ipsepro cloud-based power plant modeling with zefficiency · ipsepro is a thermodynamic process...

© 2012, Enginomix, LLC

IPSEpro Cloud-Based Power Plant Modeling

IPSEpro is a thermodynamic process modeling software package used by hundreds of power plant

owners, developers and engineering companies around the world to design, analyze and optimize

energy systems. Whether designing new plants, repowering old faciliti

operate a fleet of power plants, engineers use IPSEpro software to do the job. If you own or operate

one or more power plants, by leveraging

Enginomix can provide your organization with

you can start improving your plant operations today.

Combined Cycle Plants

Key Benefits

• Plant owners, operators and engineers use IPSEpro What

performance (capacity and efficiency), accurately reflecting changes in ambient, load, cogen

demands, control settings and equipment degradation

• IPSEpro off-design models can

dispatch, improving your fleet’s overall performance and cost

• You can use IPSEpro to optimize plant operation

assessing the level and impact of equipment degradation and evaluating equipment changes.

IPSEpro can predict performance under all major operating modes, including off

part-load operation of major equipment

• With IPSEpro, you can monitor plant performance and

can use IPSEpro models to correct key p

enabling you to make apples

another and assess relative changes

generate Degradation Impact Curves

of key plant equipment so you can prioritize maintenance activities.

• With Software-as-a-Service

expert to build or run models.

and delivered to you through a collaborative web portal, through which

company can access and run from any PC.

DRAFT

Based Power Plant Modeling with Zefficiency



energy systems. Whether designing new plants, repowering old facilities, or analyzing how to best


one or more power plants, by leveraging IPSEpro through the Zefficiency web portal foundation,

anization with easy-to-access, fully-predictive, turnkey plant models so

you can start improving your plant operations today.

Combined Cycle Plants Coal Plants

operators and engineers use IPSEpro What-If models to accurately

(capacity and efficiency), accurately reflecting changes in ambient, load, cogen

demands, control settings and equipment degradation.

can be used to generate incremental heat-rate curves

dispatch, improving your fleet’s overall performance and cost-effectiveness.

optimize plant operation by exploring plant operation strategies,


predict performance under all major operating modes, including off

load operation of major equipment

monitor plant performance and degradation in plant equipment

correct key plant performance indicators to reference conditions

enabling you to make apples-to-apples comparisons of the performance of one plant or unit to

relative changes in performance over time due to degradation

Impact Curves, ranking the cost impact of the performance degradation

of key plant equipment so you can prioritize maintenance activities.

Service, you don’t need to install software on your PCs or be a modeling

models. Your plant models are built and supported by modeling experts

delivered to you through a collaborative web portal, through which anyone in your

company can access and run from any PC.

page 1

Zefficiency



es, or analyzing how to best


the Zefficiency web portal foundation,

predictive, turnkey plant models so

accurately forecast plant

(capacity and efficiency), accurately reflecting changes in ambient, load, cogen

rate curves for plant

by exploring plant operation strategies,


predict performance under all major operating modes, including off-design and

degradation in plant equipment. You

lant performance indicators to reference conditions,

one plant or unit to

due to degradation. You can

, ranking the cost impact of the performance degradation

to install software on your PCs or be a modeling

by modeling experts,

anyone in your

IPSEpro Cloud-Based Power Plant Modeling with Zefficiency

© 2012, Enginomix, LLC DRAFT page 2

• Using IPSEpro History Analysis tools, your What-If, Heat Balance and Performance calculations

are validated and tuned using plant measured data, so your IPSEpro model results match how

your plant is running today, not how it was designed to run years ago.

• Your plant models are built and run using the IPSEpro open-equation modeling framework. The

engineering equations can be easily reviewed and adjusted by your own plant performance

engineers. Unlike the closed software solutions typical used for power plant modeling, you will

know what calculations are being used and will be able to update them yourselves.

• You can use the power of IPSEpro data validation to help identify errors in plant measurements,

and take advantage of the redundancies in measurements to generate clean, consistent sets of

validated plant data. With better measurements, you will have a more accurate view of your

plant’s performance and you can use the validated data as inputs to higher-level diagnostic

calculations, improving their accuracy and results.

