Webinar 28 - On-Line & Off-Line Simulation of A Coal-Fired Plant & Computation Tools Overview

Welcome!
Webinar #28: On Line & Off line Simulation of a Coal Plant

30 May 2018
Agenda:
* Introduction
* Philosophy of Thermoflow
* Replicating an existing coal plant, STP-PCE
* Off-Line OD Simulation, STM / TFX-PCE
* On-Line OD Simulation, Elink, U-Link
* Data Reconciliation (DRS) and System Optimization (TOPS)
* Q & A Session
Presenter: IGNACIO MARTIN (SPAIN) – GLEN GUO (CHINA)
Support: Meritt Elmasri (U.S. HQ) 1
Thermoflow Training and Support
- Standard Training
- On-site Training Course
- User’s Meetings / Advanced Workshops
- Webinars when new version is released
- Help, Tutorials, PPT, Videos
- Technical Support
 Feature Awareness Webinars
©Thermoflow Inc. 2018 – Webinar: OD Simulation Coal Plant, 30 May, 2018 by IGNACIO MARTIN – GLEN GUO 2
Feature Awareness Webinars
1- Assemblies in TFX, June 2016
2- Scripts in Thermoflow programs, GTP-GTM-TFX
3- Multi Point Design in GTP-GTM
4- Reciprocating Engines in TFX
5- TIME in GTM
6- Matching ST Perfromance in STP
7- Modeling Solar Systems in TFX
8- Combining THERMOFLEX & Application-Specific Programs
9- Methods & Methodology in GT PRO & STEAM PRO
10- Supplementary Firing & Control Loops in GT PRO & GT MASTER
11- The Wind Turbine Feature in Thermoflex
12- Modelling GT’s in Thermoflow programas-1
13- Thermoflex for on line and off line performance monitoring

14- Tflow 27, what’s new
15- Modelling GT’s in Thermoflow programas-2
16- Multi Point Design in GTP-GTM
17- Total Plant Cost in TFX
18- Steam Turbine Tunning
19- User Defined Components in TFX
20- Cooling System Optimization
………………………….
28- OD Simulation of a Coal Plant
Simulation of an existing Plant: Philosophy of Thermoflow
- Clear Definition:  What we want

 What we can achieve
- Plant Engineers involvement @ the Development and Operation
- Plant operating regime & environment (regulation, prices, …)
- Plant specific concerns
- Availability – Reliability comes first!!!
- Pay back?
- Realistic Expectations
- Unique solution for each plant
Monitoring an existing Plant: Options
1. Data acquisition system + simple data processing  Trends
2. “ + use of correction curves
Complexity
3. “ + Thermodynamic Model
4. “ + Detailed Engineered model  Thermoflow
Simulation of an existing Plant: Structure
Plant Instruments Data Acquistion

System
INTERFACE
Data Processing - Trends
System - Graphics
- Reports
-…
External Inputs Calculation Engine
Simulation of an existing Plant: Focus?

System
INTERFACE
System - Graphics
- Reports
-…
External Inputs Calculation Engine
Simulation of an existing Plant: Focus?

System
INTERFACE
System - Graphics
- Reports
-…
External Inputs THERMOFLOW
Model
Simulation of an existing Coal Plant: Limitations
- Instrumentation available & accuracy
- Flow rates measurement: coal, air, gas, water-steam flows, CW flow
- Real Time Coal properties
- ST expansion on the wet region, steam properties
- Unburnt carbon in ash measurement
- Uncounted Boiler losses (Manufacturer Margin)
- Others: PA/SA distribution
Fly/Bottom Ash distribution
…
Simulation of an existing Plant in Thermoflow: Steps
1. Replicating the Original HB  Steam Pro-PEACE

