CCGT Plant Optimisation using Real Time Data

Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.

CCGT Plant Optimisation using Real Time Data

Regional Seminar Series

Mark BateEfficiency Team LeaderEON – Connah’s Quay Power Station

2 Value now. Value over 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 Solution Results / Benefits

• Reduce Shaftline Trips

• Improve Unit Efficiencies

• Reduce CO2 emissions

• Performance Watchdog Displays optimise Plant

• Proates models with data stored in PI

• Performance Equations, ProcessBook and DataLink

• ‘d4e’ Improvement project

•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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3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.

Connah's Quay ... taking power generation forward

Hamilton North

Douglas Hamilto

n

Lennox

Deeside

Connah's Quay

Point of Ayr

Burton PointRhyl River Dee

Liverpool

Chester



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



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)

• 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.



Project History

• Installed in 2001 as part of Powertech Trial

• Used by a few engineers

• By 2003 extensive use by Operations Team

• Shaftline trips, troubleshooting

• Trend analysis



Trend Analysis



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

• Use of Datalink to create reports for various Plant performance issues (Condenser Tube Pick Report)



Unit Comparisons



Unit Comparisons



U2 Tube Pick Report



Problem with ‘GT Inlet Bleed Heating Valve’

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!

• Surely we could make use of PI Performance Equations to minimise these events and give us early warning?




• Digital State





• These PI screens helps us

• maintain a 0.5% efficiency improvement on each unit, through optimising output and performance

• saving of over £4m per year across the site.


















Benefits of ‘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….



• 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!

Benefits of ‘d4e’ Efficiency Improvement Projects



CQ_B_Shift Shift Imbalance Totalizer

Freq Resp 0 0 0 0

Station U1 U2 U3 U4Current Imbalance -0.4 0.3 0.0 2.8 MW/hr

AvailabilityTarget Generation 5824 1928 1903 No Data 1993 MWhrsActual Generation 5840 1931 1904 [-11101] All data events are filtered in summary calculation2004 MWhrs

Delivery 100.3 100.2 100.1 0.0 100.6 %

Imbalance VariationPositive Imbalance 21.3 5.3 4.2 0.0 11.8 MWhrs

Negative Imbalance -5.5 -1.8 -3.3 0.0 -0.4 MWhrs

Within +/-2MWhr 11.3 3.4 0.3 0.0 7.5 MWhrs> 2MWh Spill 4.5 0.0 0.6 0.0 3.8 MWhrs

> 2MWh Short 0.0 0.0 0.0 0.0 0.0 MWhrs

22/09/2009 13:36

More Recent Developments



CQ_U1 - Load Imbalance

-1.5

-1.0

-0.5

0.0

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Time Period

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Freq Participation U1 - Load Imbalance Spill > 2MWh Short < 2MWh

CQ_B_Shift 22/09/2009 13:51

CQ_U1 - Load Profile

-50.0

0.0

50.0

100.0

150.0

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Time Period

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Base Load Target Load Actual Generation Calculated Base Load

Live Imbalance Monitoring



CQ_U1 - Load Imbalance

-2.5

-2.0

-1.5

-1.0

-0.5

0.0

0.5

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Time Period

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Imba

lanc

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Freq Participation Load Imbalance Spill > 2MWh Short < 2MWh

Mon-21-Sep-09

CQ_U1 - Load Profile

300

305

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315

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335

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Time Period

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lanc

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Base Load Target Load Actual Generation Calculated Base Load

Imbalance Monitoring – Daily Reports



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.

Thank you

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Documents

CCGT Plant Optimisation using Real Time Data