How can you use IPSEpro to help respond to a competitive power industry environment?

IPSEpro provides a set of modeling tools and an analysis framework that will help you improve your

plant’s performance and optimize its operation in a competitive power industry environment. By going

through the IPSEpro implementation process and fully utilizing the complete set of IPSEpro modeling

tools (including What-If, Heat Balance, and Performance calculation models), experience shows you can

increase net income for your plant by 1% to 5% (net income = revenue – expenses), both by reducing

fuel expenses and by increasing plant revenue. You can reduce expenses by using IPSEpro performance

and modeling tools to trend and compare corrected plant performance, helping you to more quickly and

accurately identify and correct performance problems, thereby improving plant efficiency and reducing

plant fuel consumption. You can also improve plant net income by increasing revenue. You can use

IPSEpro What-If models, tuned to your current plant condition, to identify operating modes that

generate more net income by increasing revenue from power and/or cogen steam generation more

than the accompanying increase in expenses due to higher fuel consumption and/or lower efficiency.

IPSEpro Cloud


Put Your Power Plant in the Cloud

Using the Zefficiency framework from Zizia Solutions, En

plant models on your own collaborative web portal for direct, secure access by your engineers and

corporate planners from anywhere in the world

install special software on your PCs, and all of your users will always have secure access to the latest

IPSEpro software and plant model updates.

World-Class Models, World-Class Service

By leveraging IPSEpro through Zefficiency, you give your users access to world

and support services from Enginomix. Enginomix engineers are world

modeling: they literally wrote the book

Plant Performance Monitoring, by Gay, Palmer and Erbes

the GateCycle and EfficiencyMap software

design power plant software in history

around GateCycle (GateCycle and EfficiencyMap are

engineers have now built their knowledge and experience into

Power Plant Library), which they will use to build your plant models.

Power plant modeling has improved greatly

EPP_Lib, you can model the off-design performance of any power p

unparalleled accuracy. But not everyone has the time or inclination to become modeling experts. By

leveraging the collaborative Zefficiency

team, taking advantage of a new business model

and maintain your power plant models

• Access your models from any device with a web browser

• Use the collaborative features of Zefficiency to as

your IPSEpro plant models, from other users in your company and from Enginomix

• Get immediate access to updated software and models as they are uploaded by Enginomix

• Leave comments and suggestions for changes, a


DRAFT

the Cloud with Zefficiency

mework from Zizia Solutions, Enginomix will build and publish your IPSEpro


corporate planners from anywhere in the world. By taking advantage of Zefficiency, you don’t have to

software on your PCs, and all of your users will always have secure access to the latest

IPSEpro software and plant model updates.

Class Service

leveraging IPSEpro through Zefficiency, you give your users access to world-class modeling expertise

and support services from Enginomix. Enginomix engineers are world-renowned experts in power plant

the book on power plant performance monitoring (see the book

, by Gay, Palmer and Erbes, 2004), as well as being the primary authors of

and EfficiencyMap software packages. GateCycle was the first integrated design/off

lant software in history, and EfficiencyMap was a performance monitoring system

and EfficiencyMap are now owned and supported by GE). Enginomix

built their knowledge and experience into IPSEpro through EPP_Lib (Enginomix

Power Plant Library), which they will use to build your plant models.

improved greatly over the years, so that now, with software like IPSE

design performance of any power plant or cogeneration system with


collaborative Zefficiency web technology, you can bring modeling experts on to your

advantage of a new business model - Software-as-a-Service – to let Enginomix

and maintain your power plant models for you in the cloud:

Access your models from any device with a web browser

Use the collaborative features of Zefficiency to ask questions and get help running and changing


Get immediate access to updated software and models as they are uploaded by Enginomix

Leave comments and suggestions for changes, and get immediate feedback

page 3

publish your IPSEpro


. By taking advantage of Zefficiency, you don’t have to

software on your PCs, and all of your users will always have secure access to the latest

class modeling expertise

renowned experts in power plant

the book Power

as well as being the primary authors of

the first integrated design/off-

performance monitoring system built

by GE). Enginomix

PP_Lib (Enginomix

over the years, so that now, with software like IPSEpro with

lant or cogeneration system with


bring modeling experts on to your

let Enginomix experts build

k questions and get help running and changing


Get immediate access to updated software and models as they are uploaded by Enginomix

