Diagnostic Techniques for Improving Power Plant Performance, Reliability and Availability: A Case Study

2006 ◽  
Author(s):  
Komandur S. Sunder Raj
Keyword(s):  
Power Plant ◽  
Power Plants ◽  
Performance Monitoring ◽  
Monitoring Program ◽  
Heat Rate ◽  
Diagnostic Techniques ◽  
Lessons Learned ◽  
Plant Performance ◽  
Reliability And Availability

The objectives of an effective power plant performance monitoring program are several-fold. They include: (a) assessing the overall condition of the plant through use of parameters such as output and heat rate (b) monitoring the health of individual components such as the steam generator, turbine-generator, feedwater heaters, moisture separators/reheaters (nuclear), condenser, cooling towers, pumps, etc. (c) using the results of the program to diagnose the causes for deviations in performance (d) quantifying the performance losses (e) taking timely and cost-effective corrective actions (f) using feedback techniques and incorporating lessons learned to institute preventive actions and, (g) optimizing performance. For the plant owner, the ultimate goals are improved plant availability and reliability and reduced cost of generation. The ability to succeed depends upon a number of factors such as cost, commitment, resources, performance monitoring tools, instrumentation, training, etc. Using a case study, this paper discusses diagnostic techniques that might aid power plants in improving their performance, reliability and availability. These techniques include performance parameters, supporting/refuting matrices, logic trees and decision trees for the overall plant as well as for individual components.

Variability in Thermal Performance and Measured Heat Rate in Fossil-Fuelled Power Plants

1992 ◽  
Vol 206 (2) ◽  
pp. 109-123 ◽  
Author(s):  
F L Carvalho ◽  
F H D Conradie ◽  
H Kuerten ◽  
F J McDyer
Keyword(s):  
Thermal Performance ◽  
Power Plants ◽  
Performance Monitoring ◽  
Unit Commitment ◽  
Thermal Power ◽  
Heat Rate ◽  
Plant Performance ◽  
Plant Management ◽  
Fuel Quality ◽  
Stable Operating

The paper examines the variability of key parameters in the operation of ten thermal power plants in various commercial grid environments with a view to assessing the viability of ‘on-demand’ plant performance monitoring for heat rate declaration. The plants of various types are limited to coal- and oil-fired units in the capacity range of 305–690 MW generated output. The paper illustrates the influence of control system configuration on effective and flexible power plant management. The analysis of variability indicates that there is a reasonable probability of achieving adequately stable operating periods within the normal operating envelope of grid dispatch instructions when thermal performance monitoring and display can be undertaken with a high confidence level. The levels of variability in fuel quality, which were measured during nominally constant levels of fuel input and generated output, range from about +1 per cent for oil-fired plants to about ±5 per cent for coal-fired power plants. The implications of adopting on-line monitoring of unit heat rate as an input to the generation ordering and unit commitment process are potentially significant cost and energy conservation benefits for utilities having a high proportion of coal- and oil-fired generation.

A Case Study of Optimizing Combined Cycle Performance at Kalaeloa

2009 ◽  
Author(s):  
Helmer Andersen
Keyword(s):  
Power Plants ◽  
Performance Monitoring ◽  
Combined Cycle ◽  
Plant Performance ◽  
Operational Performance ◽  
Cycle Performance ◽  
Monitoring Tools ◽  
Online Performance Monitoring ◽  
On Line

Fuel is by far the largest expenditure for energy production for most power plants. New tools for on-line performance monitoring have been developed for reducing fuel consumption while at the same time optimizing operational performance. This paper highlights a case study where an online performance-monitoring tool was employed to continually evaluate plant performance at the Kalaeloa Combined Cycle Power Plant. Justification for investment in performance monitoring tools is presented. Additionally the influence of various loss parameters on the cycle performance is analyzed with examples. Thus, demonstrating the potential savings achieved by identifying and correcting the losses typically occurring from deficiencies in high impact component performance.

Combined Cycle Plant Performance Monitoring

2004 ◽  
Author(s):  
Michael McClintock ◽  
Kenneth L. Cramblitt
Keyword(s):  
Thermal Performance ◽  
Gas Turbines ◽  
Power Plants ◽  
Performance Monitoring ◽  
Monitoring Program ◽  
Combined Cycle ◽  
Plant Performance ◽  
Testing Procedures ◽  
Combined Cycle Plant ◽  
Reheat Steam

Monitoring thermal performance in the current generation of combined cycle power plants is frequently a challenge. The “lean” plant staff and organizational structure of the companies that own and operate these plants frequently does not allow the engineering resources to develop and maintain an effective program to monitor thermal performance. Additionally, in many combined cycle plants the highest priority is responding to market demands rather than maintaining peak efficiency. Finally, in many cases the plants are not designed with performance monitoring in mind, thus making it difficult to accurately measure commonly used indices of performance. This paper describes the performance monitoring program being established at a new combined cycle plant that is typical of many combined cycle plants built in the last five years. The plant is equipped with GE 7FA gas turbines and a GE reheat steam turbine. The program was implemented using a set of easy-to-use spreadsheets for the major plant components. The data for the calculation of indices of performance for the various components comes from the plant DCS system and the PI system (supplied by OSIsoft). In addition to the development of spreadsheets, testing procedures were developed to ensure consistent test results and plant personnel were trained to understand, use and maintain the spreadsheets and the information they produce.

