Power Gen Europe 2010 Amsterdam, June, 8-10th

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E.ON Kraftwerke GmbHKraftwerk Franken

Power Gen Europe 2010 Amsterdam, June, 8-10th

E.ON Power Plant Franken Retrofit of Control System and

Process Optimization

Dipl.-Ing. Christian Stuermer (E.ON Engineering)

speaking for Dr. Wilhelm Kleffner (E.ON Kraftwerke GmbH, Franken plant manager)

Dipl.-Ing. Joerg Gadinger (Siemens Energy Sector, Instrumentation and Electrical)

© e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.

June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.


Agenda

Power plant Franken, Germany

Drivers of the project

Optimized process with a new control system

Increased Power Output of GT

Next steps of the project



Overview and Location

Highlights of the retrofitGas turbine-UpgradeFull Automation and Process optimizationNew Field EquipmentConsolidation of both control roomsOptimization of cooling water management

Unit 1: 383 MW net max., efficiency 39%, daily average 37,5%

Unit 2: 386 MW net max., combinedcycle with GT, GT: 53 MW

Unit 2 + GT: 440 MW, efficiency 44%,daily average 41%

Operator: E.ON Kraftwerke GmbH Owner: E.ON Kraftwerke GmbH Location: Nuernberg, GermanyFuel: Gas, light fuel oil Power capacity: 823 MWHeating capacity: 30 MWth, max. 100 MWthCommissioning: 1973/1976




Control system (old condition) - overview and evaluation

Until 2004 both units official stand-by reserveLasting increase of use of both blocks since 2003Minimal plant automationStaff on stand-by-use dimensionedOld instrumentation and control systems

Δp, p, T, etc.

Centralized control room / Schreiber

AS 231 / MS 2 - 3

Teleperm B

AS 220

Simatic P Mauell /MAN Sim P

AS 230

NOx

Control room

Messages

MeasurementsTo be replaced

urgently, discontinued

Control

Technology

Drives

QualityTo be used

further

analog

Steinhaus

binary Steamturbine Auxiliarysystems




Increase of operation leads to overload the team but also secure the fulfillment of the financial targets of the plants operation.Without a clear rise of resources (conversation costs and staff) the increasing operation could not be performed. Potential result: Early shut down of the plant was forecasted for 2012/2013

At the end of 2005 a concept of lifetime- protection and plant optimization was finished with the approach, that every single measure must be economicly efficient

Also a clear improvement in the discount cash flow is expected, even with a pessimistic approach of the expected life time.The complete investment plan was approved at the beginning of 2008.

0

200

400

600

800

1000

1200

1995 2000 2005 2010 2015 2020

Gene

ratio

n (G

Wh/

year

)

year

Generation at plant

Plant Unit 2+GT Unit 1

0

100

200

300

400

500

600

700

0

50

100

150

200

250

300

350

1995 2000 2005 2010 2015

Gen

erat

ion

(GW

h/ye

ar)

Num

ber o

f st

artu

ps / y

ear

year

Startups and generationunit 2 plus GT

Starts Unit 2 + GT Starts GT Generation

Replacement of I&C-system with process optimizationOptimization of cooling water managementIncreased power output of GT



Key investment program

7

6

8 Upgrade Gas Turbine

5

5 Optimization Fuel Air System6 Optimization Freshwater Inlet7 Optimization Cooling Tower Operation

1 SPPA-T3000 incl. new field

11

1

5

8

4

4 Optimization Frequency Control

4

DCS incl. field 26Gasturbine Upgrade 7,2Cooling Water 2Peripherals 10,8

46

4%

57%

16%

23%

DCS incl. field Gasturbine Upgrade Cooling Water Peripherals

2 Common Control Room Unit 1 & 2

2

3 Optimization Startup

3

3

GT Unit 2

Unit 1

Investment without maintenance



Siemens Power Plant Automation Siemens Power Plant Automation SPPA

„one-push-button-mode“

General concepts for all areas

Fully automatic start-up-mode

Automatic distinction of start-up-modes

Automatic load setpoint fromdispatcher

Low load with steam drivenfeedwater pump

Leads to ... optimized, reproducible, fast process

Subordinated automation

Unit Control and Unit Sequence

Open loop Contols Actuators SensorsClosed loop controls

Old structure: low degree of automation, manual operationNew structure:

Set point formationGroup Controls


SSPPPPAA--

Our solution: Process Optimization Solutions SPPA-P3000



The situation: A power plant unit needs to be operated at all times at the most profitable operating point, which above all calls for greater flexibility and higher efficiency, better availability and lower emissions.

High efficiency High flexibility

High availability

Low emissions






High availability

Low emissions


Low Loss Start

Temperature Optimizer

Fast StartFast Ramp

Frequency Control

Dispatch Control



Features:Use of dynamic models with predictionIdentification of disturbances/ variations using an observer structureUse on start-up and over the entire load range

Task:Stable control of all values in every situation of operation

-- HP temperature-- Material limit-- setpoint

ConventionalControl

ϑFD low => η low

SPPA-P3000 Control

-- HP temperature-- Material limit-- setpoint

Conventional Control SPPA- P3000 Control

SPPA-P3000 Optimized Controllers Increased accuracy for main sub loop controls

All Control Concepts and Automation Concepts are new designed. Main sub loop controls were optimized e.g. HP and RH temperature control, HP Bypass Control, Burner Management, gas flow control and enthalpy/feedwater flow control.



