optimisation tools for power plants
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About us
STEAG encotec (India) Pvt. Ltd.(SeI) is wholly owned
subsidiary of STEAG encotec GmbH, Germany.
SeI offers services in the field of:
Engineering Consulting Services
Power Generation
Operation and Maintenance
Renovation & Modernization Information Technology for Power Plants
New Technologies for Power Plants
SeI has offered services in recent time to: IOCL, MSEB, GSEG,BHEL, HPGCL, NLC, etc.
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_________________________________________________
Energy Management Systems
SRSystematicEnergyManagement
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SRIntelligentIT-Solutionsfor EnergySuppliers
SRvData
Validation
SR1Lifetime
MonitoringSR2Energy
Management
SR3Energy
Controlling
SR4Power Plant
OptimizationSR5
Power Trade
System
SRkPower Cycle
Evaluation
SRpStatistic
Forecast
SRxEnergy Data
Management
SR4 Compact
Power PlantOptimization
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SR1 LifetimeMonitoringin PowerPlants
Current Demands Components of power plants exposed to high temperatures andpressures suffer serious material degradation during their lifetime.
This degradation indicates a need for component exchange or atleast its repair.
The accumulated material degradation is not proportional tooperating time, for which reason a regular monitoring of the plantoperation is recommended.
Such a monitoring must be carried out by continuously operating adata logger together with a data evaluation system.
SR1 is the solution ...
for continuously recording operating temperatures and pressuresaround all the critical components of a power plant
for calculating the creep and the fatigue
for keeping the operator well-informed about the current status ofhis plant
for reducing the cost for routine maintenance inspections as well asadditional tests
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SR1 Saving themeasuredvalues
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SR1 Calculatingthe creepdamage
1)+vs
d(
2
p=
a
ir
100[%]X
x=Cfp/T
Actualstress:
Fatigue inthe time x:
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SR1 Saving thestress cycles
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You have a varying demand of electricity, steam,
hot and chilled water, compressed air, etc. ?
You have alternative means of generating andsupplying these energies ?
SR2 helps to cut your energybill significantly!
And pays back shortly!
You have various buying and selling contracts
for your moving energies ?
SR2 EnergyManagementSystem
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SR2
Online Application Offline Application
1/2 hour Day
OnlineData
Forecasts
What / If? Year
EnergyPlant
Closed LoopControl
EnergyPlants
EnergyContracts
EnergyDemands
System Parameters
SR2 EngineeringLogic
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M M
M M
Flue Gas Desulfurizationand DeNOx Plant
Boiler 185 t/h
Oil/Gas
Deaerator
District HeatSteam 170C
Process HeatSteam 250 C
Live Steam 60 bar/500 C
175 C
138 C
G
12,5 MW
G
12,5 MW
G
12,5 MW
G
15 MW
ST 1
Air Compr. 3
Boiler 275 t/h
Coal/Gas
Boiler 375 t/h
Coal/Gas
Boiler 885 t/h
Oil/Gas
Boiler 785 t/h
Oil
ST 3 ST 4 ST 5
Air Compr. 1
SR2 Optimizationin IndustrialCogen Plant
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General Motors Germany: Daily Energy Cost Profile at Beginning of SR2 Installation
5
7
9
11
13
3
5
7
9
11
13
0 3 6 9 12 15 18 21 24
further potentialfor optimization
Hour
TDM
/h
TDM/
h
Actual Costwithout SR2
Difference7,500 US$/day
Actual Costwith SR2
Optimized Cost
Optimized Cost
Difference3,500 US$/day
Daily Energy Cost Profile after 12 Months from SR2 Installation
Verified Savings: 4,000 US$/day,equivalent to 4 % of variable cost
SR2 VerifiedSavings inIndustrialCogen Plant
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SR2 Optimizationin MunicipalHeat/PowerPlant
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2,500 US$/day
Difference Actual to Optimized Cost
Actual Variable Cost
5,000 US$/day
April 98 March 99
SR2 VerifiedSavings fromOptimizationinMunicipality
Savings afterone year:
equivalent to 8 %of variable cost
