ted in the picture.

Due to changes in the facility properties such as wear andtear of mill pulverising components, periodic fuel changesand other such examples, the other feature of a neural mo-del - which is its continuous „learning” - becomes valuable. Te possibility of verifying model properties by means ofcontinuous confrontation with laboratory tests is utilizedhere. In this case there is no requirement for tests to beperformed on a daily basis.

Te results of the operations of the trained neural modelthat determines the carbon content in y ash are presentedin the picture. Tese laboratory test results are then compa-red with the results estimated for the times when y ash wassampled.

Systematic monitoring of flammable matter in fly ash

4. MONITORING OF HEAT LOSSES

Systematic monitoring of the outlet loss of apulverised fuel boiler

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T he mill module monitors the operating conditions of themill itself, along with the inuence of the mill assembly

operation on the incomplete combustion loss in the boiler.Operators can observe the following parameters:

• Te working point as regards the unit power consumptionfor coal pulverising, as presented in the graph that has thefollowing coordinates: unit ventilation and classier position. Te operator can see the actual working point in the formof the current value of unit power consumption, and alsoa series of statistically averaged characteristics of mill ven-tilation (the working point for the reference conditions).It results in a deviation from the standard which may becaused either by the deterioration of the pulverising compo-nent condi-tion, or the fuel quality.

• Te working point as regards the unburned parts contentin y ash is presented in the graph that has the followingcoordinates: unit ventilation and classier position. In thiscase, these coordinates mean the weighted averages for theassembly of mills in operation. As in the rst example, thereare two working points: the actual working point (Cp labo-ratory measurement), and the working point for the averaged(standard) conditions).

Te presented graphs enable the mill performance and the

inuence of their operations on boiler efficiency to be assessed,along with correctional measures to be implemented with regardto the classier and air control system settings, both for the pri-mary and secondary air.

5. MONITORING OF COAL PULVERIZERS

Unit energy consumption for coal pulverising

Flammable matter content in fly ash

Screen graphics of the coal mill monitoring module

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In the program module of turbine efficiency the turbinethermal balance is calculated, including the regenerationsystem. For condensing turbines, the balance includes the

condenser with the cooling water system; and for districtheating turbines the balance of heat exchangers and the heatexport system.

Te module makes calculations for:• steam turbines• back pressure extraction turbines

• condensing turbines• gas turbines• steam and gas systems

Graphics of a back pressure turbine with bleeding

Temperature versus entropy

6. TURBINE EFFICIENCY AND THERMAL BALANCE

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Te program for calculating the efficiency is based onhaving knowledge of enthalpy and entropy at the inlet andoutlet of each turbine stage. For turbines where - in someextractions - wet steam with unknown steam quality, theprogram - based on the available measured values - syste-matically denes the steam expansion curve and determi-nes all the necessary parameters for the whole turbine owpath. Te output parameters – those that are exported to thedatabase as a result of the turbine-generator – set

calculations for internal efficiency of the HP, IP and LPparts, thermal power in characteristic points of the owsystem and the mechanical power at the shafts of the HP, IPand LP parts, thermal power in the steam from each turbi-ne extraction, the electrical power generated in cogenerationand in the condensing mode, electrical and thermal powerof auxiliaries used for production of power, heat and gene-ral needs, net and gross efficiency of energy generation, andheat and power cogeneration ratio.

Enthalpy versus entropy

Te program module for turbine efficiency calculationspresents the following additional information, which may besignicant for the operating personnel in the power plant:

Te steam path expansion line in the turbine ow path. Tis enables its current operational conditions, the throttlingdegree in the control valves and the IP valves, along with the ventilation effect of the nal stages, etc. to be evaluated.

Efficiency variation history. Tis is the course of efficiency within the last 8 hours - visualised in order to show the corre-lation between the initiated changes of operation conditionsand the efficiency.

Te efficiency deviations from its design value - whichhave occurred as a result of deviations of the actual operatingconditions from the design conditions.

Sensitivity of efficiency to the operating parameter chan-ges. Tis is the magnitude of efficiency change caused bya change in a certain physical parameter. Te operators areaware of the current impact of, for example, the incomingsteam temperature and pressure, a vacuum in the conden-ser, condenser surface contamination, heat exchange in theregenerative heaters, or a pressure drop at IP valves (in CHPplants) on the efficiency.

Te steam parameters and the parameters of streams ofsteam, water, condensate and drip as determined by calcu-lations enable all the parameters needed for making reportsas used in power industry statistics and in the productionplanning, to be calculated. Te explicit presentation of thedependency of efficiency on key factors allows the operators

to solely optimise operations.

