IT Solutions for Power Industry

1. IT Solutions for Power Industry

9. About us • STEAG encotec (India) Pvt. Ltd.(SeI) is wholly owned subsidiary of STEAG encotec GmbH, Germany. • SeI offers services in the field of: • Engineering Consulting Services • Power Generation • Operation and Maintenance • Renovation & Modernization • Information Technology for Power Plants • New Technologies for Power Plants • SeI has offered services in recent time to: IOCL, MSEB, GSEG, BHEL, HPGCL, NLC, etc.

10. SR– Systematic Energy Management _________________________________________________ Energy Management Systems

11. SR1 Lifetime Monitoring SRv Data Validation SR2 Energy Management SRp Statistic Forecast SRx Energy Data Management SR3 Energy Controlling SRk Power Cycle Evaluation SR4 Power Plant Optimization SR4 Compact Power Plant Optimization SR5 Power Trade System SR – Intelligent IT-Solutions for Energy Suppliers

12. SR1 – Lifetime Monitoring in Power Plants • Current Demands • Components of power plants exposed to high temperatures and pressures suffer serious material degradation during their lifetime. • This degradation indicates a need for component exchange or at least its repair. • The accumulated material degradation is not proportional to operating time, for which reason a regular monitoring of the plant operation is recommended. • Such a monitoring must be carried out by continuously operating a data logger together with a data evaluation system. • SR1 is the solution ... • for continuously recording operating temperatures and pressures around all the critical components of a power plant • for calculating the creep and the fatigue • for keeping the operator well-informed about the current status of his plant • for reducing the cost for routine maintenance inspections as well as additional tests

13. SR1 – Saving the measured values

14. Actual stress: Fatigue in the time x: SR1 – Calculating the creep damage

15. SR1 – Saving the stress cycles

16. SR2 – Energy Management System You have a varying demand of electricity, steam, hot and chilled water, compressed air, etc. ? You have alternative means of generating and supplying these energies ? You have various buying and selling contracts for your moving energies ? SR2 helps to cut your energy bill significantly! And pays back shortly!

17. SR2 – Engineering Logic Energy Contracts Energy Plants Energy Demands System Parameters Energy Plant SR2 Online Data Forecasts Closed Loop Control Online Application Offline Application Year 1/2 hour Day What / If?

18. Live Steam 60 bar/500 °C Flue Gas Desulfurization and DeNOx Plant Boiler 1 85 t/h Oil/Gas Boiler 7 85 t/h Oil Boiler 8 85 t/h Oil/Gas Boiler 2 75 t/h Coal/Gas Boiler 3 75 t/h Coal/Gas 175 °C M M M M 138 °C ST 1 ST 3 ST 4 ST 5 Deaerator G G G G Air Compr. 1 12,5 MW 15 MW 12,5 MW 12,5 MW Air Compr. 3 Process Heat Steam 250 °C District Heat Steam 170°C SR2 – Optimization in Industrial Cogen Plant

19. 13 11 Actual Cost Optimized Cost / h without SR2 9 Difference TDM 7,500 US$/day 7 5 13 Daily Energy Cost Profile after 12 Months from SR2 Installation Actual Cost 11 with SR2 9 TDM / h 7 Difference Optimized Cost 3,500 US$/day further potential 5 for optimization Verified Savings: 4,000 US$/day, equivalent to 4 % of variable cost 3 0 3 6 9 12 15 18 21 24 Hour SR2 – Verified Savings in Industrial Cogen Plant General Motors Germany: Daily Energy Cost Profile at Beginning of SR2 Installation

20. SR2 – Optimization in Municipal Heat/Power Plant

21. 5,000 US$/day Actual Variable Cost 2,500 US$/day Difference Actual to Optimized Cost April ‘98 March ‘99 SR2 – Verified Savings from Optimization in Municipality Savings after one year: equivalent to 8 % of variable cost

22. SR2 – How the Online System works every h 1st step every h Load Distribution (24h Forecast) Demand Forecasts 24 h operation plan every 15 min 2nd step every 15 min Online Plant Data Load Comparison (Is/Should be) Fine Tuning every 15 min Cost Comparison (Is/Should be) Balancing all the variable costs

23. Optimizing the annual budget (incl. maintenance dates) "What happens if?" simulations (incl. unexpected outage) Cost efficient "In House" studies (incl. plant additions) Identification of future bottlenecks Optimizing energy contracts SR2 – What the Offline System offers