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every 15 min
every h 1st step
2nd step
every 15 min
24 h operation plan
Fine Tuning
Balancing all thevariable costs
DemandForecasts
OnlinePlant Data
Load Distribution(24h Forecast)
Load Comparison(Is/Should be)
Cost Comparison(Is/Should be)
every 15 min
every h
SR2 Howthe OnlineSystemworks
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Optimizing the annual budget (incl. maintenance dates)"What happens if?" simulations (incl. unexpected outage)
Cost efficient "In House" studies (incl. plant additions)
Identification of future bottlenecks
Optimizing energy contracts
SR2 Whatthe OfflineSystem
offers
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Injection Condense
GT Generator
Hot Water Generator
Sat. Steam Generator
Boiler with Superheater
Boiler with Reheater
WHSG
GT
Motor (Heat and Power)
Motor Generator
Steam Turbine (3 stages)
Steam Turbogenerator(3 stages)
Motor
Generator
Pump
Compressor
Water Turbine
E-Pump
Steam Driven Pump
Heat Exchanger
Cross Flow HE
Condenser
Cross Flow Condenser
Throtthing Valve (with Spray)
Spray Atemperator
Valve
Water Storage
Steam Storage
Fuel Storage
Heater Deaerator
Condensate Tank
Energy Source
Energy Sink
Black Box (general
Energy Line
SR2 PredesignedComponents
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Client Server Applications
SR2-ConfData Configuration Module
SR2-VisPresentation Module
Online DataInterface Module
External Programs(via API)
SR2-EditPlant Configuration Module
Optional for furtherSR applications
MIP-Solver
SRp
(Optimizer)
(Forecast Module)
Problemtransformer(MPS generator)
Archiveinternal
Archiveexternal
Data Server
SR2 SystemArchitecture
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Exteral
Data / FileServer
(e.g. Netware)
LAN
SR2 ClientOnlineControl Room
(Windows95/NT)
SR2 Application
Server incl. DataServer
(Windows NT)
SRxClientOnlineData
(variable)
Results
SR2 ClientOfflineOffice
(Windows95/NT)
Measurements
ParametersPlant Bus,Terminal Bus,Interface,etc.
SR2 Integrationin Clients
InformationSystem
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SR4 Optimizationof Power
PlantOperation
Current Demands More strict environmental regulations ask for better plant control and make
it even more important and more difficult to find the best point for
economic operation of the plant Competition, especially from a deregulated market and from a growing
number of Independent Power Producers, also requires knowledge of bestprice for power output
The more and more urgently needed economic production of electricity andheat asks for maximized efficiency
Maximum efficiency needs intelligent software tools implemented in the
PMS Using online measurements and system parameters these systems should
- reduce the costs of energy production !
- simulate current plant behavior for various boundary conditions !
SR4 is the solution ...
for highlighting the entire process
for maximizing economic and environmental efficiency
for comparing todays operation with its possible best
for simulating the power plant behavior of tomorrow
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Online BalancingCurrent behavior of all components and the
entire plant efficiency, performance, power output,
fouling
Online/Offline Simulation &Forecast
Results for various power plantparameter variations and the
related fuel consumptionfigures
Online Comparison Reference-to-Current / Best-to-Current
Reference : all components at guarantee point based oncurrentoperation and ambient conditions
Best : optimized operation based on currentcomponent
and ambient conditionsClose follow-up of all relevant componentcharacteristics, calculation of cost reduction potential
SR4 Results
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Ambient
Parameters(not controllable)
ambient temp,pressure, humidityCooling water temp, (load level,heating value,combustible), etc.
Forecast
SimulationsComponentEfficiencies
(controllable during downtime)
efficiency, spec. heat rate,
gain factor,effectivity,approach temp, etc.
Comparison
OperationalParameters
(controllable during operation)
Load factor GT/ST, Soot Blowing,Steam Parameters, Cold end,
Feed water split, etc.