IPSEpro Cloud


Easy-to-Use Power Plant Models: No Experience Necessary

Your IPSEpro models on the Zefficiency portal are easy to use: no

needed. However, this does not mean that the models are simple, or lack

the contrary, behind the scenes you are running a full version of the IPSEpro thermodynamic modeling

software that has been in continuous development and use since 1989. You can use IPSEpro to model

gas turbine combined cycles, cogeneration (combined heat and power) plants, conventional steam

power plants, district heating plants, and more

scenes to support you and your plant models.

Because your IPSEpro models are based on w

models are fully-predictive simulation tools capable of predicting full

a range of ambient conditions, at different cogeneration loads,

leakage, and with some equipment in

• Plant overall gross & net power

• Plant overall gross & net efficiency and heat rate

• Total (CHP or cogen) efficiency

• Revenue from power and steam sales

• Fuel expenses

• Individual unit and/or generator output powers

• Unit-by-unit fuel consumption

• BOP power breakdown

• Pressures, temperatures, flows at key locations in the plant

• Process steam delivery and return flows

• Stack gas flow rate and composition

• Water consumption and discharge breakdown

• Feedwater flows


DRAFT

Models: No Experience Necessary

Your IPSEpro models on the Zefficiency portal are easy to use: no previous modeling experience is

. However, this does not mean that the models are simple, or lack key details and features. On



, cogeneration (combined heat and power) plants, conventional steam

power plants, district heating plants, and more, with the experts from Enginomix working behind the

scenes to support you and your plant models.

Because your IPSEpro models are based on well-proven and validated engineering software, your

predictive simulation tools capable of predicting full- and part-load performance across

range of ambient conditions, at different cogeneration loads, under varying levels of degradatio

with some equipment in- and some out-of-service. Example outputs include

Plant overall gross & net power

Plant overall gross & net efficiency and heat rate

) efficiency

and steam sales

generator output powers

unit fuel consumption

ressures, temperatures, flows at key locations in the plant

Process steam delivery and return flows

Stack gas flow rate and composition

and discharge breakdown

page 4

previous modeling experience is

key details and features. On



, cogeneration (combined heat and power) plants, conventional steam

, with the experts from Enginomix working behind the

software, your

load performance across

under varying levels of degradation and

include:



Unique advantages

The combination of IPSEpro software delivered by Enginomix through the Zefficiency web portal offers

users a unique set of advantages they can use to improve the performance of their plant:

• Model-based analysis with integrated design/off-design calculations

• Modular, state-of-the-art software with key advanced features including data validation,

optimization module, and open-equation modeling

• Enginomix expertise and experience

• Software-as-a-Service

Model-based analysis with integrated design/off-design calculations

With IPSEpro, you can build complete-plant, engineering-based models of your plant with off-design

analysis capabilities. You can use these models to forecast and study the performance, heat rate and

capacity of your power plant at any operating and load condition. You can use the models to check and

confirm claims made by vendors about the performance of current or proposed equipment. You can

predict the capacity, heat rate and economic impact of proposed operation or equipment changes to

your plant. Many of these kinds of calculations are difficult or impossible with traditional plant

calculation software tools that only focus on select pieces of equipment or simplified correction curves.

Modular, state-of-the-art open-equation software

IPSEpro software includes state-of-the-art software engineering techniques to provide you with a

flexible set of well-integrated software modules that work together to give you powerful and flexible

tools you can use to improve your plant’s performance. With IPSEpro’s PSValidate and PSOptimize

modules, you can take advantage of advanced analysis features such as data validation and

optimization, using the same plant models as you use for general plant design and analysis. And you can

take advantage of IPSEpro’s open architecture, both internally and externally. Internally, IPSEpro’s open-

equation architecture enables you to review all the engineering and equations in your models, and

quickly and easily adjust or add equations to tailor the calculations to your plant’s unique characteristics.