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T he program module for monitoring thedistrict heating module perfor-mancedetermines the balance and characteristic

parameters related to the production and ex-ternal transfer of heat. Aside from the energybalance, the thermal temperature differencein the heat exchangers for district heating aredetermined, and are used as a measure of heatexchange efficiency. In this module, steam stre-ams from the turbine extractions that feed theunder-turbine heat exchangers are calculated. Te obtained data is the basis for calculations ofturbine efficiency.

Regeneration system screen graphics

The graphics of an example of district heating module

8. DISTRICT HEATING

7. REGENERATION SYSTEM

T he regeneratiom module calculates thethermal balance and parameters as related toregenerative heaters. Tese are the following

groups of data:

• Te thermal balance of the heaters• Te heat ux to the heat exchange surface• Te steam ow from the extractions to the

heaters• Te heater thermal temperature difference

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9. EFFICIENCY OF AUXILIARIES

Consumption of power for auxi-liaries constitutes a signicantpart of CHP plant production.

Terefore it is advisable to monitor working points of large power consumersand their current efficiency. Te programmodule designed for this purpose moni-tors FD fans, mill fans, ue gas fans (IDand recirculation fans), feeding pumpsand municipal water pumps.

Te equipment efficiency is determi-ned on the basis of systematic calcula-tions of hydraulic power of the medium,and the absorbed electric power.

In another variant of screen graphics,the working power of the equipmentcan be seen in the background of equalefficiency curves. Tis family of curvesis obtained from a database containinghistorical data.

Monitoring of feed water pumps

Screen graphics of flue gas fans - the working point and the chart of current flow resistances

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T he condenser working point is signicant for turbineefficiency. It is a function of cooling system perfor-mance. Te monitoring of a cooling system, for exam-

ple, with vent coolers, is focused on indicating the correctrelationship between the cooling water temperature, the

number of cooler cells in operation, and the fan speed.

Te result is then used for setting the condenser workingpoint as these coordinates: the condenser temperature ver-sus the stream of the steam condensed, where the cooling water tempera-ture is a monitored parameter. Te whole isto inform the operators of the best operating conditions of

the condenser, along with the information on how to achievethese conditions with the cooler.

Graphic interface of the turbine condenser and the cooling tower

10. TURBINE CONDENSER AND THE COOLING TOWER

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T he task of the generator programmodule is to monitor the gene-rator working point on a circular

chart which is supplemented with li-mitation ranges. Usually the followingparameters are calculated:• Active power and reactive power on

a circular chart• Phase angle cosine and phase angle• Power angle and power triangle• Power limitations at overexcitation

and underexcitation• Changes in generator efficiency

with the power generated and pha-se angleChanges in generator efficiency arein relation to the manufacturer’s data

for nominal conditions. o this end,the module corrects the losses in cop-per and iron depending on the activeand reactive power generated.

T he technological and economicindicators are calculated for theDivision of Economic Analyses of

the CHP plant, Division of ProductionSettlements and unit operators.

Tese parameters are utilised asaggregated in various time horizons. Inorder to enable calculations to be made

for any use, the calculations are made with a time resolution of 10 seconds.

Graphic interface of the generator program module

Graphics of technological and economic indicators

12. TECHNOLOGICAL AND ECONOMIC INDICATORS

11. GENERATOR

Here is an example of an indicator setcalculated separately for the condensingcircuit and for cogeneration:

• Gross, net electric power• Power generation efficiency • Unit consumption of chemical energy of

fuels for power generation• Electrical power consumed by auxiliaries

as related to power production, and asrelated to heat production

• Termal power sent externally for hea-ting and process purposes

• Cogenerated thermal power sent exter-nally

• Heat generation efficiency • Unit consumption of fuel chemical

energy for heat generation• Termal power consumed by auxiliaries• Termal power consumed by auxiliaries

as related to power production; relatedto production of heat sent externally

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D uring start-up, shut-down and during severe loadchanges, mechanical and thermal stresses occur inthick-walled boiler components. In order to avoid

exceeding those values that are permissible, the main thick--walled components are monitored.

Te difference between the permissible stress value andthe actual stress value is dened as the stress margin. Tismargin, for any thick-walled component which may affectthe boiler start-up or shut-down speed, is monitored onli-ne. Tis parameter informs the operator of the possibility ofincreasing the start-up speed at a given time.

Te operation monitoring module contains the toolsrequired for start-up coordination.

Te basis for the calculation is the model which maps theheat accumulation process in the evaporator volume and inthe economizer.

Te picture (above) shows a fragment of the screen grap-hics for the boiler operator. Te current heat accumulationcurve and the current and optimal steam stream from theboiler are indicated.

After the heat accumulation process in the evaporatorhas been coordinated, it becomes possible to determine theacceptable increase in the fuel stream to the boiler and thereceived steam stream.

Both types of load margin enable the start-up to beconducted at the maximum speed.

Te boiler start-up monitoring module is provided witha context-sensitive prompt function for the operator. Itsobjective is to remind the operator of those activities that arenecessary to be performed at any given moment or to display warnings about unacceptable states.

