SP Pel | eer estore eh; EPRI EL3339 Performance testing Volume 2 ‘On-line measurement systems Project 1737-2 Data acquisition Final Report Control systems July 1984 Heat rate Fossil fuel power plants Current Fossil Fuel Power Plant Performance Monitoring Volume 2: Recommended R&D Programs Prepared by The Babcock & Wilcox Company Lynchburg, VirginiaCurrent Fossil Fuel Power Plant Performance Monitoring Volume 2: Recommended R&D Programs EL-3339, Volume 2 Research Project 1737-2 Final Report, July 1984 Prepared by ‘THE BABCOCK & WILCOX COMPANY Research and Development Division Lynchburg Research Center Lynchburg, Virginia 24505 Principal Investigator RR. Dixon Subcontractor STAG SYSTEMS, INC. 17822 17th Street, Suite 105 ‘Tustin, California 92680 Principal Investigator H. D, MeNair Prepared for Electric Power Research Institute 3412 Hillview Avenue Palo Alto, California 94304 EPRI Project Manager JW. Lamont Power System Planning and Operations Program Electrical Systems DivisionORDERING INFORMATION Requests for copies of this report should be directed to Research Reports Center (AAC), Box 50490, Palo Alto, CA 94303, (415) 965-4081. There is no charge for reports requested by EPRI member uilities and affiliates, U.S. utility associations, U.S. government fagencies (federal, state, and local), media, and foreign organizations wih which EPRI has an information exchange agreement. On request, ARC will send a catalog of EPRI repor's. Research Catagory: lant sts an prlormance assessment Copyright © 1888 Electric Power Research Insure Arighs reserved NoTICe “nis rpert was preparedby In egensaions) med el as an acount ct work sponsored the lei: Ponce Resour situ, ne EPR, Nether EPR menbors oF EPA, the organizations) nammedBeon, nor any pots acting ontehal fen of her: fakes any waranty expres or mped, wth respect 0 he seo ry Plomaton aoparahs, menos of process daoved inthis eprtor at sch use may not ning patel ‘mou gna or) assumes ny Tabives wth respect 0 the we oo” damages reeuig om the vse ot ‘ry infomation, appara mathod,o process dataset his enor Prepared by ‘Te Babcock & Wacox Company Lynne, VineABSTRACT A screening of 7 suggested research needs to improve economic performance of fossil Generating units and related dispatch operations was performed by a sixteen menber Industry Advisory Group along with project members, Each of the 77 topics, their ranking, and the ranking procedure are described. Those topics with high priority rankings (44 out of 77) were strategically grouped into 19 reconmended research pro- Jects, The areas addressed by the 19 projects are: © On-line Heat Rate Measurement ® system Control center Operation © Instrumentation © Diagnostics © Plant Controls and Operating Procedures Each project is described including motivation, objectives, scope, task descrip- tions, resources required, estimated costs, re'ated current projects, and reconmend- ed schedule and priority. The recommended projects are identified as prerequisite, contingent, or independent and other important interactions between them are described. iiEPRI PERSPECTIVE PROJECT DESCRIPTION This scoping study for project RP1737-2 was undertaken to define and provide direc- tion to EPRI and the power industry for future work related to power plant perfor- mance and economic dispatch. In the preparation of this report, The Babcock & Wilcox Company utilized the results of previous EPRI activities in this area. Babcock & Wilcox supplemented these results with a limited number of direct utility interviews. Two reports, of which this is the second, were developed. The first report summa- rizes the current state of the art regarding plant instrumentation, computer pro- grams, control systems, and operating procedures being used in heat rate improvement activities. This report provides more detailed R&D recommendations for a set of coordinated research projects. PROJECT OBJECTIVES The primary objective of this project was to recommend a coordinated approach to heat rate improvement and economic dispatch. Additional objectives were to deter- mine current industry practice related to heat rate improvement as a starting point and to provide useful information to member utilities. PROJECT RESULTS In identifying current industry practice, this project provided a base point for future EPRI research in this area. Several key items were identified as common to a large number of utilities; these are sunmarized below. Acceptance testing procedures are seldom used because of their time and cost re- quirements. Their use is then limited to guidelines for developing periodic and continuous performance monitoring procedures. Off-line performance analyses are generally done using one of three commercially available computer programs. On-lineanalyses, on the other hand, are performed using customized programs on small dedi- cated computers. Instrumentation is essential to performance measurement, with re- peatability and calibration maintenance as major problems. Moreover, digital com- puters with graphic cathode-ray tube displays are becoming more common in fossil Power plants for displaying information to plant operators. In addition, portable data loggers and instruments are becoming popular. Six of the many control functions have an effect on plant performance. These in- clude combustion controls, steam temperature controls, soot-blower controls, EPA emission controls, pressure controls, and turbine valve sequencing. Al] six would benefit by additional EPRI work. The project concluded that there is no typical utility or common practice regarding performance improvenent. Each utility has its own strategy, practice, and methods. Despite a tenfold increase in fuel costs, only a few utilities have any significant effort under way to improve the measurement of plant performance, which requires strong management support. After an industry survey, 44 high-priority research topics were grouped into five major research umbrella programs. These are on-line heat rate measurement, system control center operation, instrumentaticn, diagnostics, and plant controls and op- erating procedures. This report describes the five programs, including dissemina~ tion of results. fach project is described by the same format, which includes the following sections: motivation, objective, scope, task description, resources re- quired, cost, and related current projects. John Lamont, Project Manager Electrical Systems Division viCONTENTS Section Page 1 INTRODUCTION Lt 1.2 Objectives 1-3 143. Report Format 1-3 2 R&D TOPIC EVALUATION/SELECTION PROCEDURE aa 2.1 Advisory Committee Selection 2-1 2.2 Evaluation Procedure a1 3 PLAN OVERVIEW 341 3.1 Umbrella Program Definitions 3-1 3.2 Plan Objectives 3-2 3.3. Generic R&D Project Description 349 4 RECOMMENDED PROGRAMS 41 4:1. Unbrella Program A: On-Line Heat Rate Measurement 4-1 4.1.1 Static Heat Rate Measurement 4-3 4.1.1.1 Motivation 4-3 Objective 44 Scope 44 Task Description 4-4 Resources Required 4-6 Cost 4-7 Related Current Projects 4-7 Rate Measurement 4-7 Motivation 4-7 Objectives 4-8 Task Descriptions 4-8 Resources Required 4-10 Costs 4-10 Related Current Projects 4-11 viiSection 4.1.3 Guidelines for Heat Rate Measurement. 41.361 Motivation 4.1.3.2 Objectives 4.1.3.3 Scope 4.1.3.4 Task Descriptions 4.1.3.5 Resources Required 4.1.3.6 Cost 441.3.7 4.2. Unbrella Program B: Related Current Projects system Control Center Operation 4.2.1 Generating Unit Models and Dispatch Algorithms 4.2.1.1 Motivation 4.2.1.2 Objectives 4.2.1.3 Scope 4.2.1.4 Task Descriptions 4.2.1.5 Resources Required 4.2.1.6 Cost 4.20167 Related Current Projects 4.2.2 VoIt/VAR Dispatch Considerations 4.2.2.1 Motivation 4.2.2.2 Objectives 4.2.2.3 Scope 4.2.2.4 Task Descriptions 4.2.2.5 Resources Required 4.2.2.6 Cost 4.2.2.7 Related Current Projects 4.2.3 Performance Indices 4.2.3.1 Motivation 4.2.3.2 4.2.3.3 Objectives Scope 4.2.3.4 Task Descriptions 4.2.3.5 Resources Required 4.2.3.6 Cost 4.2.3.7 4.3. Umbrella Program Cz 43.1 Related Current Programs Instrumentation Instrumentation Accuracy Analysis Projects 4.3.1.1 Motivation 4.3. 