ABB PSPG-E7

MODAKOND
More efficient and dynamic unit control

© ABB Group
May 8, 2014 | Slide 1
© ABB
OPTIMAX® MODAKOND
Challenge

 Conventional solution for frequency control

(or to improve control performance for flexible plant
operation):
 throttling the turbine control valves

 Major drawback:
 Throttling losses reduce plant efficiency

 How to activate available energy reserves in order to

significantly reduce or completely eliminate throttling of the
turbine control valves (TCV)?
 Requires a perfect coordination of such reserves in order to
maintain stability of operation

© ABB Group
May 8, 2014 | Slide 2
© ABB
OPTIMAX® MODAKOND
Solution features

 Model based coordinated operation mode for boiler and

turbine
 Feed forward strategy combined with dynamic decoupling
of the closed-loop-control
 Integration of different actuators for economic provision of
primary control like
 Condensate throttling
 Throttling extraction steam to HP preheaters
 Frequency control in boiler- or turbine- follow mode with
initial pressure control or position control of the turbine
inlet valves
 For sliding or fixed pressure mode or combined
sliding/fixed pressure mode

© ABB Group
May 8, 2014 | Slide 3
© ABB
Compliance with the Grid Code requirements
Variant I: coordinated boiler following mode for sliding
pressure operation
setpoint fuel
remote dispatcher setpoint
90
load setpoint
p
LS
turbine valve
k * f grid-frequency PEI
position controller deviation %

+ – P (boiler output load)

dynamic dynamic dynamic dynamic 80 SG
pressure feed-forward MW model feed-forward
model control boiler control turbine
30 s 10 min time

+
– +
pressure
controller – turbine load
controller RH

G
– + P–
P
EI

fuel
controller

© ABB Group
May 8, 2014 | Slide 4
© ABB
Grid requirements for a fast grid-frequency support by
fossil fired power plants (Grid Code in Europe)

P
PN

% Load increase requirement for low

grid load (3GW sudden loss, total
grid load 150 GW)
2

5 seconds 30 time
Load increase requirement for high grid load
(3GW sudden loss, total grid load 300 GW)
© ABB Group
May 8, 2014 | Slide 5
© ABB
Individual calculation of the boiler steam storage
capacities using measured data

Measured responses for the boiler for a

negative step of turbine load unit load 271 MW 168 MW

utilized
live-steam flow 987 kg 1483 kg
live-steam

pressure
6,7 bar 10,0 bar
increase
live-steam
pressure

steam storage
147,0 kg/bar 148,3 kg/bar
capacity
position of the
turbine inlet
valves
steam storage
time constant 72,8 s 112,0 s
TS

© ABB Group
May 8, 2014 | Slide 6
© ABB
OPTIMAX® MODAKOND
Achieved results with MODAKOND at a 550 MW PP

setpoint fuel flow

setpoint fuel flow

current boiler load load

load setpoint generator load

model boiler load

utilized energy by MODAKOND
restored energy for MODAKOND

utilized energy by throttling restored energy for throttling

simulated grid-frequency drop

© ABB Group
May 8, 2014 | Slide 7
© ABB
Efficiency gain by MODAKOND (ABB patent)

 Enhancement of overall efficiency owing to reduction in

auxiliary load in comparison with an unit control system
without a valve position controller in the modified sliding
pressure range.
 Numerical example for a 700 MW unit:
 6,000 hours per annum in modified sliding pressure
operation with an average load of 88 %, 3 bar throttling
pressure error at the turbine inlet valves, 250 bar rated live
steam pressure, 23 MW power rating of the electrical feed
water pumps
 MODAN leads to approx. 1.2 % less pump power
consumption
 Result: Reduction in annual auxiliary load by 1,450 MWh

© ABB Group
May 8, 2014 | Slide 8
© ABB
Features of model-based unit control MODAKOND

 Full-coordination of boiler and turbine

 Applicable for power plants with fixed-pressure or sliding pressure,
which also may have district heating (additional extraction steam)
 Including the coordinated boiler and turbine following modes
with/without throttle-pressure control
 Application does not use the live-steam flow measurement
 Application runs on different HW/SW platforms
(also on non-ABB control systems)
 Primary frequency control
 fulfilling the Grid Code requirements
 without using the throttling reserve for unit load ramps
 Secondary and tertiary control support (remote dispatcher)

© ABB Group
May 8, 2014 | Slide 9
© ABB
 Variants

© ABB Group
May 8, 2014 | Slide 10
© ABB
MODAKOND variant for existing units
(only condensate stop without additional actuators)

remote dispatcher setpoint

unit setpoint
turbine valve grid-frequency
p k * f
LS
+– position controller deviation

dynamic dynamic dynamic

dynamic
pressure feed-forward feed-forward
MW model
model control boiler control turbine