2. “As built” model in STM / TFX-PCE
3. Hardware in STM / TFX-PCE
4. Controls in STM / TFX-PCE
5. Degradation in STM / TFX-PCE: “Current Status” vs “Clean Status”
6. OD Simulation Off Line
7. OD Simulation On Line, Performance Monitoring
Simulation of an existing Plant in Thermoflow: Steps
Example
1. Design in 1999  “Original Heat Balance”
2. Start Up in May 2002  “As Built” HB and first “real data”
3. Last Overhaul in Sep 2016  “Current Clean Status”
4. Now, May 2018  “Current Status”
Replicating an existing plant STP, Original HB, Steam Cycle
BOILER EFF (HHV/LHV) 89,5% / 92,6% NET POWER 464076 kW AUX 36018 kW
NET PLANT EFF (HHV/LHV) 39,4% / 40,7% NET PLANT HR (HHV/LHV) 9140 / 8838 kJ/kWh TURBINE HR 7575 kJ/kWh
45,69 m 171,5 p 542,8 T 1522,9 m

178,4 p 41 p 541,4 T 1250,2 m
1,964 m SSR
295,4 T 42,64 p 345 T 1250,2 m 166,5 p
1478,7 m 540 T 40 p
1522,9 m 540 T
1250,2 m
Blowdown 500093 kW
1,477 m 0,588 m
SSR
2,166 m
3000
HPT IPT1 LPT1x4
(2 double flow) RPM
Leak 5,164 m
17,39 m
0,048 p 32,25 T 926,3 m 0,892 x

1,685 m SSR
5,164 m LPcrs
25,87 T
42873 m
43,71 p 346,9 T 103,9 m
79,62 p 430,1 T 141,8 m
22,49 p 454,6 T 73,8 m
0,24 p 64,02 T 45,12 m
0,822 p 94,22 T 54,48 m

2,227 p 173,8 T 55,33 m
5,27 p 265,4 T 59,29 m
15 T
42252 m CT
LPcrs 10,35 p 347,8 T 1140,5 m

17,52 T 29,19 T
10,35 p 348 T 58,65 m

44062 m 44062 m
0,048 p
32,25 T
178,4 p 1144,8 m
295,4 T 0,725 x
1,089 m
1478,7 m 1,477 m
79,62 p 430,1 T
0,347 p
43,71 p 346,9 T SSR 32,24 T
1146,2 m
4,237 m
1,27 m
22,49 p 454,6 T
1,879 m
to FWH1
10,35 p 348 T
5,27 p 265,4 T 0,827 p
2,227 p 173,8 T 1,27 m GSC
0,822 p 94,22 T
0,24 p 64,02 T
77,3 p 42,43 p 21,84 p 10,05 p 5,019 p 2,121 p 0,783 p 0,228 p
427,8 T 344,8 T 453,2 T 346,6 T 263,9 T 172,4 T 92,91 T 62,94 T
141,8 m 103,9 m 73,8 m 58,65 m 59,29 m 55,33 m 54,48 m 45,12 m
295,4 T 255,3 T 255,3 T 219,7 T 219,7 T 184,9 T 180,1 T 149,3 T 149,2 T 119,3 T 119,3 T 90,13 T 90,13 T 60,17 T 60,17 T 33,2 T 19,09 p
1478,7 m 1478,7 m 1478,7 m 1146,2 m 1146,2 m 1146,2 m 1146,2 m 1146,2 m 33,2 T
1146,2 m
180,1T
TTD FWH8 TTD FWH7 TTD FWH6 DA (FWH5) TTD FWH4 TTD FWH3 TTD FWH2 TTD FWH1
-2,78 T -1,42 T -2,78 T 2,78 T 2,78 T 2,78 T 2,78 T
DCA 77,3 p DCA 42,43 p DCA 21,84 p 10,05 p DCA 5,019 p DCA 2,121 p DCA 0,783 p DCA 0,228 p
4,98 T 260,3 T 4,99 T 224,6 T 5,01 T 189,9 T 180,1 T 5,01 T 124,3 T 5,00 T 95,13 T 5,00 T 65,17 T 5,02 T 38,22 T
141,8 m 245,7 m 319,5 m 1524,4 m 59,29 m 114,6 m 169,1 m 216,1 m
desup
45,69 m
STEAM PRO 27.0 IMG-TF 1305 05-30-2018 11:48:16 SteamProperties: IAPWS-IF97
FILE: C:\Users\imart\Documents\Thermoflow27\FAW\FAW28_OD Coal\Ex_500_2.STP CYCLE SCHEMATIC
p[bar], T[C], h[kJ/kg], m[t/h], x[-]
Replicating an existing plant STP, Original HB, Steam Cycle
- Plant Criteria & Site Conditions
- Cycle type: Subcritical, Single Reheat Condensing
- Plant Size: HPT Flow, Gross Power, Net Power
- Steam Cycle conditions, Pressures & Temperatures
- Steam Turbine, Casing configuration, group efficiencies, leakage system, exhaust end-EL, losses
- FWH: number, type & connections
- Thermal parameters, TTD, DCA, DP
- Parallel trains
- hardware definitions
- Cooling System: type, Condenser Pressure, CW DT, other parameters, hardware definitions
- Pipe pressure drops
- Boiler Feed Pump: electric motor or steam turbine
- Pumps, type, margins-curve, number operating & stand by
- Auxiliary Streams: aire preheater, jet ejector, auxiliary steam, steam to sootblowers, blowdown,
desuperheating
Replicating an existing plant STP, Original HB, ST
Expansion power
Mechanical loss
Generator loss
Generator power
505911
1264,8
4553
500093
kW
kW
kW
kW
166,5 p 43,71 p 40 p 10,35 p