2 Objectives 4.3.1.3, Scope Viti Page 4-11 ail 4-1 a Coty 413 413 4-13 4-13 414 414 4-15 415 4-16 4-18 419 4-19 4-20 4-20 4-20 4-20 4-21 4-22 4-22 4-23 4-23 4-23 4-24 4-24 4-25 4-28 4-28 4-29 4-29 4-30 4-30 4-30 4-30Section 4.3164 4.3.1.5 4.3.1.6 4.3.1.7 Task Descriptions Resources Required Cost Relaced Current Projects 4.3.2 Sensor Development Projects 4.3.21 4.3.2.2 4.3.2.3 463.264 4.3.25 4.3.2.6 4.3.2.7 Motivation Object ives Scope Task Descriptions Resources Required Cost Related Current Projects 4.3.3. Sensor Validation and Auto-Calibration 4.3.3.1 4.3.3.2 4.3.3.3 4.3.34 4.3.3.5 4.3.3.6 4.3.3.7 Motivation Objectives Scope Task Descriptions Resources Required Cost. Related Current Projects 4.4 Unbrella Program D: Diagnostics 441 Boiler Diagnostics 44 441.2 44.1.3 Adel 4 4415 4.4.1.6 447 Motivation Objectives Scope Task Descriptions Resources Required Cost. Related Current Projects 4.4.2 Control System Diagnostics 44.201 464.262 44.2.3 420d 44.2.5 4.4.2.6 Motivation Scope Task Descriptions Resources Required Cost Related Current Projects ix Page 4-31 4-33 4-33 4-34 4-34 4-34 4-37 4-37 4-37 4-38 4-38 4-39 4-39 4-39 4-39 4-39 4-40 4-42 4-42 4-43 4-43 4-44 4-44 4-45 4-45 4-45, 447 447 4-47 4-47 4-47 4-48 4-48, 4-50 4-50 4-50Section 4.4.3 44.367 Incipient Failure Detection 4.4.3.1 4.4.3.2 Motivation Objective Scope Task Descriptions Resources Required Cost. Related Current Projects 4.4.4 Maintenance Schedule Optimization 44e 4.5 Unbrella Program E: 4.5.1 4.5eLe1 4.5.1.2 4,561.3 4.5.1.4 4.56165 4.5.1.6 4.50167 Motivation Objectives Scope Task Descriptions Resources Required Cost. Related Current Projects Plant Controls & Operating Procedures Startup/Shutdown Procedures Motivation Objectives Scope Task Descriptions Resources Required Cost. Related Current Projects 4.5.2 Combustion Optimization 4.5.2.1 4.5.2.2 4.5.2.3 4.56264 4.5.2.5, 4.5.2.6 4.5.27 4.5.3 Online Boiler 4.5.3.1 4.5.3.2 4.5.3.3 4.5.34 Motivation Objectives Scope Task Descriptions Resources Required Cost. Related Current Projects Controls Motivation Objectives Scope Task Descriptions Page 4-50 4-50 4-51 4-51 4-51 4-52 4-52 4-53 4-53 4-53, 4-53 4-53 4-54 4-56 4-56 4-56 4-56 4-58 4-58 4-58 4-59 4-59 4-60 4-60 4-61 4-61 4-61 4-62 4-62 4-63 4-64 4-64 4-65 4-65 4-65 4-65 4-66Section 5 4.5.3.5 Resources Required 4.5.3.6 Cost 4.5.3.7 Related Current Projects 4.5.4 Operating Strategies 4.5.4.1 Motivation 4.5.4.2 Objectives 4.5.4.3 Scope 4.5.4.4 Task Descriptions 4.5.4.5 Resources Required 4.5.4.6 Cost 4.5.4.7 Related Current Projects 4.5.5. Economic Performance of Gas Cleanup Equipment 4.5.6 PROGRAM INTERACTIONS 5.1 5.2 Schedule Information 5.2.1 5.2.2 5.2.3 5.264 4.5.5.1 Motivation 4.5.5.2 Objectives 4.5.5.3 Scope 4.5.5.4 Task Descriptions 4.5.5.5 Resources Required 4.5.5.6 Costs 4.5.5.7 Related Current Projects Automatic Control System Tuning 4.5.6.1 Motivation 4.5.6.2 Objectives 4.5.6.3 Scope 4.5.6.4 Task Descriptions 4.5.6.5 Resources Required 4.5.6.6 Cost 4.5.6.7 Related Current Projects Flow Dynamic Heat Rate Measurement (A2)/Static Heat Rate Measurenent (Al) Generating Unit Models (B1)/Static Heat Rate Measurenent (Al) Sensor Development Projects (C2)/Instrumentation Accuracy Analysis (Cl) Sensor Validation (C3)/Instrumentation Accuracy Analysis (C1) xi Page 4-67 4-68 4-68 4-68 4-68 4-69 4-69 4-69 4-70 471 471 4-71 471 4-72 4-72 4-72 4-73 4-74 474 4-74 474 4-75 4-75 4-75 4-77 4-77 4-77 $1 S-1 5-2 5-4 54 5-5Section Page 5.2.5 Incipient Failure Detection (D3)/Boiler Diagnostics 5-5 (01) and Control System Diagnostics (D2) Maintenance Schedule Optimization (D4) /Diagnostics (01,02,03) and Static Heat Rate Measurement (A1) 5.2.7 Gas Cleanup Equipment Operation (£5)/Static Heat Rate Measurement 5.2.8 Automatic Tuning (E6)/Control System Diagnostics (D2) 5.3. Plan Guidel ines/Cautions 6 REFERENCES APPENDIX A APPENDIX 8 APPENDIX C APPENDIX 0 5.3.1 dustification 5.3.2 Prerequisite Projects 5.3.3. Field Testing Requirement 5.3.4 Instrumentation 5.3.5 Other Related Projects SCOPING STUDY ADVISORY COMMITTEE INITIAL R&D TOPIC DESCRIPTION, RANKING, AND COMMENTS ADVISORY COMMITTEE ADDITIONS TO R&D TOPICS FINAL RAD TOPIC EVALUATION RESULTS xii 5-5 5-5 5-6 5-6 5-6 5-6 5? 5-7 5-7 6-1 Ae Bel cl DelILLUSTRATIONS Figure Page 3-1. Unbrella Program Roles for Improving Generating Unit Performance 3-6 3-2 Umbrella Program Roles for Improving Economic Dispatching 3-8 5-1 Recommended Schedule 5-3 xitiTABLES Table Page 3+1 Unbrella Program Topics 3-3 xvSUMMARY INTRODUCTION This report is the second and final volume documenting work on the EPRI project 1737-2 "Power Plant Instrumentation Scoping Study" sponsored by the Electrical Systems Division, The first volume EL 3339-V1 described the performance monitoring instrumentation and methods currently used in the fossil utility segment. The information was based on many utility interviews and technical papers written for EPRI sponsored heat rate improvement workshops, Furthermore, coordination with EPRI Coal Combustion Division planning, a 16-menber utility advisory conmittee, and other significant EPRI projects provided additional clarification of the current performance monitoring capability in the fossil utility industry. The primary purpose of this report is to provide guidelines for planning R&D projects for economic performance improvements at both the generating unit and electrical systems levels. Based on the information developed for the first report, a set of R&D projects are recommended and described. The recommended projects address both generating unit improvements as well as related electrical system improvements, This broad scope R&D perspective attempts to coordinate related developments between the generating unit and the electrical systen to yield a more synergistic program than heretofore pursued, PROCEDURE To provide the basis for a comprehensive R&D p-ogram, an extensive 7-step screening process of various R&D topics was established. This procedure heavily involved a 16-menber utility advisory group composed of generating unit and electrical systems experts. These steps are described briefly below. Step 1 - Identify and prepare one paragraph descriptions of 77 R&D topics. These topics were drawn from a review of current in- dustry practices, utility technical papers, EPRI personnel, and various private contractors. SlStep 2- Distribute descriptions of 77 topics to industry advisors for independent ranking and conments. Step 3- Distribute individual rankings and comments to other industry advisors . Step 4 - Discuss each of the 77. topics with the Industry Advisors in a meeting following the Joint Power Generation Conference. This resulted in a second ranking of the 77 topics. Step 5 - Tabulate ranking based on equal weights and biased weights. This step was done to identify biases of the industry advisors based on their current areas of ~esponsibility. Step 6 - EPRI Electrical Systems and Coal Conbustion Divisions review resultant rankings and modify as necessary to avoid redundant projects and assure dissimination of results. Step 7 - Final review of rankings by project menbers. As a result of this screening procedure the original 77 topics were reduced to 44 high priority topics to incorporate into @ comprehensive plan. RECOMENDED RAD PROGRAM The two major objectives of the R&D prograns are to 1) improve fossil power plant economic performance, and 2) improve economic dispatch performance by using more accurate generating unit performance information. To accomplish these objectives the 44 high priority topics were grouped under five major umbrella programs. The topics were then formed into individual projects that could be executed under individual EPRI contracts. The table below lists the resultant nineteen projects under their umbrella programs. s-2Unbret ta 3. Unbretla 1 3. Unbrella lL 2 4 Unbretla 1 Program A: On-line Heat Rate Measurement Static Heat Rate Measurement Dynamic Heat Rate Measurement Guidelines for Heat Rate Measurements Program B: System Control Center Operation Generating Unit Models Volt/VAR Dispatch Considerations Performance Indices Program C: Instrumentation Instrumentation Accuracy Analysis Sensor Development Projects Sensor Validation/Auto Calibraticn Progran D: Diagnostics Botler Diagnostics Control System Diagnostics Incipient Failure Detection Maintenance Schedule Optimization Program E: Plant Controls and Operating Procedures Start-up/Shut-down Procedures Combustion Optimization On-line Boiler Controls Operating Strategies Gas Clean-up Equipment. Operation Automatic Tuning 5-3A generic R&D project description was prepared as a guide for defining each of the nineteen projects. The generic tasks are listed below. Task 1 - Determine Potential Benefits of Recomended Inprovenent. Task 2 - Define Alternative Approaches Task 3 - First Evaluation of Alternative Approaches Task 4 - Design of Selected Approaches Task 5 - Implement and Test Selected Approaches Task 6 - Field Testing Task 7 - Dissemination of Results Of particular importance is the emphasis put on the dissemination of results (Task 7). A dissemination plan was required for all appropriate projects. SCHEDULE A schedule for the nineteen projects extends over a four year period. Prerequisite projects are scheduled first followed by those projects that are dependent upon the results from the prerequisite proj completely independent is indicated as flexible over the four year period. ts. The schedule for projects that are INTERACTIONS AND PRECAUTIONS A description of the interactions between the prerequisite and dependent projects is included, Precautions on the use of