Optimization
SR4 TheTriangle ofSimulations
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Balancing
Higher quality of relevant measured and calculated values
Compact summary of process information allows more detailed evaluation
Reference-to-Current evaluation
Continuous evaluation of components and the entire unit
Identification of faults and slowly increasing deviations
Savings of up to some 100 $/h per unit
Optimization
Optimization of components, the unit or even the entire site
Savings of up to 1 Mio $ per year
Forecast
Configurable parameter variation for different load conditions Forecast of plant efficiency deviations up to 2-3% supports the plant operation
strategy
SR4 OptimizationPotential
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Continuous monitoring of plant efficiency
Balancing, optimization and simulation tool
Cost analysis of component deficiencies
Complete thermodynamic boiler model
Suitable to answer market needs by parameter variationsthe power plant behavior of tomorrow
Graphical configuration leads to a transparent online and offlineapplication with proven data management
Extendable from SR4 Compact to a detailed, large SR4 system
SR4 TheSystemBenefits
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Basic version: SR4 Compact
Scope of Calculation:Online BalancingOnline Best-to-Current Comparison and Simulation
Main Steam Boiler: efficiency, fouling, oxygen content flue gasAir heater: pressure and oxygen content before/after heater, foulingSteam turbine: spec. heat consumption (net/gross), evaluation of water/steam-cycleCondenser / cold end: temperature, pressure, efficiencyEntire unit simulations: reference point, best point, maximum power output, other
boundary conditions
Data Preparation: Plausibility checkData Management: Data base SRxInterfaces / Hardware: PC as SR4/SRx-Server and integration in Customer-LAN
Options SR4
Standard objects : Cooling tower, blower/fans, pumps, exhaust gas cleaning, a.s.o.
Special objects : Boiler with detailed heat exchange model, optimization Cold End,a.s.o.
Optional Data Preparation
Plausibility check of input values with neural networksData reconciliation of relevant values
SR4 TheBasic System
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Main Steam Boiler + Air Heater + Flue Gas Cleaning
Net/gross boiler efficiency (current/reference), effective thermal power, heat balance,
indirect coal flow calculation, pulverizer performance, gas temperatures and interstagevelocities along the boiler,
Superheater and reheater sprays, (T/p) of live steam and hot reheat, reheater steamsidepressure drop,
fouling of furnace chamber and boiler convection zones controlled by soot blowers, fouling andleakage of rotary air preheaters,
flue gas composition, pressure drop flue gas, efficiency flue gas blower, emission monitoringevaluation ( NOx, SO2, CO ),
delta of flue gas oxygen content over air heater (current/reference), delta of flue gas pressureair heater (current/reference),
boiler simulation taking into account: fuel characteristics, combustion conditions, water-steamcycle parameters, flue gas conditions,
Gas Turbine
Net/gross efficiency GT (current/reference), back pressure at turbine outlet,
efficiency air compressor (current/reference), flue gas mass flow / temperature / oxygencontent / composition,
gas turbine simulation taking all relevant influencing parameters into account
SR4 Examplesfor Optional
Results
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SR4 Examplesfor Optional
ResultsHeat Recovery Boiler
Net/gross boiler efficiency (current/reference), pressure drop flue gas, effective thermalpower, boiler simulation
Water-Steam-Cycle
Net/gross specific heat consumption (current/reference), delta costs (current/reference),feed heater performance/optimization,
water-steam-cycle simulation taking all relevant influencing parameters into account
Condenser
Pressure / temperature / degree of recovery / media temperature difference, cold endperformance/optimization,
condenser simulation
District heating system
District heat output, el. power output equivalent
Entire unit
Net/gross unit efficiency, gross unit efficiency + current el. power output equivalent,entire unit parameter variation by activating the simulations of all relevant sub-units, severaloptimization scenarios
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SystemParameters
Heating values, fixed
costs, soot blowingparameters, ...Plausibility / Reconciliation
Online Mode
Gas Turbine / Boiler / Steam Turbine / Condenser / Plant
Balancing :Current plant behavior, efficiency,fouling, ...
Ref.-to-Current Comparison : Boiler, heatcycle, ...
Optimization :Plant optimum regardingefficiency, costs,..
Offline Mode
Gas Turbine / Boiler / Steam Turbine / Condenser / Plant
Simulation : Various scenarios, forecasts, ...
Data Base
Measurements, Formulas
Plant Management System (PMS)
Visualization Online Mode process figures, color switch, diagrams, ...
Graphical interface( Configuration mode,
offline presentation )
ObjectConfiguration
Characteristic
values, TAG
numbers,
characteristic
curves, ...
SR4 TheProgramStructure
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For the connection of SR4 to the data acquisition system a suitable interface will be used.
Approximately 200-500 measurements per unit will be selected for transfer at 1 min intervals. Allthe results are stored in an integrated data base, they can be visualized in actual (on-line) modeand historically for any period of registered time.