540 T 346,9 T 540 T 347,8 T
3405 h 3077 h 3537 h 3153 h
1522,9 M 1250,2 M 1250,2 M 1140,5 M
HPT IPT1 LPT1x4
4 6
1
7
8
0 2 5 9
43,71 p 22,49 p 10,35 p 5,27 p 0,822 p Total exhaust

346,9 T 454,6 T 348 T 265,4 T 94,22 T 0,048 p
3077 h 3365 h 3153 h 2992,3 h 2648,3 h 32,25 T
103,9 M 73,8 M 58,65 M 59,29 M 54,48 M 2297 h
79,62 p 2,227 p 0,24 p 926,3 M
430,1 T 173,8 T 64,02 T 0,892 x
3222 h 2816,5 h 2472,1 h
141,8 M 55,33 M 45,12 M
p [bar] T [C] h [kJ/kg] M [t/h]
STEAM PRO 27.0 IMG-TF Ignacio Martin Gonzalez

1305 05-30-2018 12:04:42 C:\Users\imart\Documents\Thermoflow 27\FAW\FAW28_OD Coal\Ex_500_2.STP
Replicating an existing plant STP, Original HB, FW Heaters
(1) (2) (4) (5) (6) (7) (8) (9)
79,62 p 43,71 p 22,49 p 10,35 p 5,27 p 2,227 p 0,822 p 0,24 p
430,1 T 346,9 T 454,6 T 348 T 265,4 T 173,8 T 94,22 T 64,02 T
3222 h 3077 h 3365 h 3153 h 2992,3 h 2816,5 h 2648,3 h 2472,1 h
141,8 M 103,9 M 73,8 M 58,65 M 59,29 M 55,33 M 54,48 M 45,12 M
To Boiler
178,4 p
295,4 T
1478,7 M
1,879 M
295,4 T 8D 255,3 T 7D 219,7 T 6D 5C 149,2 T 4D 119,3 T 3D 90,13 T 2D 60,17 T 1D 33,2 T

1478,7 M 1478,7 M 1478,7 M 1146,2 M 1146,2 M 1146,2 M 1146,2 M 1146,2 M
10,05 p
180,1 T 974,3Q
1524,4 M
BFP
45,69 M
p [bar] T [C] h [kJ/kg] M [t/h] Q [kJ/s] x [-]
STEAM PRO 27.0 IMG-TF Ignacio Martin Gonzalez

1305 05-30-2018 12:04:42 C:\Users\imart\Documents\Thermoflow 27\FAW\FAW28_OD Coal\Ex_500_2.STP
FWH SystemT-Q Diagram