the recommended programs is also described, ‘This recognizes that new developments affect the directions of research and the priorities of the industry. Consequently, the plan should be re-evaluated each year in light of recent progress on these and other related projects. s4Section 1 INTRODUCTION 1.1 BACKGROUND The era of Performance Improvement is upon the power industry. Load forecasts have leveled off and in sone cases have decreased, Not one new fossil or nuclear plant was ordered in 1982 or 1983, Fuel and labor costs, although sonewhat stabilized, remain high, Public utility commissions are reviewing performance improvements to help justify rate increases, Environmental controls and associated costs continue to increase. Money is very expensive when available. Each of these conditions pressures utilities toward optimizing the economic performance of existing power generation and distribution systems. This emerging climate has been recognized by the power industry and EPRI for many years, The Power Systems Planning and Operations (PSPO) group of EPRI's Electrical Systems Division recognized that all significant performance improvements were neither restricted to nor independent of generating unit performance. In the 1980 American Power Conference, Dr. John Lamont of PSPO listed three areas of improve- 1) Improved design of both control and major plant equipment. 2) Improved system and operational planning, and 3) Improved operating procedures. Existing plants would benefit primarily from the latter two. The significant message in this list is that generation improvements alone are not enough. To achieve the levels of performance desirable, improvements in generating unit and Power systems must be pursued and coordinated, For example, the methods used to allocate generation to various units could be improved if better unit performance measurements could be obtained at required time periods. However, this cannot be achieved through independent efforts. Generating unit data collection systen de- signs must provide the information required by the load scheduling and dispatching Programs. Power systems planners and dispatchers must recognize the limitations of 1the generating units and the difficulties in obtaining reliable information. A means of coordinating and communicating higher levels of information on-line must be established, Because of the need for coordination discussed above, a major joint project by EPRI PSPO and Coal Conbustion Division was undertaken in 1982 (RP 1681/2153). The prime contractor is Potomac Electric Power Co. (PEPCO). The objectives of this project are to identify, test, and demonstrate various performance improvement techniques at both generating unit and power systems levels. PEPCO's Morgantown Unit #2 has been selected as the host unit on which the various improvement techniques will be quantitatively evaluated. Techniques believed to significantly improve performance will be implemented on Morgantown 2, performance improvement measured, and the test results disseminated to the industry. This project is expected to run about five years and be a major contribution to defining improvements in operating procedures for many utilities. To help prepare for unavoidable changes, EPRI Coal Combustion Division sponsored a Fossil Plant Heat Rate Improvement Workshop in Houston in 1979, The purpose of ‘the workshop was to discuss methods of performance improvements and provide a forum for information exchange among those implementing improvement programs. Reflecting the widespread industry interest in the subject, attendance at the workshop was a "sell-out". Inspired by the successful meeting, EPRI sponsored a second workshop in Charlotte, N.C. in 1981. It too was a "sell-out". Associated with this meeting were several working committees attempting to define high priority R&D re- quirements that would facilitate performance improvements, These committees generated several lists of R& topics which are presented in the proceedings of the 1981 workshop (EPRI CS-2180). A third workshop was held in October 1983 to continue the highly successful and productive forum, Clearly there is significant interest throughout the industry to respond to the need for performance improvements. With the previous EPRI efforts, sub- stantial momentum exists. With continued support and cooperation fron the utili- ties, major performance improvements will soon be realized. 1-21.2. OBJECTIVES To help put the current state of the art in unit performance measurements in per~ spective with potential economic dispatch improvements, the Electrical systems Division independently commissioned this scoping study. The objectives of this study are to 1, Determine the current practices used by domestic and foreign utili- ties to measure and improve unit heat rate, and Develop a recommended R&D plan for the improvement of total system heat rate. This includes coordinated recommendations at the generat- ing unit level and the power systems level, The current practices were ascertained through many utility interviews and paper reviews, A separate report documents the results of that study (EL-3339 Volume 1). This report contains the recommended R&D plan based on the current practices find~ ‘ings, inputs froma large and broad-based industry advisors committee, Working Committee recommendations from the 1981 Fossil Plant Heat Rate Improvement Work - shop, and results of on-going EPRI projects. The recommended RAD plan provides a coordinated perspective upon which to select and pursue performance improvement projects through EPRI sponsorship. 1.3 REPORT FORMAT The subsequent sections of this report include a description of the procedure used to generate the recommended R&D plan and the plan itself. Section 2 discusses the procedure and refers to the five appendices for details. Section 3 provides an overview of the entire plan at the “Unbrella Program" level. The five Umbrella programs are the major divisions of the plan and are composed of several individual projects addressing various aspects of one major objective. For the most part, projects within each of the five unbrella programs are independent of projects in other umbrella programs. Section 4 describes the recommended projects within each umbrella program, There are a total of 19 projects described in this section, Finally, Section 5 addresses interactions within the plan at the project level. Associated with these inter- actions are cautions and guidelines to review when implementing the plan 1-3Section 2 R&D TOPIC EVALUATION/SELECTION PROCEDURE To provide the basis for a comprehensive R&D program directed at improving gener— ating unit and electrical system economic performance, an extensive 7-step screen ‘ing process of various R&D topics was established. The screening process included an industry advisory committee composed of utility and consulting personnel. The of the advisory committee and the seven-step screening procedure are described in the subsequent sections. 2.1 ADVISORY COMMITTEE SELECTION Since the objective of the program was to develop a broad scope R&D program, in cluding both generating unit and electrical system R&D, it was believed that an advisory committee with equally broad expertise was required, Furthermore, a good perception of R&D currently being undertaken by utilities was deemed essential, To satisfy these two criteria, the advisory comittee was conposed of generating unit, power systems, and poner pool performance experts. In selecting the advisory con- mittee menbers, particular enphasis was placed on the progressive attitude of the individual, his denonstrated expertise and experience, his current area of respon= sibility, and his interest in improvenents in the subject area. In addition to utility personnel, the advisory committee for the Scoping Study in— cluded consultants to the EPRI project “POWER PLANT PERFORMANCE IMPROVEMENT RP 1681/2153", The names of the active advisory committee members are listed in Ap pendix A. These members participated in the seven-step screening process over a period of about six months. The advisory committee provided the major direction in the selection of the ultimate topics and projects included in this recommended R&D program report. 