Externally, IPSEpro offers a well-designed and well-documented open software architecture so you can

integrate IPSEpro models with other software quickly and easily. This well-designed state-of-the-art

open software architecture is what enables IPSEpro to be made available through Zefficiency, since most

power plant engineering software still uses decades-old closed software tools and technologies.

Enginomix expertise and experience

The key people developing and supporting the IPSEpro modeling and performance monitoring solutions

offered through the Zefficiency web portal are seasoned industry experts, each with 20+ years of

experience developing and delivering software solutions for power plant design and performance

monitoring. Dr. Rodney Gay pioneered the concept of model-based performance monitoring, and he

helped design and implement GE “Smart-Plant” program. Dr. Gay, along with Dr. Michael Erbes, founded

Enter Software, Inc. in 1988, which was purchased by GE in 1999. While with Enter Software, Drs. Gay

and Erbes developed the GateCycle and EfficiencyMap software packages, which are now the standard

power plant engineering software used by GE for detailed combined cycle and steam turbine system

design and analysis. EfficiencyMap monitoring software has been installed at hundreds of power plants

around the world. Later, after leaving GE in 2004, Dr. Erbes founded Enginomix, which focuses on

developing and delivering state-of-the-art engineering software tools and services for the design,

analysis and optimization of power plants.



Software-as-a-Service

Under the Software-as-a-Service concept made possible by IPSEpro on the Zefficiency web

portal, you don’t need to install special software on your PCs or be a modeling expert to build

and run complex models. All you need to run your plant’s models on your PC is a web browser,

and secure access through the internet to the Zefficiency web portal for your plant. With

IPSEpro under Zefficiency, you can access and run detailed plant models for your plant, built

and supported by the modeling experts at Enginomix and delivered through the Zefficiency

portal. You will be able to use the Zefficiency portal to run models, collaborate with other users

at the plant and elsewhere in your company, and interact with modeling experts at Enginomix

who will help you with any questions or problems you may run into. Through the Zefficiency

web portal, you can also access and run individual equipment models and power plant

modeling tutorials, review training and background material on plant modeling provided by

Enginomix, and leave comments, suggestions and questions for other users and for Enginomix.

IPSEpro Cloud


IPSEpro – the Perfect Off-Design Modeling T

Power plants almost never run at their design

ambient, load, cogeneration requirements and equipment degradation. Since your power plant is never

running at design, you need software that can model the

such as IPSEpro with EPP_Lib.

Some of the key drivers for off-design

• ambient variations

• changing cogeneration steam

• equipment degradation

• load-following

• fuel variations

Unlike most power plant modeling software,

detailed off-design performance analysis of

world that can make this claim is GateCycle, which was de

can use IPSEpro with confidence to analyze the performance of your power plant.

• By combining detailed equipment models using the IPSEpro process modeling framework,

complete plant performance codes can be readi

• IPSEpro off-design performance models enable plant engineers to analyze more situations and

investigate new operating and control strategies than is possible with traditional, stand

equipment-based design and performance codes

• Careful preparation and support of your IPSEpro plant models by experienced engineering

modeling experts from Enginomix ensure the accuracy and usability of your models


DRAFT

Design Modeling Tool

ower plants almost never run at their design point. Power plant performance varies due to changes in


running at design, you need software that can model the off-design performance of your plant, softw

esign operation of a power plant include:

team requirements

Unlike most power plant modeling software, IPSEpro was designed from the ground up

design performance analysis of power plants (the only other power plant software in the

world that can make this claim is GateCycle, which was developed by the founders of Enginomix). So you

can use IPSEpro with confidence to analyze the performance of your power plant.

