Post on 21-Aug-2018
ACTSYS Process Management Consultants Pte LtdACTSYS Process Management Consultants Pte Ltd
9th Annual Gas Turbine
Conference
Performance Monitoring for Fuel Efficiency
16th April 2015
1
ACTSYS Process Management Consultants Pte Ltd
Agenda
• ACTSYS Overview
• Thermodynamic Performance Monitoring of Power Plants
• Case Studies
• Limitations of Online Monitoring Systems
ACTSYS Process Management Consultants Pte Ltd
Actsys Overview
Singapore Based Company
Incorporated 2001
Operating regionally (Malaysia, Indonesia, Thailand, India)
Core expertise
Thermodynamic Performance Analysis
Process Simulation / Pinch Analysis
Utilities System Optimization
Basic Engineering Design
Operations and Maintenance experience
Domain knowledge Power Plants, Refineries, Petrochemicals
Accredited as Energy Service Company by Singapore National
Environmental Agency
About Us Services
ACTSYS Process Management Consultants Pte Ltd
Actsys Overview
Power Plant Thermodynamic Performance Analysis
Energy Auditing for Improvement Opportunities
Measurement & Verification
Energy Management System
Online Dashboards
ISO50001 Gap Analysis
Process Studies and Front End Design
Training Plant Operating Principles Energy Auditing / Performance Monitoring
About Us Services
ACTSYS Process Management Consultants Pte Ltd
Plant ID Location Remark CCP Steam Plant Cogen
Tuas Power Singapore MHI 701F
Alstom GT26
367 x 4
370 x 1
PT PJB, Muara Karang Indonesia 500 x 1 200 x 2
PT PJB Gresik Indonesia 480 x 1 200 x 2
PT PJB Paiton Indonesia Coal 400 x 2
Power Seraya Singapore Siemens V94 370 x 2 250 x 6
Senoko Singapore Alstom GT26 370 x 3; 450 x 2
Gulf Electric, Samutprakarn Thailand GE Frame 6 130 x 1
Gulf Electric, Nongkhee Thailand GE Frame 6 130 x 1
Malakoff Malaysia GE Frame 9E 370 x 1
SembCorp Singapore GE Frame 9E 800 x 1
Petronas Malaysia GE Frame 5 36 x 5
Jimah Malaysia Coal 700 x 2
Indonesia Power, Labuan Indonesia Coal 300 x 2
Total MW 5938 5100 2340
Power Plant Customers
ACTSYS Process Management Consultants Pte Ltd
Thermodynamic Performance Monitoring
• Early work with Power Plants to calculate GT compressor efficiency, to evaluate OEM wash frequency recommendation
• Thermodynamic modeling approach novel to most Power Plant engineers and initial acceptance was cautious
• Collaborative development of heat balance, new & clean, incremental improvement calculation methodologies to address customer needs– Better understanding of plant efficiency losses by components
– Identification of maintenance requirements
– Post turnaround evaluation of maintenance effectiveness
• Continuous development of analysis methodology with increasing customer base
ACTSYS Process Management Consultants Pte Ltd
Performance Monitoring Objective
• Proactively identifying the plant sections that
have degraded performance
• Quantifying the degradations in terms of effect
on overall plant efficiency
• Enabling a condition based predictive
maintenance program to set and prioritize
maintenance activities that will minimize
degradation and hence maximize efficiency
ACTSYS Process Management Consultants Pte Ltd
Performance Monitoring Objective
Actual and Potential Efficiency Improvement
49.600%
49.800%
50.000%
50.200%
50.400%
50.600%
50.800%