2.2 EVALUATION PROCEDURE To begin the R&D project selection procedure, a large list of R&D topics was ident~ ified from various sources. One of the primary sources was the industry papers and WORKING GROUP SUMMARIES from the 1981 Fossil Plant Heat Rate Improvement Conference and Workshop in Charlotte, NC (EPRI CS-2180). Many current industry practices and a4problens were well documented by industry experts in that publication. Further- more, working groups were established at the conference to identify recommended RaD. The results of the working group discussions were also included in the refer enced report. A second major source of initial R&D topics was the current prac- tices report prepared under the same scoping study contract (RP 1737-2) as this report. This was a major effort at defining current practices and limitations of instrumentation and heat rate monitoring methods, Much of the information from that report was derived fron interviews with utilities. Consequently, mich first hand information about limitations and problems were identified. The third major source of RAD topics was provided by Potomac Electric Power Company and their sub- contractors as a result of their efforts on the “POWER PLANT PERFORMANCE IMPROVEMENT" project. Based on these sources sixty-six (66) RED topics were identified. A one-paragraph description of each topic was prepared and distributed to the advisory committee members for their independent ranking and conment. Their ranking and comments were then compiled into one complete list and distributed back to the advisory commit- tee. This list of topics, their one paragraph descriptions, the initial ranking by the advisory committee, and the comments by the advisory committee are included in Appendix 8. This provided each advisory committee menber an opportunity to con- sider other menbers* perspectives on the individual topics. A meeting was then arranged in conjunction with the 1982 Joint Power Generation Conference in Denver to collectively discuss each of the sixty-six items. This provided a means for each menber to present and defend his interests and concerns about each topic, The objective of the meeting was to arrive at a final advisory committee ranking of the topics based on a clearer understanding of each topic. As a result of this meeting, eleven additional topics were added to the list. This brought the total list of R&D topics to be considered to seventy-seven. The ad- ditional items recommended by the advisory committee are listed in Appendix C. The topic rankings by the advisory menbers were then tabulated to arrive at the Final set of high priority topics for further consideration, The ranking was done using two different weighting factors. First, all menbers were given equal voting weights on all R&D topics, This produced a simple average rating for each topic. The second approach adjusted the individual member's voting weight depending onwhether his current responsibility was in the generating unit or system area. For those topics directed at generating unit improvements, the advisory committee mem- bers with generating unit backgrounds were given twice the weight of those with system backgrounds. Conversely for those projects directed at electrical system improvements, advisory members with power system backgrounds were given twice the Weight of those with generating unit backgrounds. Surprisingly, this biased weighting procedure did not affect the ultimate topic ranking significantly. The results of the equal weight and biased weight tabulations are shown in Appendix D. These results provided the primary basis for identifying the R&D projects recom- mended in Section 4, The rankings provided by the advisory committee were further reviewed by EPRI Electrical systems Division and Coal Combustion Division personnel to avoid dupl i - cation of projects and insure dissemination of results. As a result, the final topic ranking was slightly modified from the rankings provided by the advisory com— mittee voting procedure. The EPRI rankings are also shown on the right column in Appendix 0, This procedure can be summarized in the following list of seven steps: © Step 1 = Identify Initial R&D Topics © Step 2 - Independent Topic Ranking/Conments By Advisory Committee Members @ Step 3 - Distribute Comments Among Advisory Committee # Step 4 ~ Group Discussion at Denver/Second Individual Ranking @ Step 5 - Tabulate Ranking Based on Equal Weight and Biased Weights © Step 6 - EPRI Ranking By Electrical Systems Division and Coal Conbusion Division © Step 7 - Final Review of EPRI Ranking by Project Members Although the procedure was somewhat elaborate and time-consuming, it provided a mechanism for identifying current related efforts and an opportunity for several utilities to interchange ideas. In fact, in some cases it was an opportunity for the Power System Operation and Generating Unit Departments within one utility to discuss prospects for overall system improvements, It is believed that the final set of projects reflects the current status and priorities of the fossil utility industry. The remaining portions of this report attempt to group these selected topics into meaningful umbrella programs and specific R&D projects. 2-3Section 3 PLAN OVERVIEW 3.1 UMBRELLA PROGRAM DEFINITIONS The previous section described the procedure by which several R&D topics were eval- uated and selected for further consideration, As a result of that effort, forty- four topics were identified by the Advisory/EPRI committee, In addition, eight re- Commendations made in the current practices report (EL 3339 V1) prepared under this same project are included in the R&D programs described below. In both cases, these topics were not RED projects in thenselves, rather they were subjects and ‘tens of concern that were reconnended for detailed investigation. To develop a coherent R&D plan based on the recommended topics, a set of umbrella Programs were established. Each topic was then assigned to one of the umbrella programs. The criteria for establishing the umbrella programs are listed below: © Each program addresses one major arza of improvement. © Each program has minimal interaction with other programs. © May be several objectives under one umbrella, but related by major goal. © Projects within umbrella programs may be interactive. Based on the criteria listed above, five umbrella programs were identified: Program A: On-line Heat Rate Measurement Program B: System Control Center Operation Program C: Instrumentation Program D: Diagnostics Program E: Plant Controls and Operating ProceduresSince many of the topics recommended for further investigation were not R&D pro- Jects in themselves, the set of topics within the umbrella programs were restruct~ ured into specific R&D projects. Sone of these projects encompass several of the recommended topics. However, eight topics became projects in thenselves. The Final grouping of topics within individual projects for each umbrella program are shown in Table 3-1. The topics discussed and recommended by the advisory/EPRI com- mittee are identified under the project title or both their topic title and origi- nal alphanumeric indicator, The alphanumeric indicator refers to the original grouping of topics as sent to advisory menbers for coment. These groupings and all alphanumeric indicators can be found in Appendix 8. For example, topic 1A7 = Develop Plant Analysis Program can be found on page 8-6. The “I” refers to power plant improvements. The “AY refers to "Performance Analysis and Diagnosis" pro- ject. The "7" is the specific topic within that group. In addition, recommenda- tions included in the current practices report are also identified under the ap- propriate project in which they are addressed, They are identified as “cP" numbers which refers to the recommendation nunber in the Current Practices report. 3.2 PLAN OBJECTIVES To understand the interactions of the five umbrella programs, it is necessary to redefine the two major objectives the Scoping Study is trying to address, Objective 1: Improve Fossil Power Plant Economic Performance Objective 2: Improve Economic Dispatch Performance by Using More Accurate Generating Unit Performance Information If each of these objectives are addressed separately, the role of the umbrella pro- grams can be more easily described. Figure 3-1 shows the roles of the unbre‘la programs for the first objective in an information flow diagram, The first question to be addressed in improving power plant economic performance is to deternine if performance degradation can be de- tected adequately. If it cannot, then projects within Program A and/or C are necessary. Program A contains projects which investigate means of measuring per- formance degradation. Program C identifies specific instruments which will facil~ itate the measurement of performance degradation in the generating unit. Until this first question can be answered positively, other programs are of limited bene- fit. 3-2Table 3-1 UMBRELLA PROGRAN TOPICS Alphanumeric PROGRAM A: ON-LINE HEAT RATE MEASUREMENT Indi cator/Page_No 1, STATIC HEAT RATE MEASUREMENT Plant Analysis Program 1A7/8-6 Optimize On-Line Heat Rate Measurements (Static Conditions) 101/8-20 Performance Testing Procedures for Steam Turbines 103/C-3 Continuous On-line Testing Procedures 076 Component Diagnostics 1A9/8-7 2, DYNAMIC HEAT RATE MEASUREMENT Optimize On-Line