By combining detailed equipment models using the IPSEpro process modeling framework,

complete plant performance codes can be readily developed

design performance models enable plant engineers to analyze more situations and

investigate new operating and control strategies than is possible with traditional, stand

based design and performance codes

eparation and support of your IPSEpro plant models by experienced engineering


page 7

point. Power plant performance varies due to changes in


performance of your plant, software

designed from the ground up to be used for

power plants (the only other power plant software in the

veloped by the founders of Enginomix). So you

By combining detailed equipment models using the IPSEpro process modeling framework,

design performance models enable plant engineers to analyze more situations and

investigate new operating and control strategies than is possible with traditional, stand-alone

eparation and support of your IPSEpro plant models by experienced engineering


IPSEpro Cloud


IPSEpro Individual Equipment Models and Thermodynamic Tutorials

In addition to detailed integrated models of your power plant, through the Zefficiency IPSEpro portlet

you will have access to a full range of individual equipment models and tutorials. Your users will be able

to use the tutorials to brush up on their

analyze the performance of key equipment

of modeling detail in the individual equipment models as in

Gas Turbines

Cooling Towers

Air-Cooled Condensers


DRAFT

Equipment Models and Thermodynamic Tutorials



to use the tutorials to brush up on their engineering skills and use individual equipment models to

equipment, separately from the rest of the plant. We use t

of modeling detail in the individual equipment models as in your IPSEpro complete plant

Steam

Condensers

Steam Turbines

PC Boilers

page 8



and use individual equipment models to

We use the same level

complete plant models.

Condensers

urbines

IPSEpro Cloud


IPSEpro What-If Models

• Calculate expected (target) plant power and heat rate for performance monitoring

• Predict changes in plant performance when operating conditions change or maintenance actions

are taken

• Study impact of suggested control and maintenance actions

• Forecast plant power and heat rate at

Enginomix will build and deliver a tuned predictive

predict plant performance in response to changes in operating conditions, load and key degradation

factors. Enginomix will demonstrate the accuracy of the

historical plant data. The What-If mod

plant performance in the future, and Enginomix will help them do it.

IPSEpro Heat Balance Calculations

IPSEpro heat balance models provide

accurate current operating data for

� Uses mass & energy principles to match/validate plant data

� Provides best estimates of current

� Provides calculated values for:

• Unreliable measurements (e.g. fuel flow, flue gas temps)

• Performance parameters (e.g., gas turbine,

• Non-measured parameters (e.g. flue gas flow, extraction flows, condenser duty, condenser

cooling water flow)


DRAFT

Calculate expected (target) plant power and heat rate for performance monitoring

in plant performance when operating conditions change or maintenance actions

tudy impact of suggested control and maintenance actions

orecast plant power and heat rate at future operating conditions

Enginomix will build and deliver a tuned predictive What-If model for each plant, able to accurately


Enginomix will demonstrate the accuracy of the What-If calculations through comparison with

models for your plant will enable plant engineers to optimize and tune

plant performance in the future, and Enginomix will help them do it.

Calculations

provide plant owners and operators with a complete set

accurate current operating data for their plant, including parameters that cannot be measured.

Uses mass & energy principles to match/validate plant data

s of current plant operating conditions

Unreliable measurements (e.g. fuel flow, flue gas temps)

Performance parameters (e.g., gas turbine, boiler & steam turbine efficiencies)

measured parameters (e.g. flue gas flow, extraction flows, condenser duty, condenser

page 9

Calculate expected (target) plant power and heat rate for performance monitoring

in plant performance when operating conditions change or maintenance actions

model for each plant, able to accurately


calculations through comparison with

plant will enable plant engineers to optimize and tune

of consistent,

plant, including parameters that cannot be measured.

)

measured parameters (e.g. flue gas flow, extraction flows, condenser duty, condenser

IPSEpro Cloud


IPSEpro Performance Calculations

What are Performance Calculations? They characterize the ability and effectiveness of equipment or

complete plant processes. Typical measures of performance include

• Capacity (Output)

• Efficiency/Heat Rate (Conversion effectiveness)

• Operating Margin (Revenues

Loss in equipment performance is d

should be and where you are. You can determine w

running your detailed IPSEpro What

and load). You can determine where you are

the plant and running it through IPSEpro model

validation functions (to correct for errors in the measurements). You can then

degradation at your plant by comparing your expected and current performance trends.


