instrumentation & controls - siemens 16-04-20… · power generation • instrumentation &...

Solutions for Combined Cycle PlantsIstanbul 16-April-2008

Dietrich-Georg Ellersiek Siemens Energy sector

Product management SPPA-P3000

Instrumentation & Controls

SPPA-P3000 Process Optimization

Copyright © Siemens AG 2007. All rights reserved

SPPA-P3000 Solutions for steam power plants© Siemens AG 2007. All rights reserved.

Power Generation • Instrumentation & ControlsL522 Dietrich Ellersiek / Istanbul 16-04-2008

Siemens Power Plant Automation Comprehensive solutions with higher benefit

IndustrialPower Plants

Waste-fired Cogeneration Plants

Wind PowerPlants

Nuclear PowerPlants

BiomassPower Plants

Coal GasificationPlants

Fossil firedPower Plants

Combined Cycle Plants

DesalinationPlants

District Heat Power Plants

SPPA-P3000 Process optimization for CCPPs© Siemens AG 2007. All rights reserved.

Power Generation • Instrumentation & ControlsL522 Ellersiek / Istanbul 16-04-2008

Increase Profitability Solutions for process optimization

5 1 2 3

Yes you can!

Can I ...

... optimize plant performance withsoftware only?



model-based, predictive feedforward structuresexploitation of inherently stable processesdecoupling of highly intermeshed subprocesses

As a result, operating behavior is extremely stable, but still features flexible and fast response

Modern control principles are the basis for high profitability

Optimum operating behavior

Modern control principlesPrediction Intrinsic stability Decoupling

High profitabilityHigh

flexibilityHigh

efficiencyHigh

availabilityLow

emissions

Highcontrol quality

Highstability

Model-basedfeedforward

Highrepeatability

Excellent control concepts are at the base of SPPA-P3000 Process Optimization Solutions:



SPPA-P3000 solutions optimize any type of combined cycle power plant

G3~STG

3~GT

G3~GT ST

clutch

Single shaft

Multi shaft1 x 1 configuration(1 GT/HRSG + 1 ST)

STGT HRSG

GT HRSG

STGT HR

SG

GT Gas turbineST Steam turbineHRSG Heat recovery

steam generator

2 x 1 configuration(2 GT/HRSG + 1 ST)

n x m configuration

Single pressureSTGT HRSG

Triple pressure(HP + IP + LP)

Double pressure(High pressure (HP)

+ low pressure (LP))

GT HRSG

LPHP

...

...



other manufacturers

Alstom/ABBGEAnsaldoHitachiMHI Toshiba

.... and others

SiemensWestinghouse

Siemens Turbines

Steamturbines

Gasturbines

SPPA-P3000 Process optimizationCCPP with turbines from all manufacturers



SPPA-P3000 solutions are suitable for any plant and operate with any type of I&C

Optimization forthird-party I&C

Partial modernizationincl. optimization

Comprehensivemodernization

SiemensAutomation

Plus Electrical systems, field, service & ma-nagement solutions

HMI HMI Siemen HMI Siemens HMI

Basic automation Third-party I&C

SiemensAutomation

Basic automation Third-party I&C

SPPA-P3000

SPPA-P3000

SPPA-P3000



Consistent engineering and HMI for basic automation and optimization

SPPA-T3000 architectureUserinterfaces

Powerservices

Processinterfaces

SPPA-T3000 Application-

Server

SPPA-P3000 ProcessOptimizationSolutions

One common platform: SPPA-P3000 fully embedded

in SPPA-T3000

SPPA-T3000 Automation

Servers



SPPA-P3000 Solutions for CCPPsHigher profitability through intelligent solutions

Fast StartFast Ramp

Frequency Control

Dispatch Control Maximum Load Plus

Low Loss Start

Temperature OptimizerBest Point

Emissions Control

Life Time Plus

High efficiency

High availability

High flexibility

Low emissions

No changes tomechanical equipment

5 1 2 3



GT Control

Control intervention

Drumlevel-control

Heat recovery boilerGas turbine Steam turbine

G GT ST

Stress thickwalledcomponents

G

Drumlevel

SPPA-P3000 Low Loss StartControl intervention and process reaction

Process reaction

ST-Control

Injection

Steam temperature,-pressure, -flow

Stress thickwalledcomponentsBypass-

valve



A Predictive Speed Optimizer

80 km/h

120 km/h

??