Heat Rate Measurements (Dynamic Conditions) 101/8-20 + GUIDELINES FOR HEAT RATE MEASUREMENTS Heat Rate Handbook 1A4/B-4 Guidelines for Continuous Performance Deviation Monitoring 1A11/8-8 0/02 Control for Boilers 1eT/C~3 Videotaped Guidelines CPi PROGRAM B: SYSTEM CONTROL CENTER OPERATION 1, GENERATING UNIT MODELS Determine Useful System Data for Unit Operation 282/8-30 Determine Cost Reduction Potential of Continuous Update of 3C1/8-34 Unit Incremental Heat Rate Investigate Effect of Incremental Heat Rate Curve Shape 302/8-34 Investigate Feasibility of Using Continuous Operating Factor 3€5/B-36 Adjustment of Unit Incremental Heat Rate Enhanced Generator Models for Use in Production Costing 302/C-4 Algorithms Determine Impact of Performance Measurement on Generation and Interchange Schedule 361/8-37 - VOLT/VAR DISPATCH CONSIDERATIONS (3C6) 3. PERFORMANCE INDICES Develop Unit State Vector 2A1/8-30 Develop System Performance Index 381/8-33 Develop Additional Dispatch Criteria 3€3/8-35 Gross MW psc. Plant Status Information cps CP - Current Practices Report Recommendation Number 343PROGRAM 2 PROGRAM 5 Table 3-1 UMBRELLA PROGRAM TOPICS (Continued) INSTRUMENTATION INSTRUMENTATION ACCURACY ANALYS!S Instrumentation Accuracy Analys*s Impact of Instrument Error Determine As-Installed Accuracy SENSOR DEVELOPNENT PROJECTS Low Cost Continuous Coal BTU Analyzer Pulverized Coal Nass Flow Meter Flame Analyzer for Pulverized Coal Burners Accurate Method of Measuring Boiler Air Flow Average Fluid Temperature Across Large Conductors Stack and Ash Pit Carbon Losses Stack Acid Dew Point Non-intrusive Portable Flow Measurements for Water Water Flow in Large Ducts SENSOR VALIDATION/AUTO CALIBRATION Sensor Validation Methodology Auto Calibration Automatic Calibration DIAGNOSTICS BOILER DIAGNOSTICS Quantify Effects of Boiler Slagging on Heat Rate Develop Method to Measure Slag 8uildup Automated Sootblowing CONTROL SYSTEM DIAGNOSTICS INCIPTENT FATLURE DETECTION MAINTENANCE SCHEDULE OPTIMIZATION CP - Current Practices Report Recommendation Nunber 3A Alphanumeric Indicator/Page N 182/8-9 cre cps 184/8-11 185/8-11 187/8-12 1B10/8-13 1811/8-13 1816/8-16 1820/8-18 1822/C-2 1823/C-2 1A8/B-6 1814/8-15 cpa 1A5/B-4 183/8-10 cP 5b 166 /8-23 1A10/8-8 166/8-27Table 3-1 UNBRELLA PROGRAM TOPICS (Continued) Alphanumeric PROGRAM E: PLANT CONTROLS AND OPERATING PROCEDURES Indicator/Page Now 1. START-UP/SHUT-DOWN. PROCEDURES Quantify Cost of Start-Up and Shutdown 1AL/B-2 Automatic Start-up Controls 1€5/8-23 2. COMBUSTION OPTIMIZATION 1A6/8-5 3. ON-LINE BOILER CONTROLS Steam Temperature Regulation 1E1/8-21 Pulverizer Controls 162/8-21 4. OPERATING STRATEGIES Variable Pressure Operation 161/8-24 Optimum Turbine Valve Point Loading 162/8-24 Evaluate Variable Pressure Operation CP5A GAS CLEANUP EQUIPMENT OPERATION Gas Cleanup Equipment Operation 1alz/c-2 Gas Cleanup Equipment. Improvements cP7 6. AUTOMATIC TUNING 1e4/8-22 CP - Current Practices Report Recommendation Nunber 35[7 EAT fare neasunenext_ |/-—] can vearomance —\\ yo Decraoarion ge berecreo? | PROGR | We TASTRUMENTATION (aveRoven orachosttcs) CAN CAUSE OF DESRADED Peneomvaice BE DETERMINED? Proce o: | Diaswasrics | es CovPRaven maTENsNCe SCHEDULING) FRSA OF auneUNce SPTINIZATION can MaINTENANCE SCHEDULE" ae OPTiMzED? ves (IMPROVED CONTROLS & PROCEDURES) proce 1 CONTROLS. & OPTIMIZED} ROCEDURES ) ARE OPERATING PROCEDURES O8 AUTO CONTROLS. OPTIMIZED? WS x0 Figure 3-1. Unbrella Program Roles for Improving Generating Unit PerformanceOnce we can be assured that performance degradation can be detected adequately, the next issue to address is whether the cause of the degraded performance can be determined. If it cannot, this suggests projects within Program D, Diagnostics, which are designed to use the information generated under Program A to determine the causes of degraded performance. Once the causes can be determined, then the issue of maintenance schedule optimiza- tion can be addressed for those topics where maintenance ts cost effective, If maintenance optimization programs are not available, then Program D, project 4, is the next appropriate step. This project is designed to develop maintenance Schedule optimization algorithms based on the results of other projects within Program D. When performance degradation and its causes can be confidently identified, and maintenance can be appropriately scheduled, the one remaining issue is to determine if the operating procedures or automatic controls can be modified to achieve a better mode of operation, Program £, Contro’s and Operating Procedures, is design- ed to investigate several controversial issues in this area. This process helps to identify both the roles of the umbrella programs and the priority of the projects within them, Note that if the answer to all of the questions in the flow diagram were "yes", no additional projects would be recom— mended, Since several projects are recommended in all the programs, it is clear that the answer to all the questions is "NO", The actual schedule described in Section 5 reflects the same prioritizing criteria as described in Figure 3-1, Many projects are scheduled in parallel rather than in the serial fashion suggested by the above discussion, This parallelism is recommended because much of the work is independent of the actual results achieved in each program and running the project's in parallel will expedite the ultimate objectives. Figure 3-2 shows a similar flow diagram for the second objective: Improve Economic Dispatch Performance Using Generating Unit Performance Information. In this case, however, an initial question currently being addressed under EPRI project RP 1681/ 2153 by PEPCO is an evaluation of the potential cost improvements possible using generating unit performance information in the economic dispatch algorithms. The results of this initial evaluation mist show an attractive cost/benefit ratio for improvement in total system economics before any of the related projects indicated by the remaining portion of the flow diagram are justified for the second ob- jective. 37OBJECTIVE: INPROVE ECONOMIC DISPATCH PERFORMANCE USING GENERATING UNIT PERFORNANCE INFORMATION 15 IMPROVEMENT poventiaL woaTs Punsuins? Sap—Y Teawunare exact (werco} t (anmmoveo HEAT RATE wortTORING) oo z ¥ ear Rare t EASUREVENT Can NET WAIT MEAT RATE 3€ MEASURED COUTINUQUSLY. ARO [ADEQUATELY DURING STEADY STATE AND. TRANSIENT ONDE IONS E 5 te PROBA maj instaientation | (IHPROYED EXTRAPOLATION METHOD) aN OE ance PeRrommence-a€ oevenwmeo 20 ota FROM MEASURED. HEAT RATEZ e STATUS INFORMATION? y E S| avenoven ec ausoar Tas) a | caw CAL coat Tans i" USE conrsnous PLANT rosea STATUS. INFORMATION? e Figure 3-2. Unbrella Program Roles Improving Economic Dispatching 3-8Pending a favorable initial evaluation, the first issue to be addressed in this ob- Jective 1s whether the generating unit econonic performance can be measured con tinuously and adequately during both steady-state and transient conditions for economic dispatch purposes. Since it is known that this is not done now nor easily achieved, projects within Prograns A and C should be addressed until this first criteria can be met, Once the generating unit performance can be adequately measured, then it is necessary to determine if the continuous or point monitoring techniques can be extrapolated over the entire load range for each generating unit. For economic dispatch optimization, it is necessary to know the generating unit performance parameters for a band around the current operating load. Heat rate is, typically thought of as a curve showing the BTU/KH over the load range. However, the curve is generated by calculating heat rate one point at a time at a few se- lected loads (usually turbine valve points) and fairing in the points. When heat rate is calculated on-line, the result represents the performance of the unit at the current load point, Since this is at only one operating point, a method for estimating the unit performance at loads above and below the current operating point mist be developed and tested, Heuristic methods are currently used to extrapolate this information on, at best, a monthly basis. Program B is designed to develop better generating unit models for use in both pre-dispatch and dispatch functions. This program will address the difficulty in determining wide range operaticn from a one point measurement. Finally, once the generating unit models can be adequately established, the economic dispatch algorithms must be modifiec to account for this new information, Again, projects within Program 8 are designed to address these questions. Once the economic dispatch algorithms are modified to handle the current generating unit information, the ultimate project objective will have been achieved. 