600
FWH8
500 82078 Q
1662,6 A FWH7
67544 Q
2098,6 A FWH6
63183 Q
1801,9 A FWH5
42775 Q
0A FWH4
400 40642 Q
1001,5 A FWH3
39164 Q
1112,7 A FWH2
39921 Q
1244,3 A FWH1
35814 Q
1453 A
TEMPERATURE C
300
200
100
0 50 100 150 200 250 300 350 400 450
HEAT TRANSFER .001 X kJ/s
STEAM PRO 27.0 IMG-TF 1305 05-30-2018 12:04:42 SteamProperties: IAPWS-IF97

FILE: C:\Users\imart\Documents\Thermoflow27\FAW\FAW28_OD Coal\Ex_500_2.STP
©Thermoflow Inc. 2018 – Webinar: OD Simulation Coal Plant, 30 May, 2018 by IGNACIO MARTIN – GLEN GUO
p T m Q A
bar C t/h kJ/s m^2 15
Replicating an existing plant STP, Original HB, Cooling Syst
Replicating an existing plant STP: Boiler design
- Fuel type, fuel preparation

- Boiler Thermal: configuration, circulation, excess air, minor losses, blowdown
- Air Handling: PA-SA, Air Pre-heating, DP, fans
- Desuperheating
- Boiler sizing: Furnace exit T, SH load, RH load, Eco load
- Furnace parameters: unburnt carbon in ash
- Stack
- Convective HX DP and hardware definition
Replicating an existing plant STP: Environment
- NOx: SCR-SNCR
- Particles: Fabric Filter-ESP
- Sulfur: FGD wet/dry
- Mercury: activated carbon injection
Replicating an existing plant STP: Auxiliary Power
- Pumps
- Fans
- Fuel Delivery, Ash Handling
- Emission Control equipment
- Transformer Losses
- Other PEACE
- Miscellaneous
From Design to Off Design
or
When in Off Design mode, STM or TFX
- Tune the Hardware

- Set the Controls
- Introduce Degradation
Tuning the Design in STM / TFX: Hardware
- Pipes
- FW Heaters
- Condenser / Cooling Tower
- ST: Inlet Nozzle Area
- Furnace Dimensions
- Boiler Convective HX
- Air Heaters
- Stack
Condenser
FWH Pipes
Furnace
Convective HX
Stack
25
Steam Pro Steam Master
Tuning the Design in STM / TFX: Controls
- Plant
- ST
- Boiler
- FWH
- Condenser
Plant Controls
Boiler Controls
ST Controls
FWH Controls
Cooling System Controls
Tuning the Design in STM / TFX: Degradation
- ST: Efficiency Degradation

- FWH: Blocked Tubes, Fouling, Leaks
- Condenser: Cleanliness Factor, Air intake
- Boiler: HX Fouling
- Others
OD Simulation Off Line
- Typical Correction curves (Elink)
- Other correction curves (steam out, steam to sootblowing, desuperheating, …)
- Effect of Operation alternatives
- Bypass FWH
- CW Pumps / CT-ACC cells on
- Excess Air-Unburnt Carbon in Ash
- Steam Air pre heating
- Effect of Degradation
- FWH blocked tubes
- AH leakage / Dirtyness
- Boiler fouling
- Condenser fouling
OD Simulation Off Line STM, Correction Curves
Part Load Curves
35
OD Simulation Off Line, STM
Steam to Sootblowers vs HX cleaning
Case 1 to 5: Steam mf to
Sootblowers, 0 to 10 t/h
Cases 6 & 7: Effect of cleaning SH2,

HTC adjustment factor 0,750,95
Excess Air / Unburnt Carbon in Ash
Air Heater Leakage / DP
FWH Bypass
OD Simulation On Line, Performance Monitoring
- Tune Thermoflex+PEACE Model

