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Power Plant Performance Optimization & Diagnostics
Kalkitech solution for Power Plant Performance Analysis, Diagnostics and Optimization (or PADO as it is known in the industry) is specially designed and developed for monitoring and optimizing the key performance indicators of individual equipments of Thermal Power Station by using advanced mathematical modeling and optimization techniques and standards from ASME PTC. The solution is capable of working with most DCSs in the industry and enables a fleet-wide optimization that assists Generation utilities in making real time decisions and curbing performance losses.
The PADO application acts as an online decision support system that utilizes information from the plant’s data acquisition system to analyze, diagnose and optimize the plant performance; by identifying and controlling the parameters that causes efficiency deviations thereby improving the overall efficiency or generation. It uses an analytical model with an intuitive graphical user interface that enables the user to accurately model the state of the plant compared to an optimized model and view it in real time. Engineers, operators, managers and executives can view the resulting information, enabling them to understand the actual plant thermal performance and make informed decisions allowing changes, upgrades and causes of significant lost Performance. The entire solution is based on Kalkitech's intelligent Power Plant Optimization software called ELTRIX.
Support Documents
The Performance Optimization and Diagnostics tool from Kalkitech provides powerful solutions for monitoring and modeling thermodynamic performance, whether on individual machines or across an entire plant / process. It also provides solutions for process optimization using first principles and fuzzy logic / neural net technologies. Applications range from advanced supervisory control, anomaly detection, predictive emissions monitoring, coal boiler optimization and many others.
The system provides input to plant operators about the change in performance and impact of each equipment in the plant contributed to the change. It further diagnoses and finds out the root causes of faults in plant equipment and improves the performance of the plant, reducing the amount of fuel necessary to obtain the electrical power required.
Typical Network Architecture:
The PADO system will be implemented in Performance calculation server and is tightly coupled with a secured communications data server to extract information from the DCS. PADO has the following main components which help to attain the desired objective:
- Communicator
- Historian
- Modeler
- Analyzer
- Optimizer
- Report Generator
This system will continuously monitor, diagnose and interpret the thermal, structural and chemical operating condition of the plant and suggest limits, priority action and areas of investigation which result in improved operating plant efficiency and availability.
Key functions of the package includes:
Key functions of the package includes:
- Performance Analysis and Monitoring of Systems and Components
- Boiler - Boiler Efficiency and its heat losses with intermediate calculation
- Turbine - Turbine Efficiency, heat rate and its intermediate calculations
- Condenser - Condenser cleanliness factor and its intermediate calculations
- Feed Water Heater - Terminal temperature difference, drain cooler approach, extraction flows and its intermediate calculations
- Deaerator - Heat duty and its intermediate calculations
- Economizer - Economizer effectiveness and its intermediate calculations
- Air Heater - Air Side Leakage, gas side leakage, pressure drop, corrected gas temperature, air side effectiveness, gas side effectiveness and its intermediate calculations
- Pumps - Pump efficiency and its intermediate calculations
- Fans - Fan efficiency and its intermediate calculations
- Heat Exchanger - Heat transfer coefficient for all heat exchangers for performing soot blower optimization
- System and Performance Optimization
- Heat rate improvement
- Reduced auxiliary power consumption
- Reduction in LOI, CO and NOx levels
- Cleaner furnace walls and convective pass
- Boiler Performance Optimization
This function continuously tracks the efficiency of the boiler system and then it compares the efficiency with the expected boiler efficiency. Further if deviation any in negative side, the system will analyze for the root cause for the same and recommend the optimized parameter in order keep the boiler efficiency within limits and optimization in fuel consumption. This module also helps to reduce NOx and other emissions while trying to improve temperature, sprays and boiler efficiency.
- Soot Blowing Optimization
The system dynamically determines boiler cleaning actions that optimally balance the plant performance parameters. It directs existing soot blowing control systems to take action in real-time to meet the unit’s key performance indicators.
- Stress Analyzer and Service Life Monitoring
Stress Analyzer module continuously monitor the critical / conditional parameters related to boiler pressure parts and it guides to calculate the service life time consumption from fatigue and creep by stress analysis.