Te start-up monitoring module enables the boilerstart-up to be conducted with as few start-up losses aspossible. Operational safety conditions are then met.

Operator’s interface for boiler start-up

13. BOILER START-UP MONITORING

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14. TURBINE START-UP MONITORING

T he operator has access to thefollowing components:

• urbine thermal restrictions con-taining start-up criteria

• Restrictions related to the shut-off valve

• HP internal body restrictions• HP external body restrictions• IP body restrictions• Special measurements

(general abstract)• General measurements• Start-up conditions for the turbine

Te eccentricity, axial shift, elonga-tions, metal temperature and bearing vibrations are monitored.

Visualisation of the turbine -generator set bearing vibrations in the X-Y plane are presented by the graphas ellipses. Te coloured surfaces ena-ble the vibration levels to be quicklyevaluated, along with the dynamics oftheir amplitude changes in relation tothe currently applicable values.

Operator’s interface for turbine start-up

Operator’s interface for turbine start-up - vibrations, elongations,and axial shift

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PRODUCTION MANAGEMENT AND MONITORING IN A POWER PLAN

Monitoring of start-up procedures for both the boilerand the turbine is provided for the operator in theform of a context-sensitive advisor. Its objective isto provide the operator close contact with the start-up pro-

cess. Te messages are broken down into two groups. Te rstcontains information about the event that is about to occurfrom the start-up procedure; the other is a set of warnings.Below are a few messages presented as examples:

T he start-up loss module is a tool for systematic deter-mination of the amount of energy loss and start-upcosts incurred during the start-up cycle. Tis includes

shut-downs, standstills and start-ups of power units. In ad-dition, this module – which was based on collected historical

data from previous start-ups - forms a start-up template forforecasting start-up loss quantities, and costs of a shut-downand any restarting of the unit that is planned for the future.

Te module uses the direct method for determiningenergy losses. It archives power unit start-up parameters for various types of start-ups into a local database:

• For cold, warm and hot start-ups (the determining factoris the turbine body temperature).

• On the basis of certain algorithms the program also iden-ties the cases where the start-up process deviates fromoptimal conditions (emergency states).

Calculations in the program are performed online. Teprogram systematically monitors the operating status ofpower equipment, looking for characteristic stages of thestart-up cycle (shut-down, standstill, start-up). Te comple-tion of each start-up is followed by calculations related tothis start-up, along with an update of the forecast start-uploss template.

o determine the specic state of the beginning andthe end of any given unit start-up, the application performsdetailed calculations for every start-up stage of the unit.

15. START-UP CONTEXT ADVISORY ASSISTANCE

16. START-UP LOSS MONITORING

Al er ts :

Economizer water temperature is under saturatio n only 6 Deg C Water in economize r i s b oi ling ! Increase water flowSuperheater IV tubes temperature is 7 Deg C over allowable valueHeat accumulation in evaporator is too hig h

Boiler related messages:• Te water temperature in the economiser is only 6.0°C

below boiling point• Water is boiling in the economiser• Te fourth stage superheater: the pipe metal tem-perature

has exceeded acceptable limits by 7°C. Increase injection!• Tere is excessive heat accumulation in the evaporator.

Increase saturation temperature at a rate of 1.52°C/min

Turbine related messages:

• Te steam temperature upstream from the shut off valvemust not fall below 186°C.• Te acceptable steam temperature gradient upstream

from the shut off valve must not exceed 1.36°C/min.• Predicted synchronization time: 19:03:00.

Examples of „context-sensitive advisor” messages.

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A ny resultant stresses on the boiler’s thick-walledpressure components are mainly from the internalpressure. Te difference between the permissible ther-

mal stress value and the actual value is dened as the thermalstress margin. For safety reasons, this margin is monitoredcontinuously.

Tis module performs the following basic functions:

• It determines the thermal stress margins in the mainpressure components of the boiler in the online mode

• It determines the safety margin for heated surfaces bymonitoring the heat load of its heating components- mainly the superheater components

Te components that restrict the boiler start-up speed areits thick-walled pressure components.

Te basic function of the boiler start-up program moduleis to systematically identify thermal stresses and then deter-

mine the margins of stress that may occur as a result of thestart-up. Mechanical stresses are calculated within appropriatestandards.

Termal stresses in the thick-walled components arecalculated online; the calculation method depends on thecomplexity of the thick-walled component shape, along withthe applied method to measure the metal temperature.

Te calculation result is then processed into information, which has two applications:

• Te information is displayed on the screen monitor of theunit operator

• Te information for the control system represents theboiler thermal restrictions.

In the rst application, the operator uses the informationobtained for manual start-up. Te method of thermal stressmargin visualisation is shown in the picture.