GT Compressor Fouling 0.051% 0.150% 0.320% 0.423% 0.030%
BFP Inefficiency 0.012% 0.020% 0.025% 0.026% 0.026%
LP Bypass 0.300% 0.320% 0.288% 0.310% 0.310%
HP Bypass 0.150% 0.150% 0.150% 0.150% 0.150%
Condenser Fouling 0.085% 0.092% 0.224% 0.225% 0.225%
IAF Pressure Drop 0.005% 0.022% 0.033% 0.054% 0.054%
Actual Efficiency 50.300% 50.100% 49.800% 49.700% 50.040%
Nov 06 Dec 06 Jan 07 Feb 07 Mar 07
GT Compr
Cold Wash
ACTSYS Process Management Consultants Pte Ltd
Thermodynamic Models
• Heat and Mass Balance calculations of all hot gas path,
steam and water flows in a Power Plant
• Equipment are all rigorously modeled based on first
principles of heat transfer and energy conversion
• Models can be tuned to replicate Design or
Commissioning Heat Balances, in order to calculate New
& Clean performance
ACTSYS Process Management Consultants Pte Ltd
First Principles of Heat Transfer
ACTSYS Process Management Consultants Pte Ltd
First Principles of Energy Conversion
• Adiabatic expansion in Steam Turbine
• Spencer Cotton Canon for expected Isentropic efficiency
• Modified Stodola equation for Pressure – Flowrate characteristics
ACTSYS Process Management Consultants Pte Ltd
CCP Plant Modeling
HPSH2
RHTR2
RHTR1 HPSH1 HPEVAP HPECO2 IPSHT R LPSHTR IPEVAP
IPECO2
HPECO1
LPEVAP HPECO0 IPECO1 LPECO FWPRHT
SP1 M1 M2SP2
HPST
IPST
M3
M4
RHDSH
HPSDSH
SP3
PI1
PI2
GT COMP
GT COMB
GT TURB
INLFLT
SSGEN
CONDSR
MAKEUP
M5
GLNDCN
DEAER
SP4
169298
GT Power kW
109848
ST Power kW
PUMP1
BFW HDR
HPBFW P
LPBFWP
IPBFWP
SP5
SP6
278.91
Gross Generator Output MW
LPST
M6
DUCT 1
PI3
HPBYPS
V1
V2
GT EXH
S1
S2
S3
S4
S5S6 S7 S8
S9 S10 S11 S12
S13
S14
S15
S16
S17 S18 S19 S20 S21
STACK
COND
DFW
LPBFW
S22
S23
S26
IPBFW
S27
S28
S29
HPSTOT
LPSHPS
IPS
S24
S25
RHTRS
HPBFW
S30S31
S32S33
S34
S35
S36
LPST OT
HPBFW 1
HPBFW 2
S37
S39S40
AIR COMPIN
CMPDSC T URBIN
FUELGS
S41
S42
S43
LPDEAR
S44S45S46
S47
S49
BFW SPP
S50
S51
S52
S53
S54
S55
S48
S56
S57 S58
CWS
CWR
S59
GLNST M
HPBPSS
S38
S60
ACTSYS Process Management Consultants Pte Ltd
Power Plant Modeling Capabilities
HRSG
HRSG Effectiveness
Duty of individual heat
transfer components
Steam Turbine
HP Turbine Power
IP Turbine Power
LP Turbine Power
HP/IP/LP Turbine Eff
Condenser
Condenser Water Flow
Condenser Duty
Condenser effectiveness
Auxiliaries
CWP Performance
BFP Performance
CEP Performance
Distribution Valve passing
Line Loss
GT GT Power Generation
GT Comp Eff.
GT Turbine Eff
GT Heat rate
IAF performance
CCPPowerStation
ACTSYS Process Management Consultants Pte Ltd
Performance Monitoring Methodology
Modeling Application
To make a Complete Heat and Mass
Balance
Establishing current performance level of
individual components and total system
Establishing the New & Clean benchmark for the
individual component and for total system
Calculate the incremental benefit from repairing
defective plant component
ACTSYS Process Management Consultants Pte Ltd
Heat & Mass Balance
• Complete quantification of all streams in a power
plant eg flue gas, cooling water, steam and fuel
flows
• Establish the present performance level of the
individual equipment eg efficiency, heat transfer
coefficients, leakages
• Enables data validation
– Measured values can be compared against the heat
balance output for validating the accuracy of
measurement.
