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.
Page 2 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 3 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 4 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
Drivers of the project
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
Page 5 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
Drivers of the project
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
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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
Page 6 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 7 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 8 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
SSPPPPAA--
Our solution: Process Optimization Solutions SPPA-P3000
E.ON Kraftwerke GmbHKraftwerk Franken
Siemens Power Plant Automation Siemens Power Plant Automation SPPA
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
Page 9 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
Our solution: Process Optimization Solutions SPPA-P3000
E.ON Kraftwerke GmbHKraftwerk Franken
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
Siemens Power Plant Automation Siemens Power Plant Automation SPPA
Low Loss Start
Temperature Optimizer
Fast StartFast Ramp
Frequency Control
Dispatch Control
Page 10 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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.
Page 11 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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.
Page 12 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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)
Page 13 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 14 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
-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
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 15 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
Stress marginsof thickwalledComponents
Measured Values forTI and TM
TI
THP TM
Optimized start-up Without thermal stress for components
Page 16 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
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
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 17 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
Using Overload Valves of Turbine.For Frequency Response in positive direction.
Using HP heater stages 1 and 3 to push. Frequency Response.
SPPA-P3000 Frequency control Minimized throttling of turbine inlet valves
Page 18 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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
SPPA-P3000 Frequency control Minimized throttling of turbine inlet valves
After Optimization:Between 3,3 and 0,5% across load range (mean average 1,9%)Efficiency effect: ~0.12%
Page 19 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
Siemens Power Plant Automation Siemens Power Plant Automation SPPA
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
Low Loss Start
Temperature OptimizerGT Modernization
Fast StartFast Ramp
Frequency Control
Dispatch Control
Page 20 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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.
Page 21 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
cccc
E.ON Kraftwerke GmbHKraftwerk Franken
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
Page 22 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
E.ON Kraftwerke GmbHKraftwerk Franken
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!
E.ON Kraftwerke GmbHKraftwerk Franken
Page 24 June 2010 © e.on 2010. All rights reserved. © Siemens AG 2010. All rights reserved.
These documents contain forward-looking statements and information – that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond e.ons’/Siemens’ control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of e.on/Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by e.on/Siemens worldwide, changes in business strategy and various other factors. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. E.on or Siemens do not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated. Trademarks mentioned in these documents are the property of e.on AG and Siemens AG, its affiliates or their respective owners.
Disclaimer ClauseE.ON Kraftwerke GmbHKraftwerk Franken
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