Te thermal stress module complements the power plantdiagnostic system. Periodic tests of the unit’s thick-walledcomponent material with non-destructive (NDE) methodsenable the degree of degradation of each component to be

assessed. However, the correctness of equipment operation inthe period between the subsequent NDE tests is monitored bythe presented thermal stress program module.

Boiler thermal stress interface

17. STRESS MONITORING

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T he operational history of power unit equipment com-ponents is recorded in the material structure, resultingin a successive loss of material mechanical properties.

Te mechanism of exhausting the service life of the materialhas been identied, and the mathematical description of thisprocess enables the current condition to be evaluated witha specic accuracy on the basis of its operational history.

he destructive effects of operat ion are measured

by two parameters:

• Te sum of material damage resulting from the stress andhigh temperature impact – or the creep wear

• Te sum of damage resulting from cyclical stress changesat a high temperature – or the fatigue wear.

Both kinds of destruction act together, and theirnumeric value is the measure of material wear (UsageFactor).

In the module for boiler start-up monitoring, mecha-

nical and thermal stresses in the selected components -recognized as criterion components - are continuously

identified. hese parameters are the basis of calculationof the combined stresses. hese total stresses cause thedegradation of material, and the effect of degradationmay be estimated based on examining the history ofstress changes during operation.

he program module calculates the fol lowingparameters:

• Te total stress in the criterion pressure components• Estimated material wear as a result of high-temperature

creep• Estimated material wear as a result of low-cycle fatigue• otal wear of the monitored components (Usage Factor)

he calculations - which are conducted continuously- enable hazardous areas to be evaluated on an ongoingbasis and the method of unit operation to be corrected inorder to limit these hazards in the future.

he picture shows an example of screen graphics whe-re the values of relative material wear due to fatigue and

creep are presented. he bar chart shows the aggregatedmaterial wear for each component in its relative form.

Screen graphics of the material wear module

18. MATERIAL DEGRADATION MONITORING


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Te program meters are an application for recordingproduction settlement parameters for which no physicalmeasurement points have been installed.

It is often necessary to monitor individual productiondata for settlement or controlling needs. At the same time,for technical reasons, it may be impossible to install meterson site. In such circumstances the program meters may beapplied. Tis application determines the required parametersbased on available measurements, using mass and energybalances or indirect calculation methods.

o ensure continuity of such measurements in the eventof failures, the program is installed at independent servers. Te application has had the necessary protection programsinstalled that prohibits any interference in the programalgorithms or in the results themselves, thus ensuring thesecurity of calculations. Te system may also use back-upmeasurements by automatically changing the calculationmethodology in case of basic measurement failure. Allinformation on the application operation is reported andrecorded, and any information as regards incorrect measu-rements is sent by e-mail to the application administrator.

Examples of parameters monitored by the programmeters:• Coal allocation to individual boilers based on indications

of the scales at the common conveyor belt• Allocation of heat production within heating water to

individual units on the basis of measurements on thecommon heating mains

• Heat production within process steam by individual units• Heat production within peak heat exchangers differentia-

ted between heat produced by co-generation and beyondco-generation

• Heat production from steam boilers

19. PROGRAM ENERGY METERS

Program meters - table with data

Program meters - graphic presentation of the parameters monitored

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W ithin operating practices of a power plant thereis often the need to analyse equipment operationin exceptional conditions. In this case, economic

calculations have been made based on a power plant (CHPplant) model. Te model is based on the characteristics ofindividual facilities, and such characteristics may be providedby a specialised company.

At present a vast majority of power plants have a mea-surement data acquisition system where the process data isrecorded. It can be used for independent identication ofstatistical characteristics of the equipment, which providesthe possibility of continuous economic analysis of facilityoperation.

ools based on an articial neural network, among others,have been used for the identication of characteristics. Tisadvanced identication technique enables the data to beanalysed in detail at a future date and veried, but rst andforemost it enables the result to be applied directly to otherapplications using the developed equipment characteristics.

Approximating functions may be directly applied by, forexample, using Microsoft Excel sheets.

Program interface for identification of equipment characteristics

20. EQUIPMENT CHARACTERISTICS


An example of the turbine IP part characteristics

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T he optimisation of the CHP plant production aims atobtaining the best ratio on revenues: from power andheat sales to expenses on fuel and other variable costs

related to energy production. Te difference between the salesrevenue and variable costs constitutes a contribution margin(but does not contain xed costs), which is the only criterionfor optimisation.

Te cost program module enables the contribution mar-gin to be identied and used in simulation optimisationsthat are run offline for comparative examinations of the various variants of production. It is also used for ongoingoptimization of production.