24. Hot Water Generator Generator Spray Atemperator Sat. Steam Generator Pump Boiler with Superheater Compressor Valve Boiler with Reheater Water Turbine Water Storage WHSG E-Pump Steam Storage GT Steam Driven Pump Fuel Storage GT Generator Heat Exchanger Heater Deaerator Motor (Heat and Power) Cross Flow HE Condensate Tank Motor Generator Condenser Energy Source Steam Turbine (3 stages) Cross Flow Condenser Energy Sink Steam Turbogenerator (3 stages) Energy Line Motor Throtthing Valve (with Spray) Black Box (general) SR2 – Predesigned Components Injection Condenser

25. Client Server Applications SR2-Edit Plant Configuration Module Problem transformer (MPS generator) SR2-Conf Data Configuration Module MIP-Solver (Optimizer) Data Server SR2-Vis Presentation Module SRp (Forecast Module) Online Data Interface Module Optional for further SR applications Archive external Archive internal External Programs (via API) SR2 – System Architecture

26. SR2 Application Server incl. Data Server (Windows NT) Exteral Data / File Server (e.g. Netware) Measurements Results LAN Parameters Plant Bus, Terminal Bus, Interface, etc. SRx Client Online Data (variable) SR2 Client Offline Office (Windows 95/NT) SR2 Client Online Control Room (Windows 95/NT) SR2 – Integration in Client‘s Information System

27. SR4 – Optimization of Power Plant Operation • Current Demands • More strict environmental regulations ask for better plant control and make it even more important and more difficult to find the best point for economic operation of the plant • Competition, especially from a deregulated market and from a growing number of Independent Power Producers, also requires knowledge of „best price“ for power output • The more and more urgently needed economic production of electricity and heat asks for maximized efficiency • Maximum efficiency needs intelligent software tools implemented in the PMS • Using online measurements and system parameters these systems should • - reduce the costs of energy production ! • - simulate current plant behavior for various boundary conditions ! • SR4 is the solution ... • for highlighting the entire process • for maximizing economic and environmental efficiency • for comparing today‘s operation with its „possible best“ • for simulating the power plant behavior of „tomorrow“

28. Online Balancing Current behavior of all components and the entire plant  efficiency, performance, power output, fouling Online Comparison Reference-to-Current / Best-to-Current Reference : all components at guarantee point based on current operation and ambient conditions Best : optimized operation based on current component and ambient conditions Close follow-up of all relevant component characteristics, calculation of cost reduction potential Online/Offline Simulation & Forecast Results for various power plant parameter variations and the related fuel consumption figures SR4 – Results

29. AmbientParameters(not controllable)ambient temp,pressure, humidity Cooling water temp, (load level, heating value,combustible), etc.Forecast ComponentEfficiencies(controllable during downtime)efficiency, spec. heat rate, gain factor,effectivity, approach temp, etc. Comparison OperationalParameters(controllable during operation)Load factor GT/ST, Soot Blowing, Steam Parameters, Cold end, Feed water split, etc. Optimization Simulations SR4 – The Triangle of Simulations

30. SR4 –Optimization Potential Balancing • Higher quality of relevant measured and calculated values • Compact summary of process information allows more detailed evaluation Reference-to-Current evaluation • Continuous evaluation of components and the entire unit • Identification of faults and slowly increasing deviations • Savings of up to some 100 $/h per unit Optimization • Optimization of components, the unit or even the entire site • Savings of up to 1 Mio $ per year Forecast • Configurable parameter variation for different load conditions • Forecast of plant efficiency deviations up to 2-3% supports the plant operation strategy

31. SR4 –The System Benefits • Continuous monitoring of plant efficiency • Balancing, optimization and simulation tool • Cost analysis of component deficiencies • Complete thermodynamic boiler model • Suitable to answer market needs by parameter variations the power plant behavior of „tomorrow“ • Graphical configuration leads to a transparent online and offline application with proven data management • Extendable from SR4 Compact to a detailed, large SR4 system