The SR4 Compact software should run exclusively on a PC application server so that sufficientcapacity is available to generate results of diagnosis and optimization every 5 minutes. The PC canbe linked to the clients PC LAN (TCP/IP) so that any authorized client (Windows NT) has access tothe online visualization of current and past operation. For this purpose the SR4 client software,available on the SR4 server is downloaded automatically when an authorized client of the LANrequires any information. The graphic and numeric presentation of SR4 Compact results includespresentation with automatic visual changes to indicate individual component deficiencies and trend
curves as well as x/y-presentations of any combination of variables (original data and results).
Testing and tuning of the system during on-line operation is to the major part done by remotecontrol of system operation. For this purpose an ISDN or telephone socket shall be supplied by theclient and the server PC will be connected to the suppliers offices. The general hardwarerequirements for SR4 Compact for the two units are specified as follows:
Trademark PC
Pentium IV, 800 MHz, 128 MB RAM; Raid 5 Array, 3x18,2 GByte HD;
CD ROM drive for Windows NT; MOD 5,2 Gbyte, with 2 storage media;
ISDN router ZyXel Prestige 100 including connection (for system tuning, trial run and for service);
Operating system Windows NT 4.0 Terminal Server (alt. Windows 2000 server);
Color monitor 19''; Color printer;
Interfaces to clients and the DCS for measuring data;
SR4 Thesystemrequirements
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SR4 Thedatarequirements
Approximately 200-500 measurements of operational data we need from your plant for balancing andoptimization
Relevant units: Gas Turbine;Boiler;Steam Turbine;Condenser;; Entire Plant
All technical specifications on boiler geometry, boiler efficiency definition, cycle calculations (design),soot blower characteristics, fuels, air preheaters, gas turbines, steam turbines, etc. have to besupplied by the customer and will be used exclusively to determine the parameters for the systemconfiguration.
Some documents in detail :
- Supply of the documents and information required for process modeling, according to ourrequirements;
- Lists of available measuring points including TAG numbers;
- P&I diagrams and flow schematics; - Functional descriptions;
- Design data and acceptance test data; - Fuel analysis; - Burner arrangement, firing sequence;
- Boiler drawing, including summary of boiler heating surface data (surface area, pitch, etc.);
- Number and arrangement of soot blowers, along with their steam or compressed air consumptioncharacteristics;
- Heat flow diagrams of the water/steam cycle and reheater mass flow data as a function of load.
- Information about operational cost factors as a basis for the determination of current operating costs;
- Information about plant-specific boundary conditions ( e.g. maximum allowable interval between twosoot blowing cycles )
- Check and approval of results.
Services to be Provided by the Purchaser
The Purchaser shall assign a project manager who shall be responsible for:
- Supply of the documents and information required for process modeling, according to ourrequirements.
- Information about operational cost factors as a basis for the determination of current operating costs;
- Information about plant-specific boundary conditions, e.g. maximum allowable interval between twosoot blowing cycles;
- Check and approval of results
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External
Data / File Server(e.g. Netware)
LAN
SR4 Client OnlineControl Room
Plant Load Schedules(WinNT / Win2000)
SR4 Application Serverincl. Data Server(WinNT / Win2000)
SRx ClientOnline Data
(WinNT /Win2000)
Results
SR4 ClientEngineering OfficeStudies & Parameters(WinNT / Win2000)
Measurements
Parameters
SR4 Integrationin Clients
InformationSystem
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Siemens : Teleperm XP, Teleperm XP-XU, WinTM (Teleperm ME)
ABB : XTC (ProControl Interface to PBS30), PIMS, GLINK
Hartmann&Braun (now ABB) : CONVISA, CONLINK
IDS : HIGH LEIT OS9, HIGH LEIT NT
B&R : DCS2000