ACTSYS Process Management Consultants Pte Ltd
CCP Plant Modeling – Heat Balance
Simulation Model Demo
ACTSYS Process Management Consultants Pte Ltd
Quantifying GT Compressor Fouling
GT Compressor Isentropic Effciency Daily avg >330MW
0.8
0.81
0.82
0.83
0.84
0.85
0.86
0.87
0.88
0.89
1/1
/05
3/2
/05
5/1
/05
6/3
0/0
5
8/2
9/0
5
10
/28
/05
12
/27
/05
2/2
5/0
6
4/2
6/0
6
6/2
5/0
6
8/2
4/0
6
10
/23
/06
12
/22
/06
2/2
0/0
7
48K EOH
GT Comp Wash
GT Comp Wash
40K CI GT
Comrpessor WashGT Comp Wash
ACTSYS Process Management Consultants Pte Ltd
GT IAF Selection Optimization
CCP1 EMW VS Freudenburg IAF
0.80
0.81
0.82
0.83
0.84
0.85
0.86
0.87
0.88
0 7
14
21
28
35
42
49
56
63
70
77
84
91
98
105
112
119
126
133
140
147
154
161
168
175
182
189
196
Days
GT
Co
mp
Isen
tro
pic
Eff
icie
ncy
EMW Filter Nov 05 ~ May 06
Freudenburg Filter from Dec 2006
Linear (Freudenburg Filter from Dec
2006)Linear (EMW Filter Nov 05 ~ May 06)
CCP1 EMW VS Freudenburg IAF
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
0 7
14
21
28
35
42
49
56
63
70
77
84
91
98
105
112
119
126
133
140
147
154
161
168
175
182
189
196
Days
IAF
Pre
ssu
re D
rop
mm
H2O
EMW Filter July ~ Dec 2005
Freudenburg Filter from Dec 2006
ACTSYS Process Management Consultants Pte Ltd
Loss of CCP Efficiency due to IGV adj
ACTSYS Process Management Consultants Pte Ltd
Loss of CCP Efficiency due to IGV adj
ACTSYS Process Management Consultants Pte Ltd
Loss of CCP Efficiency due to IGV adj
ACTSYS Process Management Consultants Pte Ltd
Loss of CCP Efficiency due to IGV adj
ACTSYS Process Management Consultants Pte Ltd
Loss of CCP Efficiency due to IGV adj
ACTSYS Process Management Consultants Pte Ltd
Unmeasured Flows – HP Bypass
HPSH2
RHTR2
RHTR1 HPSH1 HPEVAP HPECO2 IPSHT R LPSHTR IPEVAP
IPECO2
HPECO1
LPEVAP HPECO0 IPECO1 LPECO FWPRHT
SP1 M1 M2SP2
HPST
IPST
M3
M4
RHDSH
HPSDSH
SP3
PI1
PI2
GT COMP
GT COMB
GT TURB
INLFLT
SSGEN
CONDSR
MAKEUP
M5
GLNDCN
DEAER
SP4
169298
GT Power kW
109848
ST Power kW
PUMP1
BFW HDR
HPBFW P
LPBFWP
IPBFWP
SP5
SP6
278.91
Gross Generator Output MW
LPST
M6
DUCT 1
PI3
HPBYPS
V1
V2
GT EXH
S1
S2
S3
S4
S5S6 S7 S8
S9 S10 S11 S12
S13
S14
S15
S16
S17 S18 S19 S20 S21
STACK
COND
DFW
LPBFW
S22
S23
S26
IPBFW
S27
S28
S29
HPSTOT
LPSHPS
IPS
S24
S25
RHTRS
HPBFW
S30S31
S32S33
S34
S35
S36
LPST OT
HPBFW 1
HPBFW 2
S37
S39S40
AIR COMPIN
CMPDSC T URBIN
FUELGS
S41
S42
S43
LPDEAR
S44S45S46
S47
S49
BFW SPP
S50
S51
S52
S53
S54
S55
S48
S56
S57 S58
CWS
CWR
S59
GLNST M
HPBPSS
S38
S60
ACTSYS Process Management Consultants Pte Ltd
Unmeasured Flows – HP Bypass
HPST Bypass Flow
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.001
-Ja
n
15
-Ja
n
29
-Ja
n
12
-Fe
b
26
-Fe
b
12
-Ma
r
26
-Ma
r
9-A
pr
23
-Ap
r
7-M
ay
21
-Ma
y
4-J
un
18
-Ju
n
2-J
ul
16
-Ju
l
30
-Ju
l
13
-Au
g
27
-Au
g
10
-Se
p
24
-Se
p
T/H
ACTSYS Process Management Consultants Pte Ltd
