2015 asme power conference technical/technological advances for optimizing heat rate sunder raj...
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Technical/Technological Advances for Optimizing Heat Rate
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Existing Capacity Retirements
2012 2010 2011 2012
309,519 1,418 2,456 10,214
1,308 29 31 85
239 49 79 123
N/A 58 63 51
10,168 11,094 10,638 10,353
34% 31% 32% 33%
56 36 33 35
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2002 10,314 9,533 10,442 2003 10,297 9,207 10,422 2004 10,331 8,647 10,428 2005 10,373 8,551 10,436 2006 10,351 8,471 10,435 2007 10,375 8,403 10,489 2008 10,378 8,305 10,452 2009 10,414 8,159 10,459 2010 10,415 8,185 10,452 2011 10,444 8,152 10,464 2012 10,498 8,039 10,479
Average 10,381 8,514 10,451 Efficiency 33% 40% 33%
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Case Study Technical/
Technological Areas for HR Improvement
Operations Management/Optimization
Equipment Management
Performance/ Condition
Optimization
Technological Tools/
Advances
Maintenance Management/ Optimization
Process Management
Web-Based Training Performance Monitoring Neural Network Optimization Soot Blowing Optimization Digital Technology
Tune Controls Cycle Isolation
Optimize Combustion Boiler Modeling Optimize Soot
Blowing Optimize Controls
Leakage Reduction Better Air Heater Seals Restore/Replace Seals – Turbines, Air Heaters, Boiler Remove/Prevent Turbine Deposits Condenser Cleaning Instrument Calibration Tune Control Systems Predictive Maintenance
Optimize Combustion Reduce FGET
Improve Soot Blowing Calibrate Instrumentation
Reduce Excess Air Optimize Steam Conditions Real Time Data for Dispatch
Online Monitoring - Efficiency - Generation - Fuel Type, Input - Capacity Losses - Heat Input - Controllable Losses Instrument Calibration
Air Heater Modifications Upgrade Turbine - Seals, Steam Path, Partial-Arc Admission. LP Turbine Last Stage Mill Upgrades Environmental Control Systems Upgrades
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Total Turbine
ShaftEfficiency Output Efficiency Output Efficiency Output Output
lb/hr Btu/lb 109 Btu/hr % % kW % kW % kW kWBituminous 498,255 11,150 5.5555 87.68 84.29 166,740 87.53 153,316 86.36 312,326 632,382
Mechanical Losses
Electrical Losses
Generator Output
Auxiliary Power
Turbine Cycle Heat
Input
Generator Output
Turbine Cycle Heat Rate
Turbine Cycle
Efficiency
As-Burned Heat Input
Unit Output
Unit Heat Rate
Unit Efficiency
kW kW kW kW 109 Btu/hr kW Btu/kWhr % 109 Btu/hr kW Btu/kWhr %1,914 8,414 622,054 24,882 4.8711 622,054 7,831 43.6% 5.5555 597,172 9,303 36.7%
2. Prime Mover - Steam Turbine
3. Prime Mover - Generator 4. Turbine Cycle 5. Overall Unit
HP Turbine IP Turbine LP Turbine
1. Heat Source - Boiler
Amount of Fuel Burned
Higher Heating
Value
As-Burned
Heat Input
Boiler Efficiency
Type of Fuel
Burned
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Equipment/SystemA. Boiler & Auxiliaries 1995 1996 1997 1998 1999 2002 2003 2005
1. Fuel 100% PRB Coal
3. Economizer Replacement
4. Air Preheater Replacement/ Reconfiguration
5. Superheater Division Panel Modifications
B. Combustion System
1. NOx Aggressive Tuning
C. Turbine-Generator1. HP/IP/LP Turbine Replacement
D. Process Control/Optimization
1. SootblowingAdditional
Sootblowers Installation
Intelligent System
2. Instrumentation & Controls
Controls Upgrade
E. Technological Tools
1. Neural Network Process Tool
2. Plant Information (PI)
Data Collection
Tool3. Training Simulator
4. Performance Monitoring
OLM Tool
Low NOx System
Installation
2. Pulverizer Vane Wheel Replacement
Year1994
a. High-Efficiency Exhausters Installation
b. Steam Inerting System Installation
1988 1992
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HP IP LP HP IP LP HP IP LP4,202,027 3,882,035 3,288,941 4,210,690 3,904,318 3,326,712 4,210,690 3,906,792 3,315,028
2141.7 605.29 189.35 2141.7 579.32 197.67 2141.7 579.68 196.971000 1000 706.71 1000 1000 714.64 1000 1000 713.68
672.55 189.35 0.9823 643.69 197.67 0.9823 644.09 196.97 0.9823656.0 706.71 101.14 646.51 714.64 101.14 646.66 713.68 101.1484.29 87.53 86.36 88.04 91.96 86.56 88.04 91.94 88.73
166.740 153.316 312.326 176.001 151.61 320.235 175.926 152.169 326.35826.37% 24.24% 49.39% 27.17% 23.40% 49.43% 26.88% 23.25% 49.87%
222.4 222.4 279.481002.41 1000.92 1000.891023.44 1022.33 1013.271034.55 1044.64 828.96
21.03 21.41 12.3816.71 17.21 9.92
UEEP, Btu/lbAnnulus Velocity, fpsExhaust Loss, Btu/lbExhaust Loss, MW
Total Last Stage Annulus Area, sq.ft.ELEP, Btu/lb
(Percentage of Total Shaft Output)
Original DesignDescription
Steam Flow, lb/hrSteam Pressure, PsiaSteam Temperature, °FExhaust Pressure, Psia
Replacement HP/IP/LP DesignReplacement HP/IP Design
Exhaust Temperature, °FEfficiency, %Shaft Output, MW
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Total Turbine
ShaftEfficiency Output Efficiency Output Efficiency Output Output
lb/hr Btu/lb 109 Btu/hr % % kW % kW % kW kWPRB Coal 662,664 8,500 5.6326 87.68 88.04 175,926 91.94 152,169 88.73 326,358 654,453
Mechanical Losses
Electrical Losses
Generator Output
Auxiliary Power
Turbine Cycle Heat
Input
Generator Output
Turbine Cycle
Heat Rate
Turbine Cycle
Efficiency
As-Burned Heat Input
Unit Output
Unit Heat Rate
Unit Efficiency
kW kW kW kW 109 Btu/hr kW Btu/kWhr % 109 Btu/hr kW Btu/kWhr %1,914 8,774 643,765 25,751 4.9387 643,765 7,672 44.5% 5.6326 618,014 9,114 37.4%
2. Prime Mover - Steam Turbine
3. Prime Mover - Generator 4. Turbine Cycle 5. Overall Unit
HP Turbine IP Turbine LP Turbine
1. Heat Source - Boiler
Amount of Fuel Burned
Higher Heating
Value
As-Burned Heat Input
Boiler Efficiency
Type of Fuel
Burned
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Heat Rate Improvement/Optimization
Unit Specific
Virtual Models
Technological Advances
Holistic Approach
Monitoring/ Diagnostics
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Thank You!
Contact Information:
Power & Energy Systems Services
• Komandur Sunder Raj • 201-638-4635 • [email protected]
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