32. SR4 – The Basic System

33. SR4 – Examples for Optional Results Main Steam Boiler + Air Heater + Flue Gas Cleaning Net/gross boiler efficiency (current/reference), effective thermal power, heat balance, indirect coal flow calculation, pulverizer performance, gas temperatures and interstage velocities along the boiler, Superheater and reheater sprays, (T/p) of live steam and hot reheat, reheater steamside pressure drop, fouling of furnace chamber and boiler convection zones controlled by soot blowers, fouling and leakage of rotary air preheaters, flue gas composition, pressure drop flue gas, efficiency flue gas blower, emission monitoring evaluation ( NOx, SO2, CO ), delta of flue gas oxygen content over air heater (current/reference), delta of flue gas pressure air heater (current/reference), boiler simulation taking into account: fuel characteristics, combustion conditions, water-steam cycle parameters, flue gas conditions, … Gas Turbine Net/gross efficiency GT (current/reference), back pressure at turbine outlet, efficiency air compressor (current/reference), flue gas mass flow / temperature / oxygen content / composition, gas turbine simulation taking all relevant influencing parameters into account

34. SR4 – Examples for Optional Results Heat Recovery Boiler Net/gross boiler efficiency (current/reference), pressure drop flue gas, effective thermal power, boiler simulation Water-Steam-Cycle Net/gross specific heat consumption (current/reference), delta costs (current/reference), feed heater performance/optimization, water-steam-cycle simulation taking all relevant influencing parameters into account Condenser Pressure / temperature / degree of recovery / media temperature difference, cold end performance/optimization, condenser simulation District heating system District heat output, el. power output equivalent Entire unit Net/gross unit efficiency, gross unit efficiency + current el. power output equivalent, entire unit parameter variation by activating the simulations of all relevant sub-units, several optimization scenarios

35. Plant Management System (PMS) System Parameters Heating values, fixed costs, soot blowing parameters, ... Graphical interface ( Configuration mode, offline presentation ) Data Base Measurements, Formulas Plausibility / Reconciliation Online Mode Gas Turbine / Boiler / Steam Turbine / Condenser / Plant Balancing :Current plant behavior, efficiency, fouling, ... Ref.-to-Current Comparison : Boiler, heat cycle, ... Optimization :Plant optimum regarding efficiency, costs,.. Offline Mode Gas Turbine / Boiler / Steam Turbine / Condenser / Plant Simulation : Various scenarios, forecasts, ... Object Configuration Characteristic values, TAG numbers, characteristic curves, ... Visualization Online Mode process figures, color switch, diagrams, ... SR4 – The Program Structure

36. SR4 – The system requirements For the connection of SR4 to the data acquisition system a suitable interface will be used. Approximately 200-500 measurements per unit will be selected for transfer at 1 min intervals. All the results are stored in an integrated data base, they can be visualized in actual (on-line) mode and historically for any period of registered time. The SR4 Compact software should run exclusively on a PC application server so that sufficient capacity is available to generate results of diagnosis and optimization every 5 minutes. The PC can be linked to the client´s PC LAN (TCP/IP) so that any authorized client (Windows NT) has access to the online visualization of current and past operation. For this purpose the SR4 client software, available on the SR4 server is downloaded automatically when an authorized client of the LAN requires any information. The graphic and numeric presentation of SR4 Compact results includes presentation with automatic visual changes to indicate individual component deficiencies and trend curves as well as x/y-presentations of any combination of variables (original data and results). Testing and tuning of the system during on-line operation is to the major part done by remote control of system operation. For this purpose an ISDN or telephone socket shall be supplied by the client and the server PC will be connected to the supplier’s offices. The general hardware requirements for SR4 Compact for the two units are specified as follows: Trademark PC Pentium IV, 800 MHz, 128 MB RAM; Raid 5 Array, 3x18,2 GByte HD; CD ROM drive for Windows NT; MOD 5,2 Gbyte, with 2 storage media; ISDN router ZyXel Prestige 100 including connection (for system tuning, trial run and for service); Operating system Windows NT 4.0 Terminal Server (alt. Windows 2000 server); Color monitor 19''; Color printer; Interfaces to client’s and the DCS for measuring data;