OSI Software (Oil Systems) : PI System (via PI-API)
Aspen Tech : Info Plus X
SEG : VLS2000
Others : OPC-Data-Interface, DDE-Server, Profibus, M-BUS, ODBC, SQL,
OLE, FTP, MS-Excel, Yokogawa
SR4 RealizedData
Communi-cation forInterfaces
S O FB D Software for the Power Industry
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EbsilonProfessional
Plant optimization
offline with
Our clients: more than 100 utilities and manufacturers
B I D
EPOS
Performance Monitoring
online with
Software for the Power Industry
ABB, ALSTOM, BABCOCK, BEWAG, Blohm + Voss, BMW, CEE, Colenco, DSD, ECH, Envi Con,E.ON, Electrowatt Hamburg und Zrich, enertech, ENERGOPROJEKT, EVH, EVT, GKWeser,GEW Rheinenergie, gtz China, gtz India, HEW, IBT, LAUBAG, Lurgi, Mannesmann Seiffert,Mitsubishi HI, Ramboll, MVV, NEM, Schering, PCE ENERTEC, PEF, RAB, Rheinbraun, RWE,Saarberg, Siemens, SIK, Stadtwerke Chemnitz, Stadtwerke Hannover, Standardkessel Lentjes-Fasel, STEAG, TEAG, Technip, TV Nord, VA TECH, VEAG, Weig GmbH, ZBP INWAT
Frankfurt
Zwingenberg
Frankfurt
Essen
EbsilonProfessional
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EPOS
total flexible from offline to online operation
actual by high calculation velocity
Optimal use of all potentials by realistic detaillingExact What-If-calculations by identical models for simulation and validation
High availability by reliable convergence behaviour
References and experiences of over 40 online installationsfrom 0,04 MW to 1460 MW for industrial plants and utilities since 1996
Coal,oil,gas fired Nuclear ppCCP plants Mixed plantsRepowering
Modellierung EbsilonProfessional
Offline process simulation
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Mills
Fluegas path
g
Graphical modelling with tool box
Standard libraries for fuels (coal, oil, gas) oxygen carrier gas turbines water-steam user defined and extensible
Error analyzer English, French, German, Spanish,
multilingual
Interactive offline process calculation EbsilonProfessional
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Interactive offline process calculation
Input ofprocess parameters
Input air temperatureDemo example CCPTotal power 10.382 MWEfficiency 38.09%
Start of the calculation
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Offline process simulation with actual,historical or manipulated data
EbsilonProfessionalEPOS
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Choice coal mixture
water-steam-circuitair pathmillsfluegas path
fluegas desulphurization unit
Determination overheads of a power plant
historical or manipulated data EPOS
In Ebsilon integrated optimizer EbsOptimize
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Input of optimization measures
Input of variation measures
Input constraints
EbsOptimizeOptimization objectivesdesign operation modes
In the model available measures
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SR4 UnitOverview
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SR4 BoilerSections
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SR4 BPOSCalculations
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SR4 BoilerMapping
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SR4 TurbineCycle
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SR4 TurbineSection
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SR4 CondenserSection
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SR4 HPHeaterSection
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SR4 LPHeaterSection
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SR4 Air andFlue GasSection
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SR4 AH- ASection
SR4 AH B
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SR4 AH- BSection
SR4 Mill C
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SR4 Mill C
SR4
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SR4 AuxiliaryPower
Consumers
SR4 Set
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SR4 SetPointOptimization
SR4 RH
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SR4 RHMetalTemperature
Calculation
SR4 SH
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SR4 SHPlaten MetalTemperature
Calculation
SR4
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SR4 ParameterEditor