+
– +
pressure
controller – turbine load
controller RH
dynamic
feed-forward G
– + control
P–
P
EI
fuel
controller

Coordinated boiler following mode for sliding pressure operation 4 3 2 1

© ABB Group
May 8, 2014 | Slide 11
© ABB
Efficiency increase up to 0.4% through MODAKOND
(ABB-CONDSTOP: coordin. condensate & ext. steam stop)

turbine valve throttling in %

remote dispatcher setpoint 18

15 MODAN
load setpoint
turbine valve grid-frequency 12
p k * f deviation
LS
+– position controller
MODAKOND
6
dynamic dynamic dynamic (ABB-CONDSTOP)
dynamic
pressure feed-forward feed-forward
MW model
model control boiler control turbine
0 40 70 100

+
load in %
– +pressure
controller – turbine load
controller RH
dynamic
feed-forward G
– +fuel
control
P–
P
EI

controller ABB-CONDSTOP

Coordinated boiler following operation mode 4 3 2 1

© ABB Group
May 8, 2014 | Slide 12
© ABB
Ranking of the measures for primary frequency support
using the existing plant equip., off-line simulation possible

The fuel over-firing can be reduced by reducing the

steam flow to the HP heater and condensate stop.

760 MWs throttling

reserve HP heater
A7

Condensate stop

Time [s]
The parallel operation of the condensate stop and HP-heater "throttling” is reducing the
necessary turbine throttling by 75% auf 760 MWs (without this countermeasures a throttling
reserve of 3.100 MWs are necessary).
© ABB Group
May 8, 2014 | Slide 13
© ABB
Ranking of the measures for primary frequency
support depending on the grid-frequency deviation

35

HP heater 30

25

20
condensate stop
power contributions [MW]

15

10
throttling of the turbine
5

0
-250 -200 -150 -100 -50 0 50 100 150 200 250
-5

-10

-15

-20

-25

-30

-35
frequency deviation [mHz]

© ABB Group
May 8, 2014 | Slide 14
© ABB
OPTIMAX® MODAKON
Benefits

 Increase in economic efficiency by reducing the throttling

of the turbine inlet valves
 Faster load ramps for increased flexibility
 Feasibility of primary and secondary frequency control
 Gentle operation of the main components with minimized
control work
 Reduced minimum load for low load running

© ABB Group
May 8, 2014 | Slide 15
© ABB
Reference plants for MODAKOND (I)

Nominal Constant/
Power power sliding Fuel Boiler type Project Remarks
plant (gross) pressure status

quick-acting condensate control

modified valve and 3 rotary dampers:
RDK 7 550 MW sliding hard coal Benson completed  gland steam supply of the
(Germany) pressure (oil) supercritical 1985 feedwater tank,
 bleed pipes for the LP heaters 3
&4
(scope of supply: concept and basic
design of the ABB-CONDSTOP)
district heating (300 MWth), 3
modified quick-acting rotary dampers:
Rostock 550 MW sliding hard coal Benson completed  gland steam supply of the
(Germany) pressure (oil) supercritical 1995 feedwater tank,
 bleed pipes for the LP heaters 3
&4
extraction steam and operation of a
modified railway steam turbine (16 2/3 Hz,
Schkopau 1 x 373 MW sliding brown/ Benson completed 110 MW), 2 quick-acting rotary
(Germany) 1 x 391 MW pressure lignite coal supercritical 1996 dampers:
(oil)  gland steam supply of the
feedwater tank,
 bleed pipe for the LP heaters 4
Westfalen modified rehabilitation, unit with condensing
unit C 320 MW sliding hard coal Benson Completed turbine, 1 quick-acting rotary
(Germany) pressure (oil) 1997 damper only for the gland steam
supply of the feedwater tank

© ABB Group
May 8, 2014 | Slide 17
© ABB
Reference plants for MODAKOND (II)

Nominal Constant/
Power power sliding Fuel Boiler type Project Remarks
plant (gross) pressure status

Staudinger district heating, ABB-Condstop with

5 modified hard coal 1999 3 quick-acting rotary dampers:
550 MW sliding (oil) Benson completed  gland steam supply of the
Germany pressure supercritical feedwater tank,
 bleed pipes for the LP heaters 3
& 4.
Heyden
920 MW modified hard coal Benson 1999 unit with condensing turbine,
Germany sliding (oil) supercritical completed only condensate flow throttling
pressure
2001 cogeneration plant
Zolling 450 MW modified hard coal (pre-study (district heating)
sliding (oil) Benson with site only condensate flow throttling
Germany pressure tests and
simulation)

Weiher III natural hard coal unit with condensing turbine,

703 MW sliding (heavy oil) Benson 2002 only condensate flow throttling
Germany pressure

© ABB Group
May 8, 2014 | Slide 18
© ABB