Transcript Regional Seminar Series CCGT Plant Optimisation using Real Time Data Mark Bate Efficiency Team Leader EON – Connah’s Quay Power Station Empowering Business in Real.

Regional Seminar Series
CCGT Plant Optimisation using Real Time Data
Mark Bate
Efficiency Team Leader
EON – Connah’s Quay Power Station
Empowering Business in Real Time.
© Copyright 2009, OSIsoft Inc. All rights Reserved.
EON: Efficiency Targets Surpassed
“We beat our Efficiency target in 2007 by
2.6%. The 2008 result was >1% against
target . This equates to annual CO2
savings of over 135,000 Tonnes, saving
enough gas to supply the annual needs of
over 50,000 homes!.”
Mark Bate, EON Efficiency Team Leader
Business Challenge
• Reduce Shaftline Trips
• Improve Unit
Efficiencies
• Reduce CO2 emissions
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Value now. Value over time.
Solution
• Performance Watchdog
Displays optimise Plant
• Proates models with data
stored in PI
• Performance Equations,
ProcessBook and DataLink
• ‘d4e’ Improvement project
Results / Benefits
• Reduced CO2 emissions
by 135k Tonnes
• Efficiency increased by
0.5%. Saving £20k in lost
generation!
• Saving over £4m per year
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Lennox
Connah's Quay ... taking power generation forward
Douglas
Hamilton
Liverpool
Rhyl
River Dee
Burton Point
Deeside
Point of Ayr
Connah's Quay
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Chester
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Contents of Presentation
• Introduction to PI and PROATES
• Early development of Plant Monitoring
• Introduction of a Performance Watchdog Display
• Benefits of ‘d4e’ Efficiency Improvement Projects
• More recent developments
• Summary
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Introduction to PI and PROATES
• PI, ProcessBook and DataLink
•
allow Plant data to be interrogated post event or displayed as live values in
a ProcessBook Display or Excel spreadsheet
• PROATES(PROcess Analysis for Thermal Energy Systems)
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•
reads actual Plant data from PI
•
performs a series of thermal calculations based on the Plant
•
writes the results back to PI
•
calculations can also be referenced to Standard Conditions.
•
areas of poor performance are then identified and can be rectified.
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Project History
• Installed in 2001 as part of Powertech Trial
•
Used by a few engineers
• By 2003 extensive use by Operations Team
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•
Shaftline trips, troubleshooting
•
Trend analysis
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Trend Analysis
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Development of Plant Monitoring
• As the use of PI flourished…
•
Development of ‘real time’ displays for comparing Unit Performance
•
Use of ‘Multistate’ symbols on displays to act as visual alarms
•
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Use of Datalink to create reports for various Plant performance issues
(Condenser Tube Pick Report)
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ClickComparisons
Unit
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Tube
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Performance
Watchdog
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title styleDisplay
Problem with ‘GT Inlet Bleed Heating Valve’
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Performance Watchdog Display
• GT Air Inlet Bleed Heating Valve found open at around 8%, bleeding
off warm air to the GT Air Inlet. Found out using PI Trends that
this had been the case for almost 3 Days
•
Cycle Output increased by 7MW
•
Efficiency increased by 0.5%
•
This incident alone was estimated to have cost over £20k in lost generation!
•
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Surely we could make use of PI Performance Equations to minimise these
events and give us early warning?
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title styleDisplay
Performance
Watchdog
• Digital State
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Performance Watchdog Display
• These PI screens helps us
•
•
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maintain a 0.5% efficiency improvement on each unit, through
optimising output and performance
saving of over £4m per year across the site.
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Performance
Watchdog
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Performance
Watchdog
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Performance
Watchdog
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Performance
Watchdog
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Performance
Watchdog
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Benefits
‘d4e’
Efficiency
Improvement Projects
Cooling Water Systems
+0.7%
Gas Turbine / Compressor Improvements
+0.6%
• Filter upgrades and new offline wash strategy
• Compressor Core Plugs fitted
HRSG Pre Heater clean
+0.2%
• Many others….
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Benefits
‘d4e’
Efficiency
Improvement Projects
• In 2007 we beat our Efficiency target by 2.6%
• in 2008 result was >1% against target
• This equates to annual CO2 savings of over 135,000 Tonnes,
• saving enough gas to supply the annual needs of over 50,000 homes!
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More Recent Developments
CQ_B_Shift
Shift Imbalance Totalizer
Freq Resp
Station
Current Imbalance
22/09/2009 13:36
0
U1
-0.4
0
U2
0.3
0
U3
0.0
0
U4
2.8
MW/hr
Availability
Target Generation
Actual Generation
Delivery
5824
5840
100.3
1928
1931
100.2
Imbalance Variation
Positive Imbalance
Negative Imbalance
21.3
-5.5
5.3
-1.8
4.2
-3.3
0.0
0.0
11.8
-0.4
MWhrs
MWhrs
Within +/-2MWhr
> 2MWh Spill
> 2MWh Short
11.3
4.5
0.0
3.4
0.0
0.0
0.3
0.6
0.0
0.0
0.0
0.0
7.5
3.8
0.0
MWhrs
MWhrs
MWhrs
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1903 No Data
1993 MWhrs
1904 [-11101] All data events are
2004
filtered
MWhrs
in summar
100.1
0.0
100.6
%
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Live Imbalance Monitoring
CQ_U1 - Load Imbalance
22/09/2009 13:51
CQ_B_Shift
2.5
1
MW Imbalance
2.0
1.5
1.0
0.5
0.0
-0.5
1
2
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-1.0
-1.5
0
Time Period
Freq Participation
U1 - Load Imbalance
Spill > 2MWh
Short < 2MWh
MW Imbalance
CQ_U1 - Load Profile
400.0
1
350.0
300.0
1
1
1
250.0
1
200.0
150.0
1
0
100.0
0
50.0
0.0
-50.0
0
0
1
2
3
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5
6
7
8
9
10
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12
13
14
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17
18
19
20
21
22
23
24
0
Time Period
Base Load
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Target Load
Actual Generation
Calculated Base Load
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Imbalance Monitoring – Daily Reports
Mon-21-Sep-09
CQ_U1 - Load Imbalance
1.5
1
MW Imbalance
1.0
0.5
0.0
1
2
3
4
5
6
7
8
9
10
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35 36
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45
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-0.5
-1.0
-1.5
-2.0
-2.5
0
Time Period
Freq Participation
Load Imbalance
Spill > 2MWh
Short < 2MWh
CQ_U1 - Load Profile
340
1
1
335
MW Imbalance
1
330
1
325
1
320
1
0
315
0
310
0
305
0
300
0
1
2
3
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30
31 32
33
34
35 36
37 38
39
40
41 42
43
44
45
46
47
48
Time Period
Base Load
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Target Load
Actual Generation
Calculated Base Load
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In Summary
• Continually evolving process
• The PI Watchdog screens ensure we are getting the most out of the
current state of the Plant at all times
• We have been able to develop and enhance our monitoring
• PI has given us the confidence to address areas of:
•
poor plant performance
•
carry out effective cost / benefit analysis to obtain the necessary funding
• Our PI system has become an integral part of the way we operate at
Connah’s Quay.
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© Copyright 2009, OSIsoft Inc. All rights Reserved.
Thank you
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777 Davis St., Suite 250 San Leandro, CA 94577