From Commissioning to First Year Operation of a Modern Coal Fired 242 MW Plant Facility

2009 ◽  
Author(s):  
Kuda R. Mutama ◽  
Norm Duperron ◽  
John Seeliger
Keyword(s):  
Power Plant ◽  
Steam Turbine ◽  
Catalytic Reduction ◽  
Heat Rate ◽  
Daily Basis ◽  
Lessons Learned ◽  
Plant Performance ◽  
First Year ◽  
Reheat Steam ◽  
Plant Personnel

In this paper lessons learned during the period from commissioning the TS Power Plant to first year of commercial operations are discussed. It is hoped that the experience at TS Power Plant will be valuable to other new plants during the post-commissioning phase. In June 2008 the TS Power Plant commenced commercial operations. The plant is designed for a gross power output of 242 MW. Combustion takes place in a sub-critical B&W radiant boiler, which uses PRB coal for fuel to generate 1,491,000 lb/hr superheated steam at a design pressure and temperature of 2650 psi and 1055 °F respectively. The steam is used to drive a Toshiba reheat steam turbine generator set. To date the plant performance is better than expected. Actual HP turbine throttle pressures at desired load are less than design with a lower heat rate than expected. The plant has state of the art technology and follows strict emission removal standards in accordance with its air permit for the reduction of CO, NOx, SO2, mercury and particulate matter. Plant personnel addressed problems ranging from mechanical, instrumentation and control, to freezing weather issues during the first year of operations. On several occasions the plant experienced forced outages and personnel had to troubleshoot in order to identify the root cause of the problems. The critical problems developed with the DCS, coal handling system, fans and air dampers, boiler combustion systems, steam turbine auxiliaries, selective catalytic reduction system, spray dry absorber, and water treatment. A significant number of the problems were carried over from facility commissioning and new ones developed during normal operations. Plant personnel had to work through these problems on a daily basis. The operating staff had gained significant experience during the plant commissioning phase by participating in loop shooting and equipment commissioning. It is also important to note that operations staff completed a General Physics training program designed specifically around the TS Power plant systems during construction. The plant was running relatively smoothly with an average availability of 99.84% for the last three months of 2008.

Assessment of Gas Turbine and Combined Cycle Power Plant Performance Degradation

2011 ◽  
Author(s):  
Nina Hepperle ◽  
Dirk Therkorn ◽  
Ernst Schneider ◽  
Stephan Staudacher
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Power Plants ◽  
Heat Rate ◽  
Performance Degradation ◽  
Empirical Method ◽  
Combined Cycle ◽  
Performance Data ◽  
Plant Performance ◽  
Water Steam

Recoverable and non-recoverable performance degradation has a significant impact on power plant revenues. A more in depth understanding and quantification of recoverable degradation enables operators to optimize plant operation. OEM degradation curves represent usually non-recoverable degradation, but actual power output and heat rate is affected by both, recoverable and non-recoverable degradation. This paper presents an empirical method to correct longterm performance data of gas turbine and combined cycle power plants for recoverable degradation. Performance degradation can be assessed with standard plant instrumentation data, which has to be systematically stored, reduced, corrected and analyzed. Recoverable degradation includes mainly compressor and air inlet filter fouling, but also instrumentation degradation such as condensate in pressure sensing lines, condenser or bypass valve leakages. The presented correction method includes corrections of these effects for gas turbine and water steam cycle components. Applying the corrections on longterm operating data enables staff to assess the non-recoverable performance degradation any time. It can also be used to predict recovery potential of maintenance activities like compressor washings, instrumentation calibration or leakage repair. The presented correction methods are validated with long-term performance data of several power plants. It is shown that the degradation rate is site-specific and influenced by boundary conditions, which have to be considered for degradation assessments.

