Implementing

Sliding Pressure Operation

A Study in Benefits, Challenges, Design and Tuning
Presented by
Don Parker
Provecta Process Automation
Greg Alder
Scientech

August 2015

16/09/2015

Scientech Plant Performance Users Group Symposium August 2015

Overview

Historical Setting:

The changing operating scene:

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Many base-load drum boilers in 70-90s were designed for

fixed pressure,
normal operation range 80-100%.

Life extension
Unregulated renewables
Economic imperatives:
Wider range operation
Fuel cost reduction
CO2 reduction

Scientech Plant Performance Users Group Symposium August 2015

Energy Market Challenges

Pressures on Capacity and Performance

Wider, more flexible

operation
Faster Ramping
Improved efficiency
at low load

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Scientech Plant Performance Users Group Symposium August 2015

Range and Performance Changes:

4x500MW Station (Australia)

Mill autobias

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Scientech Plant Performance Users Group Symposium August 2015

Sliding pressure
Steam
Pressure

TV Posn
100%

100%
Steam Flow

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Scientech Plant Performance Users Group Symposium August 2015

Why Sliding Pressure?

Benefits in Unit Heat Rate at low load

Reduced Turbine inlet temperature

variations on load changes

Economic benefits:

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Reduced turbine throttling losses (wider valve

opening)
Reduced Feed Pump Power
Improved Hot RH temperature attainability

Fuel costs reduced

CO2 emissions reduced

Scientech Plant Performance Users Group Symposium August 2015

The Challenges

How do I quantify the benefits?

How do I optimise the pressure curve?
What are the potential downsides?

How is the control system changed to:

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Fast ramping Increased drum saturation temperature

changes
Greater fuel input variations impacts on combustion
and pulverizers
Calculate additional fuel input requirements during
ramps
Minimise pressure overshoot/undershoot
Minimise steam temperature deviations from fuel/steam
flow imbalances during ramps

Scientech Plant Performance Users Group Symposium August 2015

A Complete Solution

Known
Potential
Efficiency
Improvement
Areas

PEPSE
Scenario
Modelling

Benefit
Determination

Controls
Implementation
and Tuning

UTILIZING:
Scientechs
wide industry
experience

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Scientechs
deep knowledge
and capability

Cost model
(Client);
Calculations
(Scientech)

Provectas wide
controls
experience

1. Quantifying the Benefits

PEPSE model example

550MW gross, drum boiler, fixed pressure

Fixed and sliding pressure comparisons at half load
Two pump models applied: Electric and steam-driven
Two Hot RH temperature scenarios for 50%, fixed pressure

No temperature loss (ie full HRH temperature at 50%)

30 Deg F temperature loss (and recovery in sliding pressure)

Six 50% scenarios run:

Model

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HRH temp
Fixed
loss at 50%? Pressure

Sliding
Pressure

Elec MBFPs

N/A

Elec MBFPs

Steam MBFPs

N/A

Steam MBFPs

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1. Quantifying the Benefits

Outcomes: Turbine Net Cycle Efficiency at Half Load

MBFP
Model
Electric
Steam

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Case 1: Fixed Pressure HRH Steam Temp 970F

Case 2: Fixed Pressure HRH Steam Temp 1000F
Both cases: Sliding Pressure HRH Steam Temp 1000F

Case

Fixed Prs

39.88

40.09

40.19

40.40

Sld Prs

40.68
40.80

% Improvement

Net Heat rate

improvement

2.00

168.4 B/kWh

1.47

123.1

1.52

128.4

0.99

83.86

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1. Quantifying the Benefits

Cost Benefits

Based on typical fuel costs $2.27/MMBTU

MBFP
Model

Electric
Steam

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Case

Net Heat rate

improvement

Saving/hr
298MW

Sav per unit per

year @ 4h/day
low load (*.85)

168.4 B/kWh

$114

$140k

123.1

$83

$80k

128.4

$87

$85k

83.86

$57

$55k

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2. Optimising the Sliding Pressure Curve

PEPSE can quantify all scenarios

Required load change rate will determine drum metal

temperature change rate for any given pressure
profile.

Sliding pressure setpoint will be lagged:

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To reflect boiler milling/heat release delay and steam energy

storage delay.
Delayed pressure setpoint also minimises temperature
deviations.
Ensure delayed pressure setpoint curve does not cause
turbine governor to reach maximum at fastest ramp rate.

