Power Plant Thermodynamic
Performance Monitoring
National Energy Efficiency Conference
September 2012
Agenda
• Performance Monitoring Objective
• Performance Monitoring Methodology
• Examples of Issues Identified
• Case Studies
• Experience Establishing a PM Program
• Alignment to ISO 50001 EMS
Introduction of Tuas Power
• 2 x 600 MW oil fired
steam plants, Unit 1 &
2
• Mar & Dec 99
• 2 x 367.5 MW gas fired combined cycle plants, CCP 1 & 2
• Nov 01 & Jan 02
• 2 x 367.5 MW gas fired combined cycle plants, CCP 3 & 4
• Jul 05 & Sep 05
Installed capacity - 2,670 MW
• Facilitate Operational Adjustments and
Corrective Maintenance to ensure plant
operates at optimum thermal efficiency
• As fuel is a substantial part of power generation
cost, small gains in thermal efficiency could
achieve significant fuel savings
• Enable advance maintenance planning to
restore degraded performance of plant
components
Performance Monitoring Objective
Performance Monitoring Objective
Singapore 2009 Primary Fuel and Electricity Consumption
0
2000
4000
6000
8000
10000
12000
14000
16000
Primary HC Fuel Electricity Cons
Kil
o T
on
s O
il E
qu
ivale
nt
Others
Domestic
Commerce
Industry
Transport
Industry, Commerce,
HouseholdsPower Plants
Performance Monitoring Objective
• Proactively identifying the plant sections that
have degraded performance
• Quantifying the degradations in terms of effect
on overall plant efficiency
• Enabling a condition based predictive
maintenance program to set and prioritize
maintenance activities that will minimize
degradation and hence maximize efficiency
Performance Monitoring Objective
Actual and Potential Efficiency Improvement
49.600%
49.800%
50.000%
50.200%
50.400%
50.600%
50.800%
GT Compressor Fouling 0.051% 0.150% 0.320% 0.423% 0.030%
BFP Inefficiency 0.012% 0.020% 0.025% 0.026% 0.026%
LP Bypass 0.300% 0.320% 0.288% 0.310% 0.310%
HP Bypass 0.150% 0.150% 0.150% 0.150% 0.150%
Condenser Fouling 0.085% 0.092% 0.224% 0.225% 0.225%
IAF Pressure Drop 0.005% 0.022% 0.033% 0.054% 0.054%
Actual Efficiency 50.300% 50.100% 49.800% 49.700% 50.040%
Nov 06 Dec 06 Jan 07 Feb 07 Mar 07
GT Compr
Cold Wash
Note : Figures in this chart are fictitious to maintain data confidentiality
Performance Monitoring Methodology
Modeling Application
To make a Complete Heat and Mass
Balance
Establishing current performance level of
individual components and total system
Establishing the benchmark for the
individual component and for total system
Set targets for improvement/maintenance
Performance Monitoring Methodology
HRSG
HRSG Effectiveness
Duty of individual heat
transfer components
Steam Turbine
HP Turbine Power
IP Turbine Power
LP Turbine Power
HP/IP/LP Turbine Eff
Condenser
Condenser Water Flow
Condenser Duty
Condenser effectiveness
Auxiliaries
CWP Performance
BFP Performance
CEP Performance
Distribution Valve passing
Line Loss
GT GT Power Generation
GT Comp Eff.