Steam Turbine Sectional Performance
Individual Section Power (kW)
0.0
50000.0
100000.0
150000.0
200000.0
250000.0
300000.0
15-A
pr-
05
15-M
ay-0
5
15-J
un-0
5
15-J
ul-05
15-A
ug-0
5
15-S
ep-0
5
15-O
ct-
05
15-N
ov-0
5
15-D
ec-0
5
15-J
an-0
6
15-F
eb-0
6
LPST Power IPST Power HPST Power
Turbine Efficiency
40%
50%
60%
70%
80%
90%
100%
110%
15-A
pr-
05
15-M
ay-0
5
15-J
un-0
5
15-J
ul-05
15-A
ug-0
5
15-S
ep-0
5
15-O
ct-
05
15-N
ov-0
5
15-D
ec-0
5
15-J
an-0
6
15-F
eb-0
6
Overa
ll eff
icie
ncy (
%)
HP Turbine IP turbine LP Turbine
ACTSYS Process Management Consultants Pte Ltd
Boiler Feed Pump Efficiency
Chart 23 CCP 1 : Boiler Feed Pump Efficiency
0.55
0.60
0.65
0.70
0.75
0.80
0.85
1-A
pr
15
-Ap
r
29
-Ap
r
13
-Ma
y
27
-Ma
y
10
-Ju
n
24
-Ju
n
8-J
ul
22
-Ju
l
5-A
ug
19
-Au
g
2-S
ep
16
-Se
p
30
-Se
p
Pu
mp
Eff
icie
ncy
0
1
2
3
4
Pu
mp
ID
Pump Efficiency
Pump ID
Boiler Feed Pump Performance
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
1700
170 190 210 230 250 270 290 310
Flow (TPH)
Po
wer
Co
nsu
mp
tio
n (
kW
)
Pump 2
Pump 1
ACTSYS Process Management Consultants Pte Ltd
Condenser Cooling Water Flow (T/H)
Debris Filter
Repaired
Condenser Cooling Water Flow
ACTSYS Process Management Consultants Pte Ltd
Performance Monitoring Methodology
Modeling Application
To make a Complete Heat and Mass
Balance
Establishing current performance level of
individual components and total system
Establishing the New & Clean benchmark for the
individual component and for total system
Calculate the incremental benefit from repairing
defective plant component
ACTSYS Process Management Consultants Pte Ltd
New & Clean Performance Models
Each piece of equipment modeled separately to match guaranteed data, then read
by overall model
GT
HPSHT HPEVAP HPECONDUCT
DEAER
CONDEN
CONDST
CNDPMP
HPPUMP
CNDMIX
MAKEUP
S1 S2
S3
S4
S5 S6
S7EXH
S8
S9
S10
S11
S12
S13
S14
S15
GT
uses curves or
spreadsheet data
HRSG matches
HRSG vendor
COND matches
HEI/condenserST model
matches ST vendor
ACTSYS Process Management Consultants Pte Ltd
CCP Plant Modeling – New & Clean
Simulation Model Demo
ACTSYS Process Management Consultants Pte Ltd
New & Clean Performance
Thermodynamic
Simulation
Heat Balance
Model
Measured
Plant
Data
Actual Plant &
Equipment
Performance
Indicators
Heat Balance
Calculated Plant
Operating
Conditions
Thermodynamic
Simulation
New & Clean
Models tuned to
Design / Comm
Target Plant &
Equipment
Performance
Indicators
Plant &
Equipment
Performance
Gaps
ACTSYS Process Management Consultants Pte Ltd
HRSG Malperformance
Gresik CCP2 HRSG2.1 Steam Prod
0.00
0.20
0.40
0.60
0.80
1.00
1.20
11/24/2
004
12/1/2
004
12/8/2
004
12/15/2
004
12/22/2
004
12/29/2
004
1/5/
2005
1/12
/2005
Actu
al
/ N
&C
HP STM LP STM
ACTSYS Process Management Consultants Pte Ltd
HRSG Malperformance
ACTSYS Process Management Consultants Pte Ltd