Te input parameters for the cost module are:

• Fuel cost stream (coal, biomass, oil, biogas, gas)• Current fuel parameters• Air emissions (CO2 in the form of the environmental

charge + CO2; in the form of emission trade participa-tion, NOx, SO2)

• Stream of costs of power consumption for auxiliaries

• Stream of costs of heat consumed for auxiliaries• Sales of heat (within heating water, within process steam)• Sales of power (contracted, ordered by the medium volta-

ge line customers, and sold at the Power Exchange)• Information on property rights concerning red and green

energy • Information on the prices of contracted energy, and from

the Next Day Market

As is standard, the cost module calculates the contribu-tion margin value for a period of one hour. Daily, monthlyand other periods that constitute the sum of hourly resultsmay be calculated with database tools.

Te cost module may be used in three cases:

• For evaluation of the past period - input data is takenfrom the archive database

• For current optimisation - input data is taken from theprocess database

• For optimisation of future production - the CHP plant

22. PRODUCTION COSTS AND REVENUES

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A multi-variant analysis of CHP plant operation at setexternal conditions is only possible by means of its mathema-tical model. Te same concerns any analysis of its operatingconditions that may occur in the fu-ture. For these purpo-ses, a mathematical model of individual CHP plant facili-ties is applied. Te model is veried based on an additionalprogram module that identies the static properties of thesefacilities. Tis auxiliary module is called the „CharacteristicsMod-ule”, and is described above.

Tus models of boilers, turbines, generators, heat exchan-gers, district heating modules, and cooling systems are crea-ted. When combined, they comprise models of whole heatgenerating units and CHP plants. Te model is intendedmainly for the examination of CHP plant operating condi-tions in exceptional situations, and for the optimization of itsoperations in order to maximise prots on energy sales.

As an example, models of some of these facilities areoutlined below:

BoilerInputs values:

• Streams of coal, biomass, oil, biogas, feed water

temperatureOutput values:• Chemical energy supplied with fuel, stream of steam

Parameters:• Conguration of the mill system

TurbineInput values:

• Stream of steam to the HP turbine section, stream of

steam to the IP turbine sectionOutput Values:• Extraction steam enthalpy in extraction no. 1 and in the

other extractions.• Power transferred to the rotor shaft in the HP turbine

section, power to the shaft in the IP section

Vacuum systemInput values:

• Heat uxes from the steam ejectors, the vapour coolerand the heating water stream in the by-pass ductOutput values:

• Water temperature downstream the steam ejectors and

the vacuum cooler (C ), drip streams, heat from thesystem to water

Heat exchangerInput values:

• Heat ux transferred to the heating water, heating waterow, inlet temperature, streams and temperatures of dripto the heat exchanger, stream of additional water to thesystem

Output values:• emperature, streams of water and drip at the outlet

23. CHP PLANT MODEL

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For power production planning, knowledge of theexpected heat load of the CHP plant, along with theforecasted demand for heat in the heating water and

process steam for the whole calculation period, are required. Te module calculates the demand for heat in the heating water and process steam for the following and six subsequentdays (n+6).

Te output parameters are forecasting demand for heatin the heating water, the heat in the process steam, and thepower demand from medium voltage customers.

Te basic inputs for heat load models is data from weekly weather forecasts provided by the relevant meteoro-logical office. Te other model inputs describe the current

weather conditions and the current operation state of indivi-dual CHP plant facilities.

Auxiliary input parameters:

• ime• Week • Number of days from the winter solstice within the

heating season• Ambient temperature• Sun exposure• Wind speed

• Humidity

24. FORECASTING OF CHP PLANT HEAT LOAD

Forecast of heat transferred to the heating water. Colours: green - measured value, blue - model output, red - value difference (absolute value)

A one-customer forecast of heat in the process steam. Colours: green - measured value, blue -model output, red - value difference (absolute value)

Forecast of power sent to the MV grid customers. Colours: green - measured value, blue - modeloutput, red - value difference (absolute value)

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T he program module responsible for determining theforecast concerning power production operates on thebasis of information that is provided as regards the

expected heat load in the heating water and process steam. Tis module operates based on a model of generating facili-ties, the conguration of their operation, and the method oftheir utilization by the operators. Tis data is complementedby a list of process restrictions valid for the selected operatingconditions (technological minimums, maximum loads).

Te program module contains facilities in the form ofa number of characteristics. Tese are boilers, turbines,generators, bypass stations, heat exchangers, rejection systems(for heat) and a heat accumulator.

It has been assumed that the time period of any calcula-tions is seven days, which means that the results concern thecurrent day and the six days that follow.

Te program has a repository of weather forecast para-meters, and is used to obtain information for determiningthe forecast of the CHP load. Te data is downloaded to therepository from the relevant meteorological office at hourlyintervals. Tese parameters are stored in tables:

• Forecasts - the weather forecast

• Weather - the actual weather he unit operation conguration for the rst day of the

schedule is determined by the Duty Operating Engineer. Te conguration existing at the time of these calculationsis assumed by default. If, during calculations of any plan inthe congurations assumed, it becomes unfeasible to meetthe production requirements (technological minimum, maximum), then the program will change to the correct con-guration.