The PROFI Load Margin Computer- calculates and monitors component stress- predicts component stress before load changes- optimizes load gradients

Analogy:

Very short unit startup timesReduced fuel consumption duringstartupsSafe from component lifetime reduction

Which speed is best?



Model based Calculation is better than measuring

TITI

Thermal stress development after step change in the steam temperature

–TST –TST

THP TM

TM

TM

TITHP

100min.

-40

40

°C

t100min.

-40

40

°C

t

Input parameters, (ri, d, a, λ ,α )

The better Solution:



Model of thick-walledcomponentincluding thermal stress calculation

THPTGT,set

Prediction

Thermal stress σ

Parametercalculationdynamicalcorrection

Othercomponents

Inputparameters(ri, d, a, λ, α)

σ

(State vector)Ι

σpermiss.

TMax

P3000 Fast StartPredictive load margin computer

PredictionGT & HRSG

Maximum

MinimumGT & HRSG



Requirement Distributor: 13:00

Without:WithoutWithout::

13:0013:0012:0312:0311:1211:12 11:3011:30

With:WithWith::

Fast and repeatable Start Upprocedure

Low Loss Start



Benefit calculation for a standard CCPP unit

SPPA-P3000 Fast StartIncreased revenues from market-driven startup

Key data400 MW CCPP50 % efficiencyLoad-controlled start-up, i.e. bypass damper is used to modulate flow of gas turbine exhaust to bypass stack/ HRSG50 starts per yearElectricity price 80 €/MWh

270,000 €/year500,000 €/yearFor temperature-controlled start-up mode

AssumptionSteam turbine startup timereduced by 30 min

Benefit



Task Provide primary frequency control and spinning reserve at maximum steady-state unit load and with low-stress operating mode for gas turbine(s)

SolutionUse of steam turbine for frequency control by mobilizing thermal storage

Correction of minor frequency deviations solely by steam turbine

Gas turbine only activated here in the event of major frequency deviationsUnit control performs predictive management of thermal storage by coordinated gas and steam turbine operation on the basis of dynamic models

Benefit, e.g. 640,000 €/a Benefit calculation Increased revenues for primary frequency control and spinning reserve servicesAvoidance of fiscal penalties for non-provision of contractually agreed primary frequency control and spinning reserve servicesLow-stress operating mode for gas turbine(s)

Unit load

(sum of GT+ ST)

STload

SPPA-P3000 Frequency Control Increase range for primary frequency control

- Frequency + Frequency+ Unit load - Unit load

Correction of minor frequency deviations only by steam turbine

Fast responseof steam turbine

Smooth response of gas turbine

Unit load ramped to match powerdemande.g. 2% in 30 s

Time sequence

Application of load control for frequency deviations. “Frequency Control” is the first stage of ancillary services.

ST ST GTGT

0

GTload



SPPA-P3000 Frequency ControlInclude steam turbine into frequency control

Frequency

+

-

PGT

PGT

+

-

Steam Turbine Load increase

Steam Turbine Load decrease

Gas Turbine Load decrease

Gas Turbine Load increase

PST

PST

PGT

PGT

+

-

+

-

Gas Turbine Load decrease

Gas Turbine Load increase

Without steam turbineparticipation

With steam turbineparticipation

Insensitivity range of frequency



Set point Gas Turbine(s)