SR4 What
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SR4 WhatIf Module
SRx Raw
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SRx RawData
SRx
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SRx PlausibleData
SRx
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ReconcillatedData
SRx
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SubstitutedData
SR4
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Trending
SR4
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Economic Lossfrom soon or late sootblowing
Optimal TimeforWaterwallSootblowing
Generator Power
Waterwall effectivity (fouling)
Optimum Waterwall
Sootbl. Signal
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SRNo Client Place SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx
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ReferencesNo. Client Place SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx
1 BMW Dingolfing (D) 1999 1998 1998 1998
2 Condea Moers (D), Studie 1998
3 Jebel Ali K Dubai (VAE) 2001 2001 2001 2001
4 Endesa Teruel 1,2,3 (E), 1993
5 Endesa As Pontes 1,2,3,4 (E) 1993
6 Endesa Compostilla 3,4,5 (E) 1992
7 EVN Duernrohr 2 (A) 1990 1998 1998
8 EVN Theiss (A) 1999 1999 1999
9 Henkel Dsseldorf (D) 2001 2001 2001
10 HEW Wedel (D) 1992 1999
11 HEW Moorburg (D) 1995
12 Hidroelectrica Abono (E) 1995 1996 1996
13 Iberdrola Guardo (E) 1994
14 Infracor Marl (D) 2000 2000
15 Kali & Salz Werra (D), Studie 1999
16 LG-Power Seoul (Korea) 2001 2001
17 LVR Bedburg Hau (D) 1992
18 LVR Dsseldorf (D) 1993
19 Mainfranken-Park Wrzburg (D) 1999 1999 1999 1999
20 MiRO Karlsruhe (D) 1999 1999 1999
21 Opel Rsselsheim (D) 1990 1991 1999
22 Petronas Kertih (MY) 1999 1999 199923 Petronas Gebeng (MY) 1999 1999 1999
24 Rethmann Lnen (D), Studie 1997
25 Roche Diagnostics Mannheim (D) 1998 1999
26 RWE Meppen (D) 1994
27 RWE Ibbenbren (D) 1997 1997
SRf
No. Client Place SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx
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Referencesp
28 RWE Neurath (D), Bl. D u. E 1999 1999
29 RWE Neurath (D), Bl. A, B, C 2000 2000
30 RWE Gowerk (D) 1998
31 RWE KEO (D) 2001 2001 2001
32 Salzburg AG Salzburg (A) 2001 2001 2001 2001
33 SAP St.Leon Roth (D) 1999 1999 1999
34 Schering Berlin (D) 2001 2001 2001
35 SESA Leuna (D) 1997 1999
36 Stadtwerke Chemnitz (D), Studie 2000
37 Stadtwerke Schwbisch Hall (D) 1996 1999 1997 1997
38 Stadtwerke Hamm (D) 1994 1999
39 Stadtwerke Kempen (D) 1993
40 Stadtwerke TW Ludwigshafen (D) 2000 2001 2000 200041 Stadtwerke Dsseldorf (D) 1999 1999
42 Stadtwerke Neustrelitz (D), Studie 1996
43 Stadtwerke Rosenheim (D) 1998 2000 1999 1999
44 Stadtwerke Salzburg (A) 1999 1999 1999
45 Stadtwerke EW Wels (A) 1999 1999 1999 1999
46 Steag Lnen (D) 1997 1997
47 Steag Herne (D), Bl. 4 1998 2000 1998
48 Steag Herne (D), Bl. 3 2000 2000
49 Steag Walsum (D) 1998 199850 Unin Fenosa La Robla (E) 1989
51 Unin Fenosa Narcea (E) 1990
52 Unin Fenosa Meirama (E) 1993
53 Unin Fenosa Sabn (E) 1992
54 Verbundkraft Duernrohr 1 (A) 1998 1998
55 Wienstrom Wien (A) 1999 1999 1999 1999
SRR f
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KW Lnen, Unit 6 (Steag AG, Essen, Germany); 1996
150 MW, high ash coal / oil, 2 Turbines
KW Drnrohr, Unit 2 (EVN, Maria Enzersdorf, Austria); 1996/97350 MW, Imported coal/gas
KW Drnrohr, Unit 1 (Verbundkraft, Vienna, Austria); 1996/97410 MW, Imported coal/gas
KW Ibbenbren, Unit B (RWE, Essen, Germany); 1996/97750 MW, Anthracite, wet bottom furnace
HKW Herne, Unit 4 (Steag AG, Essen, Germany); 1997500 MW, high ash coal, 400 MW district heating
KW Neurath, Unit E (RWE, Essen, Germany); 1998/1999600 MW
References
SRR f
-
7/30/2019 Optimisation Tools for Power Plants
78/78
KW Simmering Unit 3 (Wiener Stadtwerke AG, Austria);
1999 Combined cycle, 487,3 MWel, District heating 350 MW,
KW Thei 2000 (EVN AG, Austria); 1999
Combined cycle, 454 MWel
KW Neurath, Unit D (RWE, Essen, Germany); 1999
600 MW
HKW Herne, Unit 3 (Steag AG, Essen, Germany); 2000
300 MW, high ash coal, 150 MW district heating
KW Neurath, Units A/B/C (RWE, Essen, Germany); 2000
300 MW each
KW1, Unit 4 und 5 (Infracor, Hls, Marl, Germany); 2000
150 MW each, coal/ chemical residues
References