Te power price forecast at the Next Day Market isacquired from the data obtained via the Internet from thePower Exchange ( owarowa Giełda Energii S.A.) Price values are stored in tables.

Determination of process restrictions for heatproduction. Te program contains tables of optimal unit working points as a function of conguration, heat pro-duction within the heating water, and the process steam ow. Te minimum and maximum heat production within wateris determined based on the tables for a given conguration

and process steam production. Heat production within theheating water limits the possibility of potential charging anddischarging the accumulator.

Calculation of maximum and minimum uxes ofaccumulator charging and discharging heat.

Te maximum and minimum accumulator chargingand discharging streams are calculated based on the heatproduction forecast, along with the heating water ows andtemperature calculated from the balance, DIR may changeand reset the default minimums and maximums with a formin the User interface.

Assigning the heat production to the accumulator andto the heat distribution system according to the Next DayMarket power price criterion.

Te program assigns the accumulator charging ordischarging uxes so that the biggest charging ux is whenthe Next Day Market price is at its peak level. Tese areiterative calculations. Te economic effect is assessed accor-ding to the power price criterion only in the rst step ofiteration, when the contribution margin is not yet known. Insubsequent calculation steps, the criterion is replaced withthe contribution margin. As a result of iterative calculations,

the optimal working points of the heat generation units andthe accumulator are determined, taking into account bothprocess limitations and the DIR settings.

Calculation of the contribution margin and powerproduction

Te program calculates the contribution margin andunit working points with a table of optimal working points- within a specic unit conguration, heat production withinthe heating water, process steam production, and heat ux toor from the accumulator.

Te working points determine the gross active power bythe turbine-generator set, the heat production within theheating water and process steam, and the power consumedby unit and non-unit auxiliaries.

Te contribution margin for optimisation purposes isdetermined in the cost module.

Te program determines the accumulated heat that isoptimal for the „contribution margin”, and heat productionby the units by changing daily increments of heat in theaccumulator.

25. ELECTRIC LOAD FORECASTING

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26. PROFIT OPTIMIZATION - THE „COGENOPT” MODULE

T he simulation module enables the unit, along with the whole CHP plant behaviour in various operation condi-tions, to be examined. Te basis of the module is a model

based on mass balance and thermal balance, and characteri-stics are determined from the data collected in the processdatabase. Te model is static, and the module operates offline.

Te simulation enables, among others, the followingdependencies to be determined:

• Te selection of operation variant that ensures optimumprot

• Te inuence of altered fuel parameters on the technolo-gical and economic indicators

• Te behaviour of technological and economic indicatorsat various loads

• Determining the inuence of steam parameter changes in

power and heat production• Te inuence of heating water parameters on unitoperations

Screen graphics of facility configuration variantselectionInput data table: weather, sales prices, fuel prices

Active power from the generators Heat production to the heating water

Fuel for combustion Comparison of various operation variants andattainable eco-nomic effects

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T his application is intended for managing the CHP plantoperation in order to provide:

• Economic distribution of load to the heat generatingunits and the condensing turbine-generator set

• Heat accumulation in an approach that ensures effectiveutilisation of fuel chemical energy

Te application has the following built-in mechanisms:• Forecasting of demand for heat within the heating water

•Forecasting of process steam demand

• Forecasting of the power price sold in theNext Day Market

• A mathematical model of CHP plant facilities containingtheir valid characteristics

• A mathematical description of costs related to energyproduction and sales revenues

• A program for the optimization of load distributionaccording to economic criterion

• Forecasting power production for the following day • Determining the actual values of the set powers of gene-

rating units• Ensuring that CHP plant departments are coordinated in

order to contract sales• Archiving of calculation results

A power production forecast on a selected day in the future

Graphic interface of the „CogenoptA” module

27. OPTIMAL PLANT OPERATION WITH HEAT ACCUMULATOR– THE “COGENOPT A” MODULE

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Heat production to the heating water at any hour of theselected day from the six days’ time period

A power production forecast

A heat accumulator utilization forecast

Set value of gross power production per minute for one ofthe turbine-generator sets resulting from the economic load

distribution

Gross power production planned for day n+1 by individual generating units

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Graphic interface for configuring the CHP plant for the following days

Graphic interface - sales data for the Sales Department

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APPLICATION PLATFORM

Location of the application server containing software for monitoring CHP plant operations

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REFERENCE LIST

A. Monitoring of unit efficiency:No. Description Implementation Date

1 A heat generating unit with capacity 125MEe and 180 MWt, a dual fuelboiler (coal, coal sludge). Monitoring of the boiler, turbine and heatgenerating system efficiency was applied.

