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Software for Modeling & Problem Analysis. AEP Participants: Chao Lin Charles Olsen Bill Reinhart Tom McCartney. Discussion Topics: Computational Fluid Dynamics (CFD) analysis Finite element analysis Heat balance analysis Reliability analysis. CFD Analysis
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Software for Modeling & Problem Analysis
AEP Participants: • Chao Lin • Charles Olsen • Bill Reinhart • Tom McCartney
Discussion Topics: • Computational Fluid Dynamics (CFD) analysis • Finite element analysis • Heat balance analysis • Reliability analysis
CFD Analysis • CFD analyses are done both in-house and contracted to outside vendors • AEP uses FluentTM software • CFD useful for designing modifications and enhancements to improve unit performance
CFD Analysis Example – Dam Spillway • Ran 2-Dimensional model to estimate trajectory of water to assure no erosion impact on surrounding soil • Ran as transient, allowing water level to rise until the height of water over the spillway approximated a worst-case postulated scenario
CFD Analysis Example – Ash Collection • Muskingum River Unit 5 has problems with large ash particles plugging SCR catalyst plates. • This has resulted in forced outages to clean the catalyst plates, which impacts NOx emissions and energy revenues • Ran CFD analysis to assess effectiveness of adding hoppers in the ductwork
Finite Element Analysis • FE analyses are done both in-house and contracted to outside vendors • AEP uses ANSYSTM software • FE useful for designing modifications and assuring we are operating equipment within design limits
FE Thermal Analysis Example – Cook Nuclear Plant Thermal Barrier
FE Thermal Analysis Example – Cook Nuclear Plant Thermal Barrier
FE Stress Analysis Example – Mitchell Unit 2 Flow Accelerated Corrosion in Feedwater Pipe
FE Modal Analysis Example – Cardinal Unit 3 Economizer Tube Vibration
FE Modal Analysis Example – Cardinal Unit 3 Economizer Tube Vibration
Heat Balance Analysis • Many heat balance analyses done in-house • AEP uses ThermoflowTM and PEPSETM software • Heat balance analyses include existing and new units • Evaluate equipment upgrades • Evaluate savings from modified operation • Optimize design of heat cycle
Heat Balance Analysis – Control Valve Upgrade • The control/stop valves on the AEP 1300 MW series units have a higher than design pressure drop. • Used PEPSETM to estimate heat rate improvement, generation gain for replacement valves with lower pressure drop. • Installation of replacement valves improved heat rate by 17 kJ/KWH
Heat Balance Analysis – Control Valve Upgrade • Installation of replacement valves improved heat rate by 17 kJ/KWH • Efficiency improvement enhanced generating capability by 3.8 MW • Decreased pressure drop improved generating capability by 28.1 MW, for a total of 31.9 MW
Heat Balance Analysis – Other Examples • Evaluate turbine rotor design upgrades • Evaluate steam generator performance with different fuel blends • Evaluate improvements in startup steam utilization • Run heat balance model to evaluate reasons for off-design unit performance
Reliability Analysis • RaptorTM operations analysis software • Simulate reliability of power plant systems • Model reliability and cost effects of preventative maintenance, installed spares, equipment failures, etc. • Model failed components that cause other components to fail