Fouled HRSG Tubes @ level 8
ACTSYS Process Management Consultants Pte Ltd
Flue Gas Inlet Flue Gas to Stack
Fe
ed
wa
ter
Pre
he
ate
r
E-3
Condensate
Extraction PumpPreheated Water
To Deaerator
V-1
Bypass
Valve
Passing Valve
HRSG Deterioration
ACTSYS Process Management Consultants Pte Ltd
Stack temp Vs Feedwater Preheater Temperature
0.90
0.95
1.00
1.05
1.10
1-Jan-05
15-Jan-05
29-Jan-05
12-Feb-05
26-Feb-05
12-Mar-05
26-Mar-05
9-Apr-05
23-Apr-05
7-May-05
21-May-05
4-Jun-05
18-Jun-05
2-Jul-05
16-Jul-05
30-Jul-05
13-Aug-05
27-Aug-05
10-Sep-05
24-Sep-05
8-Oct-05
22-Oct-05
5-Nov-05
19-Nov-05
3-Dec-05
17-Dec-05
31-Dec-05
Stack T
Feedwater Preheater T
Valve Repaired
(Actual) / (New and Clean Performance)
HRSG Deterioration
ACTSYS Process Management Consultants Pte Ltd
Poor Steam Turbine Section
Steam 3 ST Power Output
0.00
0.20
0.40
0.60
0.80
1.00
1.20
11/2
4/200
4
12/1
/200
4
12/8
/200
4
12/1
5/200
4
12/2
2/200
4
12/2
9/200
4
1/5/
2005
1/12
/200
5
Actu
al /
N&
C
HPST IPST LPST ST
ACTSYS Process Management Consultants Pte Ltd
Poor Steam Turbine Section
ACTSYS Process Management Consultants Pte Ltd
Condenser Performance
Condenser Press ACT/NC
Condenser
Air Ingress
Solved
ACTSYS Process Management Consultants Pte Ltd
Performance Monitoring Methodology
Modeling Application
To make a Complete Heat and Mass
Balance
Establishing current performance level of
individual components and total system
Establishing the New & Clean benchmark for the
individual component and for total system
Calculate the incremental benefit from repairing
defective plant component
ACTSYS Process Management Consultants Pte Ltd
Incremental Benefit Analyses
• As Plant Management you are only interested in
how a defective plant component affects
– Overall Plant efficiency / heatrate
– Baseload capability
• Quantification enables prioritization and
scheduling of corrective maintenance in next
turnaround
ACTSYS Process Management Consultants Pte Ltd
Incremental Benefit Analysis
Actual and Potential Efficiency Improvement
49.600%
49.800%
50.000%
50.200%
50.400%
50.600%
50.800%
GT Compressor Fouling 0.051% 0.150% 0.320% 0.423% 0.030%
BFP Inefficiency 0.012% 0.020% 0.025% 0.026% 0.026%
LP Bypass 0.300% 0.320% 0.288% 0.310% 0.310%
HP Bypass 0.150% 0.150% 0.150% 0.150% 0.150%
Condenser Fouling 0.085% 0.092% 0.224% 0.225% 0.225%
IAF Pressure Drop 0.005% 0.022% 0.033% 0.054% 0.054%
Actual Efficiency 50.300% 50.100% 49.800% 49.700% 50.040%
Nov 06 Dec 06 Jan 07 Feb 07 Mar 07
GT Compr
Cold Wash
ACTSYS Process Management Consultants Pte Ltd
Examples of Issues Identified
• Lost of efficiency after MI due to IGV reprogramming
• Boiler Feed Pump minimum flow recycle valve passing
• Identification of Passing HPST Bypass Valve
• FW Preheater Bypass Valve passing
• Selection of Optimum Inlet Air Filter
• Condenser Cooling Water Optimization