CHP KATOWICEul. Siemianowicka 60 40-301Katowice

2000-06-30

2 A 50 MWe and 104 MWt heat generating unit. A pulverised coal boiler.Monitoring of the boiler, turbine and heat generating system efficiency wasapplied.

CHP Białystok II, Unit no. 2ul. W. Andersa 3,15-124 Białystok

2002-03-30

3 Unit no. 4 comprising a condensing turbine-generator set and auxiliaries.Monitoring of the turbine and generator efficiency was applied. Monitoringof fan coolers and turbine condenser operating conditions was applied.

CHP Białystok II, Unit no. 4ul. W. Andersa 3, 15-124 Białystok

2004-01-16

4 A Babcock Borsig Power CFB boiler fired with coal, bark, sawdust and otherkinds of biomass. A boiler efficiency module with an extended laboratorymodule estimating the elemental composition of the fuel compositeburned was applied.

CFB Saturn IPP Frantschach –Świecie,ul. Bydgoska, 186-100 Świecie

2004-03-16

5 An OP140 type boiler with the capacity of 140t/h operating in variableconditions intended for supplying steam to paper-making machines.

Boiler no. 5 (OP140), Saturn Power Plantul. Bydgoska 1, 86-100 Świecie

2004-03-30

6 A heat generating unit with a Foster Wheeler boiler for hard coal. CHP ELCHO ChorzówUnit no. 1

2005-09-30

7 A heat generating unit with a Foster Wheeler boiler for hard coal. CHP ELCHO ChorzówUnit no. 2

2006-05-30

8 A turbine-generator set fed by extraction steam in the Saturn CHP Plant. Saturn Power Plantul. Bydgoska 1, 86-100 Świecie

2006-06-30

9 A heat generating unit consisting of an OP230 boiler and a 32MWturbine intednded for steam generation for the production process in theChemical Plant.

ZCH Police, CHP IIUnit no. 1

2007-08-20

10 A heat generating unit consisting of an OP230 boiler and a 32MW turbineintended for steam generation for the production process in the ChemicalPlant.

ZCH Police, CHP IIUnit no. 2 2007-06-30

11 A Babcock Borsig Power CFB boiler fired with coal, bark, sawdust and otherkinds of biomass, with an additional biogas option. A boiler efficiencymodule upgrade, with an extended laboratory module estimating theelemental composition of the fuel composite burned with the additionalfuel (biogas), was applied.

CFB Saturn IPP Frantschach –Świecieul. Bydgoska 1, 86-100 Świecie

2009-10-16

12 An OP140 type boiler with a capacity of 140t/h operating in variableconditions, and intended for supplying steam to paper-making machines.The efficiency module was provided with an option including biogascombustion.

Boiler no. 5 (OP140), Saturn Power Plantul. Bydgoska 1, 86-100 Świecie

2009-10-30

13 A 55 MWe heat generating duo-unit. Boiler no. 5 for biomass. Boiler no. 6for pulverised coal. Monitoring of the boiler, turbine and heat generatingsystem efficiency was applied.

CHP Białystok II, Unit no. 1ul. W. Andersa 3, 15-124 Białystok

2008-07-30

14 A 50 MWe heat generating unit. Boiler no. 8 for pulverised coal. Monitoringof the boiler, turbine and heat generating system efficiency was applied.

CHP Białystok II, Unit no. 3ul. W. Andersa 3,15-124 Białystok

2008-04-30

15 A 55 MWe heat generating duo-unit. Boiler no. 5 for biomass. Boiler no. 6for pulverised coal in the process system with two turbines. Hybrid powergeneration - green power. Monitoring of the boiler, turbine and heatgenerating system efficiency was upgraded.

CHP Białystok II, Unit no 1ul. W. Andersa 3, 15-124 Białystok

2009-05-30

16 A program heat meter from boiler no 6. CHP Białystok II, Unit no. 1ul. W. Andersa 3, 15-124 Białystok

2010-11-30

17 A program heat meter from boiler no 7. and 8. CHP Białystok II, Unit no. 2ul. W. Andersa 3, 15-124 Białystok

2010-11-30

18 Developing and implementing - in practice - of an IT infrastructure formonitoring of production and technological and economic indicators forten power plants of the NUON company (The Netherlands).

NUON Holadnia, Keulsekade 1813534 Utrecht NL

2010-11-30

19 Application of an IT system for monitoring of operations of the Lage Waidepower plant (collaboration with NUON as part of the INSYP project).

NUON Holadnia, Keulsekade 1813534 Utrecht NL

2007-05-30

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B. Program for supporting production settlements:

C. Identification of characteristics of generating facilities:

D. Combustion optimisation:

E. Start-up monitoring:

No. Description Implementation Date20 A CHP plant with three heat generating units, a condensing facility, a water boiler

and two peak heat exchangers. The program supports settlement of the power andheat produced in compliance with the Energy Regulatory Office requirements.