DRAFT

Calculations


ical measures of performance include:

Efficiency/Heat Rate (Conversion effectiveness)

Operating Margin (Revenues – Cost)

degradation, which is defined as the difference between where you

You can determine where you should be (your expected

running your detailed IPSEpro What-If plant models at your current plant operating conditions (ambient

here you are (your current performance) by using measured d

the plant and running it through IPSEpro model-based heat balance calculations with advanced data

validation functions (to correct for errors in the measurements). You can then evaluate equipment

at your plant by comparing your expected and current performance trends.

page 10


, which is defined as the difference between where you

expected performance) by

at your current plant operating conditions (ambient

) by using measured data from

calculations with advanced data

evaluate equipment

at your plant by comparing your expected and current performance trends.

IPSEpro Cloud


IPSEpro Software

IPSEpro is a commercially available process modeling software package developed by SimTech of Graz,

Austria. It is used to perform detailed steady

systems.

With IPSEpro, users graphically construct a model for their power plant model using icons representing

plant equipment. In IPSEpro design mode, the user specifies the performance

information from the equipment vendors and current

calculates (“sizes”) the equipment to match the specified

IPSEpro works in the other direction: the user defines

the corresponding “as-built” performance.

number of cases covering variations in design parameters as well as plant

design” conditions.

IPSEpro Advantages

• Open-equation libraries: EPP_

GateCycle, and equations can be reviewed (and easily customized and enhanced) by users.

• Integrated online monitoring software modules

• Optional data validation calculation module (PSValidate)

• Additional model libraries available for flue

modeling fuel processing, ash handling and other applications)

• Integrated Off-Design Modeling Capabilities:

the off-design calculations are part of the same plant models and calculation framework as the

design-point models


DRAFT


Austria. It is used to perform detailed steady-state design and off-design analyses of thermal power

sers graphically construct a model for their power plant model using icons representing

design mode, the user specifies the performance attributes required

information from the equipment vendors and current plant measurements. The software then

equipment to match the specified performance criteria. In off-design

works in the other direction: the user defines operational conditions, and the model

built” performance. IPSEpro models are extremely flexible, allowing an indefinite

variations in design parameters as well as plant performance under “off

: EPP_Lib (developed by Enginomix) includes icon models equivalent to


Integrated online monitoring software modules (IPSEpro Plant Operation Suite)

calculation module (PSValidate)

available for flue-gas cleaning and detailed solid-stream modeling (for

modeling fuel processing, ash handling and other applications)

Design Modeling Capabilities: Unlike most power-plant software, with I

design calculations are part of the same plant models and calculation framework as the

page 11


design analyses of thermal power

sers graphically construct a model for their power plant model using icons representing

attributes required using

. The software then

design mode,

the model calculates

extremely flexible, allowing an indefinite

performance under “off-

Lib (developed by Enginomix) includes icon models equivalent to


(IPSEpro Plant Operation Suite)

stream modeling (for

plant software, with IPSEpro

design calculations are part of the same plant models and calculation framework as the



Using IPSEpro and Zefficiency for Acceptance Testing

With its power and flexibility, IPSEpro is the ideal modeling package for you to use acceptance test

calculations. Power plants are made up of many different pieces of thermal equipment which are

individually designed, usually by different vendors, but interact with each other once the system is put

together. Each piece of equipment may not be operating at its design point even when the whole plant

is at its design conditions. Performance data from the vendor on each piece of equipment is in its own

unique format. To further complicate matters, cogeneration plant performance is strongly dependent

on ambient conditions, host steam loads and process return flows. These external constraints will never

be or remain at the ‘guarantee’ conditions during an acceptance test run. Because of all these factors,

some method of correcting acceptance test data to the guarantee point conditions which is consistent

with each vendor’s performance calculations is necessary for accurate assessment of plant performance.

Accuracy is important for all parties involved, as performance margins are very tight in today’s

competitive plant development environment.

One unique aspect about IPSEpro is that the design of individual power plant components can be

individually configured, and then linked together in a complete-plant off-design model to evaluate the

performance of the full, integrated system. This approach is especially useful for studies involving plant

retrofit, such as gas turbine upgrades, repowering of steam turbines, hot-windbox repowering, and

existing plant modification studies. One useful feature of the IPSEpro modeling approach is that the

individual design of each component can be easily updated with new vendor data, without affecting the

other component models.

ipsepro cloud-based power plant modeling with zefficiency · ipsepro is a thermodynamic process...

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