3.3. GENERIC R&D PROJECT DESCRIPTION The R&D projects recommended in this report should be motivated by anticipated improvements. These expected improvements are frequently difficult to identify and nearly impossible to quantify at the beginnirg of a project. However, to maintain @ focus of project objectives, a clear description of the anticipated benefits of each project should be developed by the preject contractor and provide the basis for decisions during the course of a project. 349To be useful to the power industry at large, these projects should also be carried fron initial justification through design, field testing, and, ultimately, effective dissemination, To assure that each project described in Section 4 adheres to these qualifications, a generic R&D project procedure was identified as describ- ed below: Task 1 - Determine Potential Benefits of Recommended Improvement (dust fication) AIL projects should begin with a clear and quantitative justi fi- cation, This task 1s included in most of the reconmended projects Since quantitative justificat’on does not currently exist. Task 2 - Define Alternative Approaches To avoid fixation on a specific approach to a problem, alternative approaches and their advantages and disadvantages should be ident i- fied. This will force the contractor to consider approaches sug- gested by sources other than his own and justify his selection of approaches relative to others. Task 3 - First Evaluation A preliminary evaluation of all alternatives should be performed to screen out unlikely candidates, This should typically be a paper evaluation limited to six weeks. The remaining alternatives will be evaluated in more depth. Task 4 - Design This addresses the specific design of the selected approaches, Task 5 - Implenent and Test The complete design should be implemented on prototype or expert - mental hardware and tested ina laboratory environment wherever possible. This avoids the high cost of field testing prior to initial debugging and further evaluation of the potential benefits in light of the cost of implenentation, Based on test results only the most promising designs or techniques will be field. tested. Alternative approaches should be reduced to’ a naxinun of three at this point.Task 6 - Field Testing Upon successful completion of laboratory testing, a field test should be planned whenever appropriate. This will help identify all potential areas and unexpected implementation costs. This infor- mation is necessary for a utility to determine if they will pursue ‘the same approach reported within the project. Final recom- mendations should indicate which alternatives is best suited for the various conditions or plant characteristics. Task 7 - Disseminate Results This task is distinguished from docunentation of results because the dissemination process is more comprehensive and meaningful than the mere documentation of results. Documentation is a subset of the dissemination process. All projects should include a dissemination plan, Not all projects fit within the generic R&D project described above, However, most of the projects described in Section 4 contain all of the elements of the generic project. Many projects call for a “host” unit test site, To provide acceptable testing con- ditions, a test site must meet several criteria such as high quality monitoring capability, cooperative and skilled personnel, and typical plant characteristics and environment, Most, if not all, plants would require some modification to meet the host site requirements, For this reason, it is desirable to limit the number Of host sites to as few as possible while maintaining the generic value of the pro- jects. This potentially significant cost factor should be considered in each Project definition. 31section 4 RECOMMENDED PROGRAMS The five umbrella programs discussed in Section 3 are described in detail in this Section. Each program is composed of several projects which can be contracted Separately but which contribute to the objective of the umbrella program. The overview of each umbrella program is presented followed by detailed descriptions of the proposed projects within the umbrella program. Estimated levels of effort and resources required are identified for each project to aid in identifying qualified bidders. Related projects in the industry known to the authors are identified to avert redundant work and provide good starting points. There are a total of 19 projects for the five umbrella programs described herein. The interactions between projects and cautions in implementing the overall program and identified in Section 5. 4.1 UMBRELLA PROGRAM A: ON-LINE HEAT RATE MEASUREMENT Continuous or frequent (at least one measurement per hour) heat rate measurement has two applications: 1, Provide a comparison with prescribed target heat rates to indicated performance degradation (diagnostics), and 2, Provide the economic dispatch control (EDC) system with accurate and current information on which to allocate load among several units. The first application is currently practiced by many utilities to varying degrees of success. The major R&D thrust for this application is toward better resolution of the reasons for performance degradation, i.e., better diagnostics. To improve the diagnostics, energy losses not previously measured, such as turbine seal losses, must be determined and their contribution to the net unit heat rate mst be calculated. Also, the impact of uncontrollable conditions such as anbient tenper- ature changes and miscellaneous steam flow paths must be accounted for so that the comparison of plant performance under different operating conditions is valid. 41Heat rate measurenents for this application are made with the plant at steady-state conditions for extended periods of time, It is generally believed, by generating unit performance engineers, that pernanently installed instrumentation 1s in~ adequate for accurate heat rate and diagnostic measurements. However, the degree of {inadequacy and the means of diagnosing major performance losses are not known quantitatively. Consequently, a major project is recommended to ascertain the achievable accuracy of heat rate monitoring and component diagnostics using perma nently installed instrumentation, This project is restricted to steady-state plant operation and is described in Section 4.1.1. ‘The second application of heat rate measurement mentioned above, economic dispatch control, is not done anywhere today. The difficulty in accurately measuring heat rate on-line and the inability of current EDC programs to incorporate on-line meas- urements has discouraged attempts to pursue this application, For this application continuous on-line heat rate measurement is possible with the instrumentation and computer capability currently installed in most coal fired plants. However, two requirements must be met: 1, The instrumentation mst be calibrated, and 2. the plant mst be at steady state when the measurements are taken to eliminate the effects of transient changes in energy storage. The issue of instrumentation calibration is addressed under the Instrumentation umbrella program and will not be discussed here, The steady state operation re quirement, however, is currently inadequately addressed. Current practice is to simply average measurenents over a 10-30 minute period after the unit has been held at a fixed load unti1 all temperatures reach an equilibrium. For economic dispatch control (EOC) it is desirable to have the heat rate measured at several load/levels - and under actual operatirg conditions. Since those plants on EDC may not stay at one load for Tong periods of time, the current averaging methods will produce erroneous heat rates regardless of whether the “loss method" or “input/- output" method is used. There are no existing methods for calculating heat rate on-line when the plant is changing load; yet it is those plants for which accurate on-line heat rate measurenent would provide the greatest benefit. The plants that currently calculate heat rate continuously based on coal flow, coal BTU, and mega- watts, are only averaging measurenents and transient effects over a short period of time, These heat rate measurenents are indicative of plant performance but not sufficiently accurate nor representative of a specific load point. Consequently,an R&D project is recommended to address this problem and is described under Section 4.1.2. Finally for both applications, it is apparent that guidelines and information on proven measurement methods and heat rate improvement ideas would be of value to the industry. Many widely known techniques such as excess air control using CO/O2 measurement are not known or fully understood by many other utilities. Consequent — ly, @ project directed at information consolidation and dissemination is also re— commended and described in Section 4.1.3. 