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3. Modifying the Controls

Main areas affected

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Boiler Demand (dynamic feedforward; pressure controller)

Pressure setpoint
Steam temperature (gain adaption and feedforwards)

Design changes

Response analysis tests

Simulation and tuning

Scientech Plant Performance Users Group Symposium August 2015

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Unit Coordinated Mode (BF+MW)

Unit
Demand

AGC

Pressure
SP
Overfiring

+ +
+

O2 Trim

PID

PI

_
P
F

FUEL
MILLS

MW

TV
SUPERHEATER
Boiler

AIR
FEEDWATER

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Scientech Plant Performance Users Group Symposium August 2015

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Load changes in Fixed and Sliding Pressure (simulations)

180

180

160

160

Press Bar
MW%
Gov Posn %

140

MWD
Fuel Flow%

Press Bar
MW%
Gov Posn %
MWD
Fuel Flow%
New P-SP
Basic P-SP

140
120
100
80

Coord Mode
Load Ramp

120

80
60

40

40
2500

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3000

New P-SP
Basic P-SP

100

60

20
2000

Coord Mode
(Sliding Pressure)

3500

4000

4500

5000

5500

20
2000

2500

3000

3500

Scientech Plant Performance Users Group Symposium August 2015

4000

4500

5000

5500

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Design Basis: 2-DOF Controller

A 2-Degree-of-Freedom structure provides control

parameters to independently manipulate both
setpoint and disturbance responses.
Simpler structures do not model the expected
process response into the setpoint, nor provide
model-based feedforward dynamics.
Tuned for load changing

Tuned for disturbances

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Model-based Sliding Pressure Control

Simulation results showing the effect on pressure

response (light blue) when

a feedforward to fuel (green) is added to the fuel demand and

the pressure setpoint is passed through a second order lag.

10

10

9
8

7
6
6

5
4
4

3
2
2

0
-2

200

400

600

800

1000

1200

1400

1600

1800

2000

-1

200

400

600

800

1000

1200

1400

1600

1800

2000

Basic control structure (left) and 2-DOF structure (right).

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Pressure Setpoint (Response Model) Dynamics

Simplified pressure model:

Turbine CV
position

Steam flow
Fuel
Demand

PT 3

Grinding and
Heat release delay

Steam Pressure

Integ.
Boiler energy storage

Field Data:

Step change in fuel flow (CV fixed)

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LAG

Step change in Throttle Valve position

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Pressure Setpoint Formation

The sliding pressure setpoint is dynamically modified

to minimise:

Three setpoint model components:

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Pressure controller over-correction

Steam temperature disturbances.

Initial pressure change as governor moves before fuel has any

impact on steam production (pressure direction reversal)
Delay to pressure changes due to energy storage in metal and
waterwalls as the saturation temperature changes
Delay in heat input from the additional fuel due to milling,
combustion and heat transfer processes

Scientech Plant Performance Users Group Symposium August 2015

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Pressure Setpoint Formation

Model-based pressure setpoint

Governor-movement
pressure response model
Calculated
CV Posn

Dyn

F(t)

Adapt

Unit Load
Demand

F(x)

Rate
Lim

F(t)
High order

P-SP

Energy + Inertial
Storage Delay
Model
Model

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Identification tools used to determine parameters

Need to ensure sufficient throttle valve headroom
for fastest ramp rate.

Scientech Plant Performance Users Group Symposium August 2015

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System Identification: Boiler Energy Storage

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Scientech Plant Performance Users Group Symposium August 2015

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MW
Demand

AGC or Local

Syst. Freq.

Unit Master
Modifications

Tracking
signals

Transfer
Droop
F(x)
w ith DB

<

Capability

MSP

Gross MW

Add static Setpoint

curve
Delay P-SP

ULD

F(t)

Press-SP

Delay model

Decoupling

Add overfiring transient

component

F(t)

MSP

F(x)

(model based)

F(x)

and relief

PID
a/b

PID

Dyn

Dyn

MW trim

ULD

**
storage

Calc CV demand

compensat'n
feedfwd
delay compensation
feedfwd

Turbine
Dem and

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** Dyn - adaptive transient overfiring

Scientech Plant Performance Users Group Symposium August 2015

<>

Fuel/Air
Dem and

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Tuning

Pressure-ramp tuning overfiring calibration

Load-ramp tuning dynamic setpoint calibration

Low/mid/high range ramps

Load-based adjustments around model data

Steam temperature attemperator outlet temperature

setpoint feedforward calibration

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Initial settings from energy storage models

Set procedures followed to optimise

Based on steam/fuel dynamic mismatch

Iterative: spray flow affects pressure response

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Load ramping

SH and RH
Temps

Main Steam
Pressure and SP

Turbine
Master

Overfiring signals
Fuel Demand

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Scientech Plant Performance Users Group Symposium August 2015

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Conclusion

Low load operation is expected to become more

prevalent as renewable penetration increases.

PEPSE has shown Sliding Pressure can provide

significant

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Cost savings
CO2 reduction
Reduction in turbine inlet thermal cycling.

Model-based DCS design provides fast ramping with

minimal disturbances.

Use of advanced identification and tuning tools

minimises optimisation time.
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