- Connect to the DCS (Elink - ULink)
- Select Inputs & Outputs to be considered as Inputs / Outputs
- Select Inputs & Outputs to be reconciled
- Calculate degradation parameters
- Enter external inputs
- Set and Admin. the User Interface
See Webinar n. 13, June 2017
TFX: Control Loop to find degradation parameters
Condenser Fouling
@ Current Conditions (Ambient, Load, CW Pumps, …):
Cond P Cleanliness
mbar Factor
Expected from TFX 61,4 80%
Measured 63,2 ???
TFX: Degradation
FWH blocked tubes / fouling
OD Simulation On-Line, other TF tools
- DRS: Data Reconciliation System

- TOPS: Optimizer
Computation Tools
Introduce four types of computation tool:
* Control Loops
* Searcher
* Data Reconciliation System (DRS)
* Thermoflow's Optimization System(TOPS)
These tools must be used together with our programs such as GT Master, Thermoflex etc.
Presenter: Glen GUO(CHINA)
Support: Meritt Elmasri (U.S. HQ)
Where to find these tools?
* Control Loops (GT Master, Thermoflex)
* Searcher (Thermoflex)
©Thermoflow Inc. 2018 – Webinar: On line and off line OD simulation of a coal plant, 30 May, 2018
Where to find these tools?
* DRS (Excel Addin)
* TOPS (Excel Addin)
To be adjusted & to be matched
Computation Engine
input parameters (GTP, GTM, STP, STM, TFX etc.)
output parameters
E.g. To achieve a certain net power in GTM, we adjust GT load percentage.

We can use trial method manually, but it’s tedious/time-consuming.
Control loops is automatical trial method, save your time!
Control Loops Interface in GTM
At one time, there is only one input parameter to be adjusted although you may pick up to three inputs in control loops.
How to choose computation tools
Adjust One Match One

Input Parameter Computation Engine Output Parameter
Control Loops
How to start work with data reconciliation
Imagine that you get hundreds of gauge measurements from DCS.

A small part of these measurements are inaccurate.
But you don’t know which ones are faulty.
Theoretically every measurement is suspicious.
How to start your work since you trust none of them?
We don’t trust any individual measurement, but we trust the
whole of them, so we’ll match many parameters simultaneously.
Adjust Many Match Many

Computation Engine
Input Parameters Output Parameters
DRS
DRS background
DRS is useful in online/offline monitoring for data reconciliation.

Measurements always include uncertainty caused by random and
systematic errors. In operating power plants various levels of effort
are dedicated to accurately measuring the quantities used to
monitor and control the plant. The DRS uses a model-based
approach to help isolate faulty sensors, quantify the accuracy of
other measurements, and fill-in unmeasured quantities.
Least square method
Minimize the sum of the squares of the weighted error signals. The
error signals are defined as the difference between the MQs and
the corresponding CEOs at the current nominal point.
DRS Process
DRS example
There are four DRS example files in the sample directory.

Show (DRS4)RHTGTCC.xls
Adjust One Find One Extreme

Input Parameter Computation Engine Output Parameter
No idea of the value in advance
Searcher
Searcher interface
Adjust Many Parameters Find One Extreme Parameter

Computation Engine
No idea of the value in advance
TOPS
TOPS example
TOPS example
There are two TOPS example files in the sample directory.

Show (TOPS2)CCGTLoadOptimization.xls
If you run TOPS for design models of our programs, you optimize
the design;
If you run TOPS for OFF-design models of our programs, you
optimize the operating for existing power plants.
TOPS example
TOPS vs Elink(Multiple design)
If you want to optimize 10
parameters simultaneously and
each parameter has 5 trials.
5^10= 9,765,625 combinations!
With Elink, if your PC computes one

combination within 10 seconds, it will cost
you 3 years to find the optimized solution!
With TOPS you can find it within minutes!
Computation Tools Summary
1) Both control loops and searcher are “1 adjustable vs 1
target” tools. When you want to match the target value
in advance please use control loops otherwise use
searcher to find the unknown extreme value.
2) DRS is “N vs N” tool, much powerful than 1 vs 1 control
loops when matching output values.
3) TOPS is “N vs 1” tool, much powerful than searcher
when finding one extreme/optimized value.
DRS and TOPS for online/offline simulation
Our customers may build up online/offline monitoring system with
accurate hardware model plus DRS & TOPS modules.
In this way, they will master the real status of existing plants and
get operating optimization suggestions.
Q & A Session
- Please forward your questions on the WebEx Chat
- Further questions by email to: info@thermoflow.com
- PP Presentation will be available on the Website / Tutorials