Set point Steam Turbine

Additional fuelfor pressure

change

k x ∆f

Calculationof pressure

drop

Additional fuel for use of steam storage

Set pointpressure

SPPA-P3000 Frequency ControlUse steam storage in HRSGs* for frequency control

* HRSG = Heat Recovery Steam generator

+

Unit ControlCoordinationGTs and ST

+

+

Set point Load unit

Pressure+ -

-

Stabiliser



SPPA-P3000 Frequency ControlSmoother operation of gas turbine

92

94

96

98

100

102

104

-50 0 50 100 150 200 250 300 350 40092

94

96

98

100

102

104

-50 50 150 250 350

Maximum Load Gas turbine

Load Gas turbineLoad Steam Turbine Load Unit

Additional steady-state load Unit



SPPA-P3000 Frequency ControlCoordinated response of GT and ST

Smooth reaction and only small overshoot of gas turbine

GT

ST

Unit load and set point



Key data400 MW CCPP50 % efficiency5000 operating hours/year, with 2000 of these at full loadFull-load level reduced by 5.3 MWRevenue 1): 115 €/kW/a


640,000 €/year

AssumptionFrequency control inRange of ± 8 MW

Benefit

SPPA-P3000 Frequency ControlLucrative services through frequency control

1) Current average value data from EnBW, E.ON, RWE, Vattenfall



Benefit, e.g. 1.250,000 €/a Benefit calculationIncreased revenue thanks to

Fast and repeatable response to changed load demands

High ranking of the plant with grid dispatcher

Power% MCR

Faster reaction on demands

SPPA-P3000Fast rampSPPA-P3000Fast ramp

t

Power% MCR



t

OldLoad rampOldLoad rampOldLoad rampOldLoad ramp

Power% MCR



t

Load Faster Reaction on Demands

SPPA-P3000Fast ramp

Time

OldLoad rampOldLoad rampOldLoad ramp

OldLoad Ramp

SPPA-P3000Fast Ramp

The "Fast Ramp" solution realizes stable and repeatable load ramps according to the dynamic requirements.

SPPA-P3000 Fast Ramp Respond reliably to market requirements

SolutionUnit control performs predictive management of thermal storage by coordinated gas and steam turbine operation on the basis of dynamic modelsOptimum, repeatable interaction of lower-level closed-loop controls by use of proven Siemens automation concepts for critical lower-level controls, e.g. for steam temperature control

Task Significant improvement of load gradients free from restrictions imposed by controls and from the need for manual actions



Set Point

00

Min/Max

Set point CT 1...n

Set point ST

Set point CT n...

1/n

1/n

y=f(x)

∆PST,dyn

∆PST,dyn

DelaysCT/HRSG/ST

SPPA-P3000 Process OptimizationDispatch Control

GT part

Dispatcher

1

1



Key data400 MW CCPPRevenue (+)1): 90 €/kW/aRevenue (-)1) : 35 €/kW/a


1,250,000 €/year

AssumptionLoad gradients increasedfrom 2 to 2.5% min, extendingthe load range from 40 MW to 50 MW after 5 min periodBenefit

SPPA-P3000 Fast RampIncreased revenues by faster ramps

1) Current average value data from EnBW, E.ON, RWE, Vattenfall



Project ExecutionFive steps with the customer toward success

On-site analysis

Presentation and decision

Implemen-tation and fine-tuning

Optimizedoperation

Discussion of situation

Contract

• Operating experience

• Targets• Options for optimization

• Result:Which solutions are feasible for this unit?

• Establish, localize and quantify existing potential

• Examine and evaluate archive data and control schematics

• Plant tests and limits

Enhanced performance and higher profitability are guaranteed:Flexibility EfficiencyEmissionsAvailability

• Result: Evaluation of examined solutions

• Proposal:Scope of modernization, different variants?

• Benefits?• Profitability

(return on investment)?

• Engineeringbased on com-prehensivepower plant know-how

• Start of installa-tion while plant is still in operation

• Outage and connection to plant I&C

• Commissioning / fine-tuning

• Handover to customer



Powering the worldProfitable and reliable power generation

More than 2000 power plants in operation worldwide with electrical systems, I&C systems

and IT technology supplied by Siemens



Siemens Power Plant AutomationCollaborative partnership for your benefit

instrumentation & controls - siemens 16-04-20… · power generation • instrumentation &...

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