4.1.1 Static Heat Rate Neasurement 4.1.1.1 Motivation, Accurate static heat rate measurement can provide the basis for improvements in many areas: © Better diagnostics © Optimized maintenance schedul ing © Improved economic dispatch ‘© Longer component life Improved diagnostics, scheduling, and conponent life, however, depend on improved performance monitoring of individual components. Most utilities use permanently installed instrumentation to monitor the nominaT performance of a unit, However, this information is not used by maintenance or operations personnel for maintenance scheduling or modifying operating procedures . The information is used primarily for managenent. There is a general belief that ‘the performance monitoring achieved with permanently installed instrumentation and plant computers has inadequate accuracy for many applications such as acceptance tests or heat rate curves. If the actual accuracy obtained can be documented, and the limitations of permanent instrumentation for heat rate measurements can be determined, then the static heat rate measurements can be substantially improved leading to the benefits identified above. Net unit heat rate can be determined using an input/output (1/0) method or a devi— ation method. The 1/0 method measures fuel 3TU flow in and watts out of the site (generated watts minus station power) and directly calculates the net unit heat 403rate in M BTU/megawatt-hr. This method requires practically no computation and is ideal for economic dispatch applications, but is both difficult to measure ac- curately and does not provide any component diagnostic information. The deviation method calculates performance degradation of each major component and then calculates that effect on net unit heat rate, This method is more computa- tionally complex but provides more diagnostic information about the system compo- nents. Both methods should be addressed in the project recommended below. Due to its simplicity, the limitations of the 1/0 method should be examined, These Timit- ations should be compared with the computational complexities of the deviation method for economic dispatch information. Furthermore, the diagnostic information fon the turbine cycle components generated under this project should be documented in FORTRAN subroutine form, Therefore, turbine cycle diagnostics will not appear in Program D = Diagnostics since it is vest covered under this project. 4.1.1.2 Objective, The objective of this project is to determine the adequacy of permanently installed instrumentation and conventional power plant computers to (1) accurately calculate the net unit neat rate and (2) determine the causes of performance degradation. Existing modsling codes will be used and evaluated in determining causes of performance degradation, 4.1.1.3 Scope. This project shall be directed at coal-fired cycling and base- Joad generating units having various boiler, turbine and cooling water configura- tions. It shall begin by identifying all the desirable information and proceed through a field test ona host unit to confirm the achievable accuracy using permanently installed instrumentation and state-of-the art power plant computers. 4.1.1.4 Task Descriptions. The objectives of this project will be achieved through the following five tasks Task 1 - Identify Sources of Heat Rate Degradation At least five common boiler turbine configurations shall be analyzed to identify the primary source of heat rate degradation. The con- figurations shall include, but not be limited to, the equipment con- figurations shown in the table below.Turbine Boi ler Fuel Design Cooling Supercritical once-thru high alkalai/sulphur base load lake or river Supercritical once thru low alkalai/sulphur base Toad cooling tower Task Task Drum boiler coal only base load lake or river Drum boiler coal/oil firing base load cooling tower Drum boiler lignite cycling a Neat rate degradation shall include any factors that cause a detect- able increase in heat rate for a period longer than one hour, This will include such itens as cost of sootblowing, turbine seal leaks, and inefficient combustion, Heat rate measurements must be made relative to a reference measurement deemed the best achievable for that unit under given environmenta: conditions. The infornation shall be obtained through records already available by utilities. Performance degradation shall be measured at the conponent level; for example, turbine performance, boiler performance, condenser perforn- ance, a3 well as on a net unit performance level. Current means of measuring or calculating conponent performance shall also. be identi- fied as part of this task. This shall include existing conputer modeling codes. The result of this task shall be a list correlating heat rate degradation with equipment configurations. 2 = Determine Instrumentation and Analysis Requirements Based on the sources of performance degradation identified in Task 1, ‘the instrumentation and analyses required to measure performance degradation quantitatively shall be identified, This instrunentat ion Vist shall be compared with the current list of instrumentation typi- cally installed in plants to determine the common instrument defi- ciency. The on-line and off-line roles of computer modeling codes such as syntha, PEPSE, and THERM shall be identified along with their associ- ated input and computer requirements, Computational requirements and historical data retention requirements ‘including the number of points and sampling frequency shall also be identified and compared with currently installed plant computer systems. The availability and cost of the required instrumentation and computer system shall be identivied. The results of this task shall be a summary report defining the monitoring system and instru- mentation status of typical U.S. coal fired plants. 3 = Design/and Build Monitoring system ‘A comprehensive performance monitoring system shall be designed based on the instrumentation and analysis requirements specified under Task 2. The systen design shall be tailored to a selected host site, Thedesign shall include a historical data retention for trending unit and component performance over at least a one year period of time. Both the input/output method and the deviation methods shall be in- corporated into the design for testing and comparison. The results of this task shall be a complete design document and one ready~ to-ship monitoring system. The algorithms used to detect component degradation shall be coded in FORTRAN 77 for direct application by other utilities, Task 4 - Field Testing A field testing plan shall be developed to show how the new monitor- ing system designed under Task 3 shall be quantitatively compared with conventional monitoring systems. Furthermore, a quantitative measurement. of the system accuracy for both the input/output and de- viation methods mist be determined during the field testing program. The ultimate system cost and improvement must be documented, The system designed under Task 3 shall be implemented ina field de- Ployable computer system provided by the contractor and installed in the host utility site, Installation shall include the instrunenta- tion required by the performance algorithms as well as the computer system itself. The instrumentation systems shall be tested independ— ently and prior to interfacing to the plant computer. The output of this task shall be a field test results report. Task 5 - Docunentation The above four tasks shall be documented in a written report for distribution to the power industry. Furthermore, a videotape of the field testing program showing the system design’ and the benchmark comparison with conventional systems shall also be prepared, The videotape shall show the field test installation and results along with the operations personnel response at the host site, In addition the diagnostic algorithms to detect component degradation shall be documented separately for use by other utilities. The use ‘of the existing computer codes shall also be evaluated and docu~ mented. 4.1.1.5 Resources Required. The contractor selected for this project must have extensive field testing and unit performance monitoring background, He or his subcontractor mist have a good working knowledge of the state-of-the-art instrumen- tation and computer systens available for power plant applications. Furthermore, he must have 2 field deployable computer system for the field testing phase. 4-64.1.1.6 Cost, The estimated cost for the five tasks are described below: Task Description Nanhours 1 Identify Sources of Performance Degradation 450 2 - Determine Instrumentation and Analysis Requirements 800 3 = Design and Build Monitoring Syster 3,000 4 - Field Testing 3,000 5 = Docunentat fon 11,500 Total 8,750 Since the contractor is expected to provide the field deployable computer for this project, no significant computer costs are anticipated, Project duration is esti— mated to be 30 months. 