Developing Updated Performance

Parameters for EPRIs Heat Rate

Improvement Guidelines
EPRI Heat Rate Improvement
Conference - 2013
Bill Kettenacker, PE
Scott Nedrow

February 5-7, 2013

Introduction

Purpose of This Effort

Update 1986 Appendix B - Performance Parameter
Accounting Manual in Heat Rate Improvement
Guidelines for Existing Fossil Plants (EPRI CS-4554)
Purpose of Guidelines . . . (to) develop generic
guidelines enabling utilities to implement plant heatrate improvement programs.
Old Guidelines Based on Industry Experience (129
plants)
- No Specific Load
- No Specific Plant Size
New Guidelines Based Solely on Computer Simulation
- Many Loads
- 3 Plant Sizes
3

Why is Heat Rate Important?

0.5% Heat Rate Improvement = $750,000 / yr
-

640 MW Coal Unit

$3.80 / mmBTU
72% Capacity Factor
9,900 BTU / kW-hr Heat Rate

Other Benefits
- Increased Generation
- Reduced Emissions

Parameters Studied
HP Turbine Efficiency

Coal Moisture

IP Turbine Efficiency

Auxiliary Power

Main Steam Pressure

Makeup

Main Steam Temperature

Feedwater Heater Performance

Reheat Temperature

Reduced Load Operation

SH Attemperation Flow
RH Attemperation Flow
Excess O2
Exit Gas Temperature
Condenser Backpressure
Unburned Carbon

How Study Was Performed

PEPSE Software Analysis
3 Different Plants for T/G Studies,
150 MW, 300 MW, 650 MW,
Interpolate to 500 MW for Average
T/G - 9 Loads, 110% - 20%
1 Boiler for Its Studies 4M lb/hr
Steam Flow
Boiler 1 Load, Variation in
Parameters
Results Tabulated in a
Spreadsheet

Load

BTU/kwh/F

110%
100%
75%
50%
25%

1.972
14.980
122.246
400.017
891.393

PEPSE
Modular, steady-state, first-principle, energy
balance program Windows based
35+ yrs application by utilities, A-Es, others
All types of plants

fossil
nuclear
gas turbine/combined cycle
heat recovery
geothermal
cogeneration
thermal solar

Representative Turbine Cycle

Representative Boiler

Procedure
T/G - PEPSE Model - Cases for Plant and Load
- 150 MW, 300 MW, 650 MW
- 110% Load to 20% Load
- Results Interpolated to 500 MW
Boiler PEPSE Model - Cases for Single
Plant/Load
Results Tabulated in Spreadsheet
- Heat Rate
- Generation (Not in 1986 Report)
Correlations Developed from the Tabulated
Results

Report Page HP Efficiency

HP Efficiency Heat Rate

HP Efficiency - Generation

Report Page - Condenser

Condenser Backpressure Heat Rate

HR vs. BP
250

Heat Rate (BTU/kW-hr)

200
150
150 MW

100

300 MW
650 MW

50
0
-50
-2

-1.5

-1

-0.5

0
0.5
BP (in-Hg)

1.5

2.5

Condenser Backpressure - Generation

MW vs. BP
2

Power (MW)

0
-2
150 MW

-4

300 MW
650 MW

-6
-8
-10
-2

-1.5

-1

-0.5

0
0.5
BP (in-Hg)

1.5

2.5

Turbine Cycle Results 2012 vs 1986

Parameter

Units

2012
PEPSE

1986
Guidelines

1986
Guidelines

HPEfficiency

B/kWh/%

15.4

18.8

17.9 21.5

IPEfficiency

B/kWh/%

11.3

14.5

11.0 19.1

MainSteamPress B/kWh/psi

0.30

0.35

0.03 0.65

MainSteamTemp B/kWh/oF

1.1

1.4

0.7 1.7

ReheatTemp

B/kWh/oF

1.0

1.3

0.9 1.9

CondenserBP

B/kWh/''Hga

Curve

204.0

42 269

MakeUpFlow

B/kWh/%

54.9

24.0

4 88

AuxiliaryPower

B/kWh/%

70.0

86.0

64 97

Boiler Results 2012 vs 1986

Parameter

Units

2012
PEPSE

1986
Guidelines

1986
Guidelines

SHAttempFlow B/kWh/%MSFlow

3.0

2.5

1.3 3.1

RHAttempFlow B/kWh/%MSFlow

17.9

21.5

10.0 36.6

ExcessO2

B/kWh/%

26.7

29.4

10.0 36.0

ExitGasTemp

B/kWh/oF

2.0

2.7

2.1 4.2

UnburnedC

B/kWh/%

12.8

11.7

6.0 12.8

CoalMoisture

B/kWh/%

18.2

7.8

6.0 10.0

FWHR Results 2012 vs 1986

Parameter

Units

2012
PEPSE

1986
Guidelines

1986
Guidelines

FWHR1TTD

B/kWh/oF

1.8

2.1

1.3 2.3

FWHR2TTD

B/kWh/oF

0.64

0.54

0.33 0.63

FWHR1OOS B/kWh

117.6

94

FWHR2OOS B/kWh

23.1

70

Conclusions
1986 vs 2012 Results Very Close, a Few
Differences
Software Predictions (2012) = Industry
Experience (1986)
New EPRI Guidelines Are Accurate Method to
Determine Performance Parameter Changes
Software an Accurate Way to Calculate
Performance Parameter Changes

20

Questions