- Video will be available on the Service Center
Thank you!
GLEN GUO - CHINA guo@thermoflow.com

IGNACIO MARTIN - SPAIN martin@thermoflow.com

Webinar 28 - On-Line & Off-Line Simulation of A Coal-Fired Plant & Computation Tools Overview

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Webinar 28 - On-Line & Off-Line Simulation of A Coal-Fired Plant & Computation Tools Overview

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Welcome!

Webinar #28: On Line & Off line Simulation of a Coal Plant

2- Scripts in Thermoflow programs, GTP-GTM-TFX

3- Multi Point Design in GTP-GTM

4- Reciprocating Engines in TFX

6- Matching ST Perfromance in STP

7- Modeling Solar Systems in TFX

8- Combining THERMOFLEX & Application-Specific Programs

9- Methods & Methodology in GT PRO & STEAM PRO

10- Supplementary Firing & Control Loops in GT PRO & GT MASTER

11- The Wind Turbine Feature in Thermoflex

12- Modelling GT’s in Thermoflow programas-1

13- Thermoflex for on line and off line performance monitoring

15- Modelling GT’s in Thermoflow programas-2

16- Multi Point Design in GTP-GTM

17- Total Plant Cost in TFX

18- Steam Turbine Tunning

19- User Defined Components in TFX

20- Cooling System Optimization

28- OD Simulation of a Coal Plant

- Clear Definition:  What we want

- Unique solution for each plant

1. Data acquisition system + simple data processing  Trends

2. “ + use of correction curves

4. “ + Detailed Engineered model  Thermoflow

Plant Instruments Data Acquistion

Plant Instruments Data Acquistion

Plant Instruments Data Acquistion

1. Replicating the Original HB  Steam Pro-PEACE

45,69 m 171,5 p 542,8 T 1522,9 m

0,048 p 32,25 T 926,3 m 0,892 x

43,71 p 346,9 T 103,9 m

79,62 p 430,1 T 141,8 m

22,49 p 454,6 T 73,8 m

0,24 p 64,02 T 45,12 m

0,822 p 94,22 T 54,48 m

LPcrs 10,35 p 347,8 T 1140,5 m

10,35 p 348 T 58,65 m

166,5 p 43,71 p 40 p 10,35 p

HPT IPT1 LPT1x4

43,71 p 22,49 p 10,35 p 5,27 p 0,822 p Total exhaust

p [bar] T [C] h [kJ/kg] M [t/h]

STEAM PRO 27.0 IMG-TF Ignacio Martin Gonzalez

295,4 T 8D 255,3 T 7D 219,7 T 6D 5C 149,2 T 4D 119,3 T 3D 90,13 T 2D 60,17 T 1D 33,2 T

p [bar] T [C] h [kJ/kg] M [t/h] Q [kJ/s] x [-]

STEAM PRO 27.0 IMG-TF Ignacio Martin Gonzalez

FWH SystemT-Q Diagram

0 50 100 150 200 250 300 350 400 450

HEAT TRANSFER .001 X kJ/s

STEAM PRO 27.0 IMG-TF 1305 05-30-2018 12:04:42 SteamProperties: IAPWS-IF97

- Fuel type, fuel preparation

- Tune the Hardware

Cooling System Controls

- ST: Efficiency Degradation

Part Load Curves

Steam to Sootblowers vs HX cleaning

Cases 6 & 7: Effect of cleaning SH2,

Excess Air / Unburnt Carbon in Ash

Air Heater Leakage / DP

- Tune Thermoflex+PEACE Model

See Webinar n. 13, June 2017

@ Current Conditions (Ambient, Load, CW Pumps, …):

FWH blocked tubes / fouling