Before: partly manual mode for start-up and load changes, low accuracy

SPPA-P3000 Optimized Controllers Optimized Temperature Controls!

After Optimization:fully automatic with a state controller (LQG), ca. +5 / -10 K accuracy in normal load range. Temperature Max Setpoint at 535°C, Turbine Temperature leads Setpoint. Gradient Calculation from Boiler Stress and Turbine Stress.



Optimized Cooling Water Management

Old structure:no automation, only a few local controllers, Operator has to take care of it all the time, 5 Cooling towers, each unit with two pumps, several control valves/flaps

After Optimization:Fully automized start-ups and shut-downs of cooling towers, pumps, exact controlled values adhering to legal regulations. Less on-site-power! First examination yielded 0.3 MW = 4% (base ca. 9 MW at full load)



Optimized start-up Faster to the grid

FeaturesModel-based formation of setpoints for main steam pressure and temperature, and of firing rate Automatic startup of boiler and turbineAutomatic differentiation between cold, warm and hot starts with bumplesstransfer to coordinated power operation

Task:To get the unit back on the grid in the shortest possible time without thermal stresses for thick-walled components violating permissible limits. T TT

DrainHP-BypControl

Gas burners

T

Thermalstress

SteamQuality

Turbinevalves

Steam TControl

ShortStart-up-time

ST

Boiler

GTG

Aux-steamPreheating

BoilerPreheatingWith GT

Before 2000: ca. 20 start-upsForecast: Unit 2 ~ 170 Start-ups per year, Unit 1 ~ 80 Start-ups per year


-15 0 -12 0 -90 -60 -3 0 0 30

Te m p e ra tu re

F u e l (-2 5 % to P m a x )

P re s s u re

P o w e r

Tim e-2 5 %

tim e / m in

S ynchro-n ization

o u tp u t

Fuel Consumption and Poweroutput at Startup(cumulated during start-up time)

100%

74%

26%

0%

20%

40%

60%

80%

100%

0% 20% 40% 60% 80% 100%

Power output

Fuel

Con

sum

ptio

n (a

dded

up

over

tim

e)

Fuel consumption before optimizationFuel consumption after optimizationEconomy of fuelSynchronization

Economy of Fuel > 25 %eaqualsSaving of Startup Time


Optimized start-up Less start-up costs

After Optimization:Reproducible Reduction of start-up-time for every start-up mode. Reproducible reduced fuel consumption. Increased revenue through reproducible startup and shutdown to exploit market situation



Stress marginsof thickwalledComponents

Measured Values forTI and TM

TI

THP TM

Optimized start-up Without thermal stress for components


FeatureAdjustment of minimized throttling of turbine inlet valves, Using Overload valves for frequency responseUsing HP-heater steam valves for frequency response On base of a model-based unit control and optimized underlayed control loops

TaskMinimized losses caused by throttling of turbine inlet valves without negative effect on flexibility


TurbineSTTurbineValves

OverloadValves

Minimized throttling

HP-Heater

Opening with kdf

Throttling with kdf

GT

Gas burners

Overfiring

SPPA-P3000 Frequency control Minimized throttling of turbine inlet valves



Using Overload Valves of Turbine.For Frequency Response in positive direction.

Using HP heater stages 1 and 3 to push. Frequency Response.




Primary Control Franken

0

1

2

3

4

5

6

0 50 100 150 200 250 300 350 400

Load [MW]

Thro

ttlin

g de

gree

before Retrofit [%]after Retrofit [%]

Before: 5% throttling of turbine inlet valves


After Optimization:Between 3,3 and 0,5% across load range (mean average 1,9%)Efficiency effect: ~0.12%






High availability

Low emissions

Low Loss Start

Temperature OptimizerGT Modernization

Fast StartFast Ramp

Frequency Control

Dispatch Control



GT Increased Output

Adherence to NOx values in accordance with 13th BImSchV in

natural gas premix mode at base and peak load

Uprating on implementation ofupgrades in natural gas operation

Base load: + 6.29 MW* (LTF 1)Peak load: + 7.88 MW* (LTF >1)

*=ISO-conditions

Design point: 53 MW

Features:Optimized Temperature Control (OTC)Turbine upgradeInner Casing upgradeElectro Hydraulic Converter ReplacementAdvanced Compressor Cleaning systemetc.


cccc


GT increased output

Test on existing V93.0 for verification of V93.1 upgrade

Turbine inlet temperature

NOx

50 MW

62 MW

760°C 830°C

Jan. 23, 2008 (air = + 4.7°C, > 80 % rel. humidity, real values, non-ISO)

LTF = 1

LTF Test = 4

LTF = Life time factor (equiv. hours / hour)

Netoutput

LTF New Design = 1



Next steps and result

Steps fullfilled:More than 150 start-ups with 20%-25% less fuel consumption per yearHigher efficiency in the load range (minimum 0.25 %)

Next steps:After finishing the GT modernization higher efficiency of unit 2 through higher outlet

temperature of GTLongtime optimization of both units

Result:The economics of modernization and upgrade activities compare very favorablyto new plant capacity purchase

The renewing of the control system itself –without the other steps of plant optimization –was valued by E.ON / EKW as economic, even in peak load operation of both unitse.g. due to staff concept, availibility, process control etc.

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Many thanks for your kind attention!



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Disclaimer ClauseE.ON Kraftwerke GmbHKraftwerk Franken

Power Gen Europe 2010 Amsterdam, June, 8-10th

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