Application of On-Line Optimization Technology to Plant Operation

2000 ◽  
Author(s):  
Rodney R. Gay
Keyword(s):  
Power Generation ◽  
Power Plant ◽  
Gas Turbine ◽  
Power Plants ◽  
Heat Rate ◽  
Combined Cycle ◽  
Plant Performance ◽  
Plant Operation ◽  
Budget Analysis ◽  
On Line

Traditionally optimization has been thought of as a technology to set power plant controllable parameters (i.e. gas turbine power levels, duct burner fuel flows, auxiliary boiler fuel flows or bypass/letdown flows) so as to maximize plant operations. However, there are additional applications of optimizer technology that may be even more beneficial than simply finding the best control settings for current operation. Most smaller, simpler power plants (such as a single gas turbine in combined cycle operation) perceive little need for on-line optimization, but in fact could benefit significantly from the application of optimizer technology. An optimizer must contain a mathematical model of the power plant performance and of the economic revenue and cost streams associated with the plant. This model can be exercised in the “what-if” mode to supply valuable on-line information to the plant operators. The following quantities can be calculated: Target Heat Rate Correction of Current Plant Operation to Guarantee Conditions Current Power Generation Capacity (Availability) Average Cost of a Megawatt Produced Cost of Last Megawatt Cost of Process Steam Produced Cost of Last Pound of Process Steam Heat Rate Increment Due to Load Change Prediction of Future Power Generation Capability (24 Hour Prediction) Prediction of Future Fuel Consumption (24 Hour Prediction) Impact of Equipment Operational Constraints Impact of Maintenance Actions Plant Budget Analysis Comparison of Various Operational Strategies Over Time Evaluation of Plant Upgrades The paper describes examples of optimizer applications other than the on-line computation of control setting that have provided benefit to plant operators. Actual plant data will be used to illustrate the examples.

Performance Testing of Coal Fired Power Plants

2007 ◽  
Author(s):  
Shane E. Powers ◽  
William C. Wood
Keyword(s):  
Power Plant ◽  
Power Plants ◽  
Performance Test ◽  
Model Development ◽  
Performance Testing ◽  
The United States ◽  
Plant Performance ◽  
Cycle Performance ◽  
Test Program

With the renewed interest in the construction of coal-fired power plants in the United States, there has also been an increased interest in the methodology used to calculate/determine the overall performance of a coal fired power plant. This methodology is detailed in the ASME PTC 46 (1996) Code, which provides an excellent framework for determining the power output and heat rate of coal fired power plants. Unfortunately, the power industry has been slow to adopt this methodology, in part because of the lack of some details in the Code regarding the planning needed to design a performance test program for the determination of coal fired power plant performance. This paper will expand on the ASME PTC 46 (1996) Code by discussing key concepts that need to be addressed when planning an overall plant performance test of a coal fired power plant. The most difficult aspect of calculating coal fired power plant performance is integrating the calculation of boiler performance with the calculation of turbine cycle performance and other balance of plant aspects. If proper planning of the performance test is not performed, the integration of boiler and turbine data will result in a test result that does not accurately reflect the true performance of the overall plant. This planning must start very early in the development of the test program, and be implemented in all stages of the test program design. This paper will address the necessary planning of the test program, including: • Determination of Actual Plant Performance. • Selection of a Test Goal. • Development of the Basic Correction Algorithm. • Designing a Plant Model. • Development of Correction Curves. • Operation of the Power Plant during the Test. All nomenclature in this paper utilizes the ASME PTC 46 definitions for the calculation and correction of plant performance.

Automating attendance recording of contingent labours at a large construction site

2012 ◽  
Vol 2 (8) ◽  
pp. 1-9
Author(s):  
Saroj Koul
Keyword(s):  
Power Plant ◽  
Radio Frequency Identification ◽  
Power Plants ◽  
Subject Area ◽  
Management Control ◽  
Class Discussion ◽  
Construction Site ◽  
Large Power ◽  
Content Type

Subject area Operations and human resourcing. Study level/applicability This case study is intended for use in graduate, executive level management and doctoral programs. The case study illustrates a combined IT and HR driven participative management control system in a flexible organization structure. It is intended for a class discussion rather than to illustrate either effective or ineffective handling of an administrative situation. Case overview The case describes the situation of managing unskilled workforces (≥14,000 workers) during the construction phase of the 4 × 250MW power plants both for purposes of turnout as well as due compensation, in the event of an accident. The approved labour forces appointed for 45 × 8 h. Man-days after a rigorous fitness test and approvals of the safety officer are allocated housing and other necessary amenities and a commensurate compensation system. Expected learning outcomes These include: illustrating typical organizational responsibility structure at a construction site of a large power plant; illustrating the planning and administrative control mechanism in implementing strategy at a construction site of a large power plant; offering students the opportunity to understand and view a typical operational (project) structure; allowing students to speculate adaptations in the wake of an ever-changing business and company environment; and providing an opportunity to introduce a power scenario in India, Indian labour laws and radio frequency identification technology and to relate this to the case in context. Supplementary materials Teaching notes are available; please consult your librarian for access.

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