ABB PSPG-E7

Optimax Plant Performance Monitoring

Key performance indicators,
controllable losses, what-if
ABB Group
May 8, 2014 | Slide 1
ABB
OPTIMAX Plant Performance Monitoring
Challenge

Power plant operators are in charge to keep up efficiency

under continuously changing loads.
Power plant maintenance staff shall reduce both unplanned
outages and maintenance costs.
Power plant managers strive for meaningful figures for
strategic decisions.

ABB Group
May 8, 2014 | Slide 2
ABB
OPTIMAX Plant Performance Monitoring
Solution

Features
Standard tool library (ISO, ASME, DIN)
for easy calculation engineering
Calculates deviations between actual
and expected performance
Converts performance deviation to
short- and long-term degradation
Interface to ABBs Power Generation
Information Management System
(PGIM)

ABB Group
May 8, 2014 | Slide 3
ABB
OPTIMAX Plant Performance Monitoring
Starting point: monitoring of process values in DCS

Process values alone usually give no information

about the efficiency or the process quality of a plant

12.8
12.0 12.4 11.8
12.3
123,453 12,2 23.4
12,5 2,4
3,7
0,2233
23.4
4,0 12.4
12.6 23.4

ABB Group
May 8, 2014 | Slide 4
ABB
OPTIMAX Plant Performance Monitoring
Determination of performance indicators

Performance indicators are determined by using

multiple process values

90% 39% 12.8

12.0 12.4 11.8 87%
72% 12.3
123,453 12,2 23.4
12,5 2,4
3,7
0,2233
23.4
4,0 12.4
12.6 23.4

96% 68% 72%

ABB Group
May 8, 2014 | Slide 5
ABB
OPTIMAX Plant Performance Monitoring
Key performance indicator example: condenser

T1 T2

FCoolWater TC = Tsaturated (PCondenser)

Qth = FCoolWater * spec.HeatCoeffWater * (T2 - T1)

A = Condenser Surface

Heat Transfer Coefficient kActual =

Source:
ABB Technik 3/1997
ABB Group
May 8, 2014 | Slide 6
ABB
OPTIMAX Plant Performance Monitoring
Key performance indicators module library

Steam Generators Air preheaters

(fossil-fired, SG) Condensers
Heat Recovery Steam Pumps, fans
Generators (HRSG)
Generators
Combustion stoichiometry
(for SG or HRSG) Overall plant balance
Gas turbines Auxiliary power and steam
Steam turbines District heat
Feed water heaters Process steam
Evaporators Mathematical and statistical
calculations
Super heaters
Water/steam properties
Heat exchangers
Gas properties
Desuperheaters

ABB Group
May 8, 2014 | Slide 7
ABB
OPTIMAX Plant Performance Monitoring
Generation of reference values

dP primary air fan [mBAR] over Current primary air fan [A] from
20.04.2011 to 01.05.2012
Online calculation of
reference values depending
180
on e.g.
160
Temperature
140

120 Air pressure

100
Load
80
y = -0.006x2 + 1.8903x + 22.553
R = 0.9694
Fuel sort
60

40 ...
20
Reference characteristics
0
0 20 40 60 80 100 120
extracted from heat
balance sheets or fitted to
archived process data from
acceptance tests of new
plant or after major retrofit
ABB Group
May 8, 2014 | Slide 8
ABB
OPTIMAX Plant Performance Monitoring
Calculations configuration

ABB Group
May 8, 2014 | Slide 9
ABB
OPTIMAX Plant Performance Monitoring
Controllable losses
Controllable losses include measured process
values that can be controlled by the plant
operator and having a known impact on plant
energy losses when deviating from the design
point, e.g.:
ABB Group
May 8, 2014 | Slide 10
ABB
Flue-gas temperature at boiler exit
O2 flue gas concentration at boiler exit
Electrical auxiliary power
Condenser pressure
Condensate water temperature at feed
water tank inlet
Feed water temperature at boiler inlet
Feed water temperature at economizer
outlet
Live steam temperature
Live steam pressure
Process mimic presents for each controllable loss:
Actual measurement value
Design value (=expected value)
Impact on plant efficiency / heat rate
Additional plant fuel consumption due
to actual deviation from design value
OPTIMAX Plant Performance Monitoring
What if calculations

Replace controllable losses

actual measurement values
by manually defined What-
if values.
The calculation shows the
impact of all deviations of
controllable losses from
their design values.

ABB Group
May 8, 2014 | Slide 11
ABB
OPTIMAX Plant Performance Monitoring
Report of performance calculations

Standard Reports e.g.:

Consumed and produced quantities
Components operating hours
Actuators number of switching cycles
Report of Performance Calculations
e.g.:
Performance values averages,
standard deviations
Performance values averages
clustered into specific
component/unit operation
ranges/modes

ABB Group
May 8, 2014 | Slide 12
ABB
OPTIMAX Plant Performance Monitoring
Report configuration

ABB Group
May 8, 2014 | Slide 13
ABB
OPTIMAX PlantPerformance
Standard calculation of performance deviations

act exp
Calculation according
to implemented Reference value
standards

reference
Measured
characteristic
inputs
curves

act
p1 p2 T1 Tamb FCW KPI=
exp

ABB Group
May 8, 2014 | Slide 14
ABB
OPTIMAX PlantPerformance
Identifying the origin of performance deviations

Total Plant
exp
act

exp exp
act act

Plant Area 1 Plant Area 2

exp exp
act act

Component 1 Component 2
ABB Group
May 8, 2014 | Slide 15
ABB
OPTIMAX Plant Performance Monitoring
Benefits

Applicable for different plant

types
Increases overall plant
efficiency by detecting sub-
optimal operation modes
Improves plant availability
and predictive maintenance
strategies by detecting
material degradations

ABB Group
May 8, 2014 | Slide 16
ABB
OPTIMAX Plant Performance Monitoring
Key performance indicators for steam power plants

Steam generator Preheater

Thermal efficiency according to Logarithmic linear medium
DIN or ASME PTC temperature difference
Efficiency economizer Heat rate impact
Efficiency feed water preheater Efficiency
Condenser Steam turbine
Expected condenser pressure Thermal efficiency/ heat rate
impact
Cleanliness/heat rate
Isentropic heat power extractions
Shaft power
Unit balances
Heat rate of unit

Auxiliary power consumption

Auxiliary steam consumption
Heat flow to district heating
ABB Group
May 8, 2014 | Slide 18
ABB
OPTIMAX Plant Performance Monitoring
Key performance indicators for combined cycle power plants

GT calculations acc. ISO2314, DIN4341, HRSG calculations acc. ASME-PTC4.4

ASME-PTC22 Calculate actual thermal efficiency
Calculate actual efficiency and exhaust according to either:
mass flow and enthalpy
input / output method
Correct expected power and efficiency
to ISO conditions based on correction thermal loss method
curves for: Calculate actual exergetic efficiency
ambient air pressure, temperature, Expected efficiency based on
humidity correction curves can be calculated
dp inlet and exhaust by using the math and core tools

grid frequency
Calculate expected power and efficiency
from design curves

ABB Group
May 8, 2014 | Slide 19
ABB