GT Turbine Eff
GT Heat rate
IAF performance
CCP Power Station
Performance Monitoring Methodology
HPSH2
RHTR2
RHTR1 HPSH1 HPEVAP HPECO2 IPSHTR LPSHTR IPEVAP
IPECO2
HPECO1
LPEVAP HPECO0 IPECO1 LPECO FWPRHT
SP1 M1 M2SP2
HPST
IPST
M3
M4
RHDSH
HPSDSH
SP3
PI1
PI2
GTCOMP
GTCOMB
GTTURB
INLFLT
SSGEN
CONDSR
MAKEUP
M5
GLNDCN
DEAER
SP4
169298
GT Power kW
109848
ST Power kW
PUMP1
BFWHDR
HPBFWP
LPBFWP
IPBFWP
SP5
SP6
278.91
Gross Generator Output MW
LPST
M6
DUCT1
PI3
HPBYPS
V1
V2
GTEXH
S1
S2
S3
S4
S5S6 S7 S8
S9 S10 S11 S12
S13
S14
S15
S16
S17 S18 S19 S20 S21STACK
COND
DFW
LPBFW
S22
S23
S26
IPBFW
S27
S28
S29
HPSTOT
LPSHPS
IPS
S24
S25
RHTRS
HPBFW
S30S31
S32S33
S34
S35
S36
LPSTOT
HPBFW1
HPBFW2
S37
S39S40
AIR COMPIN
CMPDSC TURBIN
FUELGS
S41
S42
S43
LPDEAR
S44S45S46
S47
S49
BFWSPP
S50
S51
S52
S53
S54
S55
S48
S56
S57 S58
CWS
CWR
S59
GLNSTM
HPBPSS
S38
S60
Performance Monitoring Methodology
• Complete quantification of all streams in a power
plant eg flue gas, cooling water, steam and fuel
flows
• Establish the present performance level of the
individual equipment eg efficiency, heat transfer
coefficients, leakages
• Enables data validation
– Measured values can be compared against the heat
balance output for validating the accuracy of
measurement.
Performance Monitoring Methodology
Modeling Application
To make a Complete Heat and Mass
Balance
Establishing current performance level of
individual components and total system
Establishing the benchmark for the
individual component and for total system
Set targets for improvement/maintenance
Performance Monitoring Methodology
Each piece of equipment modeled separately to match guaranteed data,
then read by overall model
GT
HPSHT HPEVAP HPECONDUCT
DEAER
CONDEN
CONDST
CNDPMP
HPPUMP
CNDMIX
MAKEUP
S1 S2
S3
S4
S5 S6
S7EXH
S8
S9
S10
S11
S12
S13
S14
S15
GT
uses curves or
spreadsheet data
HRSG matches
HRSG vendor
COND matches
HEI/condenser ST model
matches ST vendor
Performance Monitoring Methodology
• Construct software models of the plant components tuned
to design performance
• New & Clean performance is the benchmark
Inputs Benchmark
Gas Turbine Ambient Temp, Press,
Load
Heatrate
HRSG GT Exh Flow, Temp HP, IP, LP steam
Stack Temp
Steam Turbine HPS Flow, Temp, Press,
IPS Flow, Temp, Press,
Condenser Press
HP, IP, LP section sliding
Press, Power, Efficiency
Condenser LPST Exh Flow, Enthalpy,
Cooling Water Flow, Temp
Vacuum
Examples of Issues Identified
• Lost of efficiency after MI due to IGV reprogramming
• Boiler Feed Pump minimum flow recycle valve passing
• Identification of Passing HPST Bypass Valve
• FW Preheater Bypass Valve passing
• Selection of Optimum Inlet Air Filter
• Condenser Cooling Water Optimization
• Condenser Cooling Water Debris Filter Choke
• HPST Bypass Spray Valve Passing
• HRSG HP and RH Spray Valve Passing
• Condenser Air Ingress
• Condenser Tube Fouling
Case Study : FW Preheater Bypass
Flue Gas Inlet Flue Gas to StackF
ee
d w
ate
r
Pre
he
ate
r
E-3
Condensate
Extraction PumpPreheated Water
To Deaerator
V-1
Bypass
Valve
Passing Valve
Case Study : FW Preheater Bypass
Stack temp Vs Feedwater Preheater Temperature
0.90
0.95
1.00
1.05
1.10
1-Jan-05
15-Jan-05
29-Jan-05
12-Feb-05
26-Feb-05
12-Mar-05
26-Mar-05
9-Apr-05
23-Apr-05
7-May-05
21-May-05
4-Jun-05
18-Jun-05
2-Jul-05
16-Jul-05
30-Jul-05
13-Aug-05
27-Aug-05
10-Sep-05
24-Sep-05
8-Oct-05
22-Oct-05
5-Nov-05
19-Nov-05
3-Dec-05
17-Dec-05
31-Dec-05
Stack T
Feedwater Preheater T
Valve Repaired
(Actual) / (New and Clean Performance)
Case Study : Cond Debris Filter Choke
Condenser
Cooling Water A Side
Cooling Water Out
LPST Exhaust
(steam water mixture)
Condensate
(saturated water)
Cooling Water B Side
Cooling Water B Side
Debris Filter Choke
Debris
Filter
Condenser Cooling Water Flow (T/H)
Debris Filter
Repaired
• Condenser cooling water flow dropped in June 2011 and it is because B
side water path was choked.