4.1.1.7 Related Current Projects. The project jointly funded by EPRI Coal Combustion and Electrical Systems Division, FP 1681-2153, is designed to address many aspects of the above project. Any sutsequent work in this area should be coordinated through this ongoing project. 4.1.2 Dynamic Heat Rate Measurement 4.1.2.1 Motivation, As discussed in the introductory paragraphs to this section, unit heat rate is not currently measured under transient conditions. To measure net heat rate, the unit must be at steady state conditions so that all the transient effects have died out and an accurate measurement can be obtained, Un— fortunately, the economic dispatch program (EDC) can more efficiently allocate load throughout the system if the current net unit heat rate is known for all units within the system, The EDC program allocates load to units assigned load following responsibility, Those units are seldom at a fixed load long enough to obtain an accurate heat rate measurement with current testing and measurement techniques. Thermal time constants will present getting good data for 1-4 hours after a load change. Consequently, if the EDC program is to operate on current updated informa— tion, a new method of determining heat rate during transient conditions must be developed, The problem of measuring heat rate during transients has been recognized by a few utilities in the past. In particular, Southwestern Public Service in conjunction with University of Texas, Austin, have developed a conceptual test program called a linear operations test which was intended to provide a means of measuring unit heat rate at various load points while still contributing to the load swing schedule on 47a daily basis [6]. An analysis procedure and a test program was established but was never implemented, Parts of the program are continuing but with different ob- Jectives than this program currently has. A second study performed by Power Technologies, Inc. [3], funded by EPRI, addressed ‘the change in plant efficiency during transients, This study indicated that. there were negligible irreversible changes in energy storages throughout the plant as the unit moved fron high load to low load and back. However, this study did not ad- dress any methods for measuring heat rate during the transients. A substantial amount of modeling expertise has been developed by EPRI in the last Five years that provides significant tools to address this problem, The Modular Modeling System developed jointly by the Coal Combustion and Nuclear Power Divi- sions has recently released for widespread utility use and provides a means for modeling the dynamics of a complete power plant. Several utilities have already used the Modular Modeling System and have indicated their satisfaction with the ability to accurately represent the operation of their plant. 4.1.2.2 Objectives. The objectives of this project are to develop, evaluate, and demonstrate methods to measure net unit heat rate during transient conditions, The frequency of net unit heat rate measurement and computation mist be at Teast one complete measurement cycle per ten minutes and the measurement mist be accurate within £2 percent. 4.1.2.3 Task Descriptions. The objectives of this project should be address- ed to the following six tasks. Task 1 - Characterized Typical Cycling Plants The characteristics of cycling units that have a major bearing on dynamic behavior shall be identified, All EPRI member utility cycling units shall be grouped according to these characteristics. Most of the data required for this characterization has already been compiled in a previous EPRI report “Survey of Cyclic Load Capabili- ties of Fossil Steam Generating Units" [5]. This characterization shall provide a means for defining the typical cycling plant and a basis for evaluating the dynamic measurenent methods throughout the industry. Characteristics such as rate of load change, minimum and maximum loads, type of instrumentation available for units, nunber of units participating in EDC, and factors that limit the rate of load change capability shall be considered, A previous EPRI survey con~ ducted by Philadelphia Electric and reported in EPRI report EL-2461 “Improved Economic Dispatch of Power Systems" shall be used for guidance in these areas, The output of this task shall be a brief 4-8Task Task Task Task Task report showing the grouping of units, the criteria for grouping, and a description of the "typical" cycling plant(s). 2 ~ Preliminary Design Based on the characterization developed in Task 1, a method for meas~ uring heat rate during transients shall be conceptually designed, A block diagram showing various measurements, analyses, and outputs shall be prepared, Any additional instrumentation or computation equipment required will be identified. The output of this task will be a conceptual design report and a preliminary cost benefit analy- sis. 3 = Select a Host unit To provide a basis for a detailed design, a host unit shall be iden- tified. The criteria for selecting the host unit shall be based on the characteristics defined in Task :. Based on the current heat rate improvement program at EPRI, PEPCO's Morgantown II Unit would be a first choice if it met the requirements for this project. 4 Detailed Design and Modeling ‘The methodology described in Task 2 shall be developed using data from a host unit, The required mathematical models shall be devel- oped and tested and compared with aveilable data, The model shall de based on design parameters and transient data from the host. unit and shall be modeled using industry-accepted first principles models such as the EPRI Modular Modeling System (MNS). The output of this task shall be a complete and validated dynamic model of the host unit along with validation documentation, 5 - Simulation Testing The detailed design for the host unit shall be implemented in a digi- tal computer and tested against the model of the host unit. The ability to accurately measure heat rate under various normal load change transients shall be determinec by exercising the model through those transients. A test plan shall be developed identifying the specific transients to be run, the criteria for test completion, and sensitivity tests required to assure confidence in the results, " Se- vere transients such as rapid load reductions and frequency ex- Cursions shall not be valid test conditions. Modifications to the heat rate measuring system design based on testing results shall be made under this task. The output of this task is the documentation of the simlation test plan and test results, conclusions, and recon— mendations. 6 - Field Test /Evaluation/Demonstration Once the detailed design is debugged against the simulation test, it shall be implemented in a field deployable digital computer for field evaluation. The computer shall be installed at the host unit and 49test runs shal] be made to determine the accuracy of measurements ~ To do this, two separate test programs shall be run, The first test procedure shall calculate the heat rate with the new method under transient conditions. The heat rate at various loads shall be deter- mined, The second test procedure shall spot check some of the values calculated by the transient teat rate measurement system, Those tests shall be performed at steady state to assure the same level of accuracy was obtained by the transient method. A plot of the heat. rate at various loads using beth calculational methods will be used to compare the results. If both calculational methods produce the same results within 1f, the dyramic method shall be reviewed for pos - sible improvenents and’ subsequent action planned. Upon successful completion of the heat rate measurement, a denon - stration to other utilities will be prepared. The output of this task shall be a demonstration on the host unit. Task 7 - Documentation A final report will be prepared that describes the final design of the system and the field test results. 4.1.2.4 Resources Required. This project tnvolves a substantial amount of analysis of plant dynamics. Consequently, the expertise required for this project involves substantial power plant modeling and optinization capability. A working knowledge of plant digital computers and instrumentation is also required, Since instrumentation will be key issue, the selection of a host utility that is both well instrumented and agreeable is essential. 4.1.2.5 Costs. Estimated manhours cost for this project are listed below: Task Descriptions Nanhours 1 = Characterize Typical Cycling Plants 240 2 - Preliminary Design 200 3 = Select a Host Unit 60 4 = Detailed Design and Modeling 1,800 5 - Simulation Testing 900 6 