CHP Białystok II,ul. W. Andersa 3,15-124 Białystok

2010-05-30

No. Description Implementation Date21 A CHP plant with three heat generating units and a condensing facility. A program

for determining production characteristics of boilers and turbines, their efficiency,and other technical indicators (63 predefined characteristics) was applied.


2010-05-30

No. Description Implementation Date22 An OP140 boiler for coal with beater wheel mills feeding 12 PC burners arranged

tangentially. A program for determining set values of air controllers, secondary airdumpers, mill classifiers, and coal feeders, was applied.

Boiler no. 5 (OP140),Saturn Power Plantul. Bydgoska 1, 86-100 Świecie

2005-07-12

No. Description Implementation Date24 A CFB Foster Wheeler boiler for coal and coal slurry. Components that limit the start-

up speed: drum (bottom and top generating line), superheater headers. „Intrex”type heat exchanger pipes placed in the fluidised bed. The program monitorsmechanical and thermal stresses, sets limit values of thermal stress margins, anddetermines the limits of start-up speed.

CHP KATOWICE, ul.Siemianowicka 60, 40-301Katowice

2000-06-30

25 Monitoring of start-up of an OP230 type boiler and a 13UP55 turbine. Monitoredcomponents: drum, quick-closing valve, turbine internal body, external body, flange.

Functions: To determine limitations of the start-up change speed and load changescaused by thermal stresses in the monitored components of the boiler and turbinein the online mode. In addition, context-sensitive tracking of start-up procedureexecution was applied.

CHP Białystok II, Unit no. 2,ul. W. Andersa 3,15-124 Białystok

2002-03-30

26 V63 type turbine start-up monitoring. Monitored components: quick-closing valve,turbine body, and flange.

CHP Białystok II, Unit no. 4 ,ul. W. Andersa 3,15-124 Białystok

2004-01-16

27 Monitoring of start-up of a OP230 type boiler and a 13UP55 turbine. Monitoredcomponents: drum, quick-closing valve, turbine internal body, external body, flange.


Boiler no. 5 (OP230), SaturnPower Plant, ul. Bydgoska 1,86-100 Świecie

2004-03-30




2009-07-30




2009-09-30

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No. Description Implementation Date

34 A CHP plant with three heat generating units, a condensing unit, a water boiler, andtwo peak heat exchangers. A program for supporting operation management in the „offline” mode -COGENOPT was applied. The program determines the economic distribution ofload to units and other facilities according to the criterion of profit achieved fromproduction. Based on this program, the personnel can determine loads of individualfacilities which ensure the most profitable operation.


2010-11-30

35 A CHP plant with three heat generating units, a condensing unit, and a heataccumulator. A program for supporting operation management in the „online” mode -COGENOPT_A was applied. The program determines the economic distribution ofload to units and other facilities according to the criterion of profit achieved fromproduction. The program determines the method for utilising the accumulatoracc. to the profit criterion. The accumulator is charged when the power price isat its highest level. The program determines the hours when the heat should be

accumulated, and the time when it may be discharged. Based on this programthe personnel can determine the loads of individual facilities and the accumulator which ensures the most profitable operation of the CHP plant.


2012-01-10

F. Stress and material degradation monitoring:

G. Optimization of CHP plant operation:

No. Description Implementation Date30 A supercritical unit with a capacity of 500MW fired with hard coal. The "Thermal Stress

Monitoring System" (TSMS) program was applied for stress monitoring during a start-up and a shut-down in critical thick-walled boiler components and in superheaterpipes with a high heat load. In each monitored component, a degradation levelresulting from the high temperature creep and low-cycle fatigue of material isdetermined.

BORYONG Power Plant (Korea)Unit No 6

2006-03-28

31 A supercritical unit with a capacity of 500MW fired with hard coal. The "Thermal StressMonitoring System" (TSMS) program was applied for stress monitoring during a start-up and a shut-down in critical thick-walled boiler components and in superheaterpipes with a high heat load. In each monitored component, a degradation levelresulting from the high temperature creep and low-cycle fatigue of material isdetermined.


2006-05-31

32 A supercritical unit with a capacity of 500MW fired with hard coal. The "Thermal StressMonitoring System" (TSMS) program was applied for stress monitoring during a start-up and a shut-down in critical thick-walled boiler components and in superheaterpipes with a high heat load. In each monitored component, a degradation level

resulting from the high temperature creep and low-cycle fatigue of material isdetermined.


2006-05-31

33 A supercritical unit with a capacity of 500MW fired with hard coal. The "Thermal StressMonitoring System" (TSMS) program was applied for stress monitoring during a start-up and a shut-down in critical thick-walled boiler components and in superheaterpipes with a high heat load. In each monitored component, a degradation levelresulting from the high temperature creep and low-cycle fatigue of material isdetermined.


2007-06-31

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