• Transmission shaft gear of debris filter was replaced with a new one during
July 2011 shutdown. Condenser cooling water flow resumed back.
Case Study : Cond Debris Filter Choke
• Condenser performance was very poor in Q1 and Q2 2007 (Condenser
Pressure ACT/NC is very high). It was then found out that the vacuum pump
sealing strainer was clogged and the pump was running with less sealing
water. After it is rectified, the Condenser performance has improved
significantly.
Case Study : Condenser Air Ingress
Condenser Press ACT/NC
Condenser
Air Ingress
Solved
Experience Establishing a PM Program
• 2003 engaged ACTSYS for thermodynamic analysis of
MHI GT performance
• 2004 – Present, annual Performance Monitoring contract
with ACTSYS on all CCPs
• Quarterly reporting and presentations, review
performance gaps and required corrective actions
• Involvement of Maintenance, Equipment specialists,
Instrumentation, Operations
• Close working relationship where ACTSYS engineers
track plant performance and correlates findings to
operational and maintenance events
Experience Establishing a PM Program
Operations &
Maintenance Presentation & Discussion of Results
Plant
Data
Reports
Discussion Points
Plant Info System
Data Reconciliation Heat Balances
Performance Models
Plant
Data
Theoretical Analysis &
Interpretation
Decision Support
Alignment to ISO 50001 EMS
TP Mgmt provides the framework for setting and
reviewing energy objectives and targets
Allocating resources and setting up of a
methodology for analyzing energy usage
Operating and maintaining systems and
equipment, in accordance with operational
criteria
For all Energy Performance Indicators review
non-conformities => check Actual versus “New
& Clean”
Determining and implementing the appropriate
action needed
Quarterly Performance
Review Meetings
ISO 50001 EMS Implemented PM System
Thank you
GT
SH
AF
T P
OW
ER
(3
4.2
3%
)
INLET AIR (1.45%)
HP STEAM (34.39%)
HP
TU
RB
PO
WE
R (
2.1
8%
)
LP TURB POWER (10.87%)
CONDENSER LOSS 33.53%
SHAFT POWER
IP TURB POWER (6.68%)
AU
XIL
IAR
Y P
OW
ER
(0
.22
%)
ROTOR COOLING LOSS (2.09%)
COMBUSTOR LOSS (0.49%)
CO
MP
RE
SS
OR
WO
RK
(…
.% o
f G
T
Sh
aft
Po
we
r)
FUEL S
ENSIB
LE HEAT
1.00%
DUCT L
OSS (0
.35%
)
RADIATION LOSS
(0.34%)
PIPE L
OSS (0
.08%
)
LP STEAM (4.03%)STACK LOSS (8.97%)
IP STEAM (8.6%)
CHEMICAL
ENERGY
(97.32%)
RADIATION LOSS (0.06%)
RA
DIA
TIO
N L
OS
S
(0.0
9%)
RA
DIA
TIO
N L
OS
S
(0.0
4%)