- Water Chemistry Management
It has long been a well-known fact in power industry that corrosion in steam generators is an area of significant concern to both the manufacturers and end users of such equipment. A primary objective of Water Chemistry Management module is to avoid the internal boiler tube corrosion. Further this module helps to improve the life of boiler pressure parts, decrease the consumption of chemical dosing, minimize the sale formation in boiler tubes, and prevent the carry over of impurities to turbine. For this, parameters like alkalinity, sodium level, pH level, silica level need to be continuously monitored.
- Regenerative Cycle Performance Optimization
In thermodynamic power cycles, an improvement of even 0.5% in overall cycle efficiency is an important gain. One of the more common ways to improve the efficiency of a steam cycle is to use regeneration cycle in feed water heaters. This module continuously tracks performance of regenerative equipments like Turbine and Feed water heater and provides the message to operator about the current performance and deviations from the expected.
- Emission Analysis and Monitoring
Emission Analysis and monitoring module works in conjunction with BPOS. The combustion optimization module in BPOS helps to optimize the combustion air and fuel flow required to meet the demand. By optimizing the airflow, the amount of waste heat generated through the system will also get optimized and the amount of emission parameters also reduced. This is done by the set points given to the airflow system.
This module will continuously measure, monitor and analyse the plant emissions such as SOx, NOx, CO, CO2, mercury emission and Suspended Particulate Matter (SPM). Threshold values of CO and NOx can be entered manually in this module. If the measured values exceed the threshold limit, alarm will annunciate.
- Merit Order Dispatch
Merit Order Dispatch module optimizes the generation cost of power plants having multiple generating units. The objective of this module is to find the least cost loading for individual units from the given specific station demand. Generation cost curve of each unit is identified from historical data and performance calculation results. Optimization techniques are applied to these curves to identify the load for each unit, which results in least generation cost from the given station demand. The Merit Order Dispatch module runs in a continuous advisory mode since the station demand is expected to vary continuously or with short duration.
ELTRIX POD Module:
ELTRIX Plant Performance Optimization and Diagnostics (POD) module provides a number of optimization and diagnostics functionalities for Gas fired and Coal fired power plants. When combined with ELTRIX Plant Performance Management (PPM) module, it gives a complete solution for Performance Analysis Diagnostics and Optimization (PADO).
To know more about Kalkitech Performance Analysis Diagnostics and Optimization, please visit Performance Optimization and Diagnostics
ELTRIX Plant Performance Optimization and Diagnostics (POD) module provides a number of optimization and diagnostics functionalities for Gas fired and Coal fired power plants. When combined with ELTRIX Plant Performance Management (PPM) module, it gives a complete solution for Performance Analysis Diagnostics and Optimization (PADO).
To know more about Kalkitech Performance Analysis Diagnostics and Optimization, please visit Performance Optimization and Diagnostics
ELTRIX PPM Module:
Kalkitech’s ELTRIX Plant Performance Management (PPM) module enables operator to constantly ensure optimal operation of generating unit. The PPM module is closely integrated with generation unit control system (DCS) and acts as an extension to the DCS.
To know more about Kalkitech Plant Performance Management, please visit Plant Performance Management
Historian:
Historian is a real-time data software for acquiring, storing and displaying large amounts of operations and engineering information. It collects data from Communicator deep within the enterprise and stores it in a highly compressed format, allowing time-series data to be stored online in its original resolution. It enables accurate and timely performance-based decisions that improve operating costs. Historian stores the parameters relevant for identifying the performance of individual equipments. Along with the process parameter it continuously records the status of equipment. Kalkitech has partnered with INSTEP Software LLC to provide their leading historian application eDNA as a solution.
To know more about eDNA, please visit eDNA Overview
Historian is a real-time data software for acquiring, storing and displaying large amounts of operations and engineering information. It collects data from Communicator deep within the enterprise and stores it in a highly compressed format, allowing time-series data to be stored online in its original resolution. It enables accurate and timely performance-based decisions that improve operating costs. Historian stores the parameters relevant for identifying the performance of individual equipments. Along with the process parameter it continuously records the status of equipment. Kalkitech has partnered with INSTEP Software LLC to provide their leading historian application eDNA as a solution.
To know more about eDNA, please visit eDNA Overview