37. SR4 – The data requirements Approximately 200-500 measurements of operational data we need from your plant for balancing and optimization Relevant units: Gas Turbine;Boiler;Steam Turbine;Condenser;…; Entire Plant All technical specifications on boiler geometry, boiler efficiency definition, cycle calculations (design), soot blower characteristics, fuels, air preheaters, gas turbines, steam turbines, etc. have to be supplied by the customer and will be used exclusively to determine the parameters for the system configuration. Some documents in detail : - Supply of the documents and information required for process modeling, according to our requirements; - Lists of available measuring points including TAG numbers; - P&I diagrams and flow schematics; - Functional descriptions; - Design data and acceptance test data; - Fuel analysis; - Burner arrangement, firing sequence; - Boiler drawing, including summary of boiler heating surface data (surface area, pitch, etc.); - Number and arrangement of soot blowers, along with their steam or compressed air consumption characteristics; - Heat flow diagrams of the water/steam cycle and reheater mass flow data as a function of load. - Information about operational cost factors as a basis for the determination of current operating costs; - Information about plant-specific boundary conditions ( e.g. maximum allowable interval between two soot blowing cycles ) - Check and approval of results. Services to be Provided by the Purchaser The Purchaser shall assign a project manager who shall be responsible for: - Supply of the documents and information required for process modeling, according to our requirements. - Information about operational cost factors as a basis for the determination of current operating costs; - Information about plant-specific boundary conditions, e.g. maximum allowable interval between two soot blowing cycles; - Check and approval of results

38. SR4 Application Server incl. Data Server (WinNT / Win2000) External Data / File Server (e.g. Netware) Measurements Results LAN Parameters SR4 Client Engineering Office Studies & Parameters (WinNT / Win2000) SRx Client Online Data (WinNT / Win2000) SR4 Client Online Control Room Plant Load Schedules (WinNT / Win2000) SR4 – Integration in Client‘s Information System

39. SR4 – Realized Data Communi-cation for Interfaces Siemens : Teleperm XP, Teleperm XP-XU, WinTM (Teleperm ME) ABB : XTC (ProControl Interface to PBS30), PIMS, GLINK Hartmann&Braun (now ABB) : CONVISA, CONLINK IDS : HIGH LEIT OS9, HIGH LEIT NT B&R : DCS2000 OSI Software (Oil Systems) :PI System (via PI-API) Aspen Tech : Info Plus X SEG : VLS2000 Others : OPC-Data-Interface, DDE-Server, Profibus, M-BUS, ODBC, SQL, OLE, FTP, MS-Excel, Yokogawa

40. S O F B I D Essen Frankfurt Frankfurt Zwingenberg Software for the Power Industry Plant optimization offline with Performance Monitoring online with EbsilonProfessional EPOS Our clients: more than 100 utilities and manufacturers ABB, ALSTOM, BABCOCK, BEWAG, Blohm + Voss, BMW, CEE, Colenco, DSD, ECH, Envi Con, E.ON, Electrowatt Hamburg und Zürich, enertech, ENERGOPROJEKT, EVH, EVT, GKWeser, GEW Rheinenergie, gtz China, gtz India, HEW, IBT, LAUBAG, Lurgi, Mannesmann Seiffert, Mitsubishi HI, Ramboll, MVV, NEM, Schering, PCE ENERTEC, PEF, RAB, Rheinbraun, RWE, Saarberg, Siemens, SIK, Stadtwerke Chemnitz, Stadtwerke Hannover, Standardkessel Lentjes-Fasel, STEAG, TEAG, Technip, TÜV Nord, VA TECH, VEAG, Weig GmbH, ZBP INWAT

41. EbsilonProfessional EPOS References and experiences of over 40 online installations from 0,04 MW to 1460 MW for industrial plants and utilities since 1996 Coal,oil,gas fired Nuclear pp Mixed plants CCP plants Repowering • total flexible from offline to online operation • actual by high calculation velocity • Optimal use of all potentials by realistic detailling • Exact What-If-calculations by identical models for simulation and validation • High availability by reliable convergence behaviour

42. Offline process simulation EbsilonProfessional Modellierung Mills • Graphical modelling with tool box • Standard libraries for • fuels (coal, oil, gas) • oxygen carrier • gas turbines • water-steam • user defined and extensible • Error analyzer • English, French, German, Spanish, • multilingual Fluegas path

43. EbsilonProfessional Interactive offline process calculation Input air temperature Start of the calculation Demo example CCP Total power 10.382 MW Efficiency 38.09% Input of process parameters

45. Offline process simulation with actual, historical or manipulated data EbsilonProfessional EPOS Choice coal mixture Determination overheads of a power plant water-steam-circuit air path mills fluegas path fluegas desulphurization unit

46. In Ebsilon integrated optimizer EbsOptimize • Optimization objectives • design • operation modes Input of optimization measures Input of variation measures Input constraints In the model available measures

48. Simhadri Output Screens

49. SR4 – Unit Overview

50. SR4 – Boiler Sections