• Condenser Cooling Water Debris Filter Choke
• HPST Bypass Spray Valve Passing
• HRSG HP and RH Spray Valve Passing
• Condenser Air Ingress
• Condenser Tube Fouling
ACTSYS Process Management Consultants Pte Ltd
Limitations of Online Systems
ACTSYS Process Management Consultants Pte Ltd
Limitation of Online Systems
• Black box
– Plant engineers over time will suffer an increasing
lack of knowledge of model calculations, which plant
measurements are inputs and assumptions
– Plant component performance degradation results are
still high level indicators, they do not lead to the actual
problem eg detailed equipment level
– As all result screens are preprogrammed, drill down
capability to determine root cause is limited
– Difficult to use results as decision support to
determine corrective maintenance activities
ACTSYS Process Management Consultants Pte Ltd
Limitation of Online Systems
• Not all losses are calculated, eg
– Online models normally do not include bypass valves
(eg HPST, FWPH) or recirc valves (eg BFW min flow);
they are all assumed to be tight closed and not
passing
– Drain valves are also assumed to be tight
– Steam flow to auxiliary steam header is not
accounted for
• Above listed losses are common especially as a
plant ages and if not detected and repaired can
lead to very significant efficiency and water
losses
ACTSYS Process Management Consultants Pte Ltd
Limitation of Online Systems
• Time trends of performance factors are very useful
– Detect Degradation trends
– Comparison of Performance
• Pre and Post inspection
• Change of plant components eg Inlet Air Filter
• Change of equipment control tuning eg IGV control curve
– Drifting of measurements
• X-Y plots of performance variables also offer insightful
views into root cause of performance degradation
• Online systems offer little possibility for such analysis
ACTSYS Process Management Consultants Pte Ltd
Conclusions
• Thermodynamic Performance Monitoring ensures plant degradations that cause efficiency loss are identified and corrected early
• Skill set that needs to be fostered in today’s competitive power industry
• Online systems have practical limitations and do not give the same in-depth analyses
ACTSYS Process Management Consultants Pte Ltd
Thank You
GT
SH
AF
T P
OW
ER
(3
4.2
3%
)INLET AIR (1.45%)
HP STEAM (34.39%)
HP
TU
RB
PO
WE
R (
2.1
8%
)
LP TURB POWER (10.87%)
CONDENSER LOSS 33.53%
SHAFT POWER
IP TURB POWER (6.68%)
AU
XIL
IAR
Y P
OW
ER
(0
.22%
)
ROTOR COOLING LOSS (2.09%)
COMBUSTOR LOSS (0.49%)
CO
MP
RE
SS
OR
WO
RK
(…
.% o
f G
T
Sh
aft
Po
we
r)
FUEL
SENSIB
LE H
EAT
1.00
%
DUCT L
OSS (0
.35%
)
RADIATION LOSS
(0.34%)
PIP
E L
OSS (0
.08%
)
LP STEAM (4.03%)STACK LOSS (8.97%)
IP STEAM (8.6%)
CHEMICAL
ENERGY
(97.32%)
RADIATION LOSS (0.06%)
RA
DIA
TIO
N L
OS
S
(0.0
9%
)
RA
DIA
TIO
N L
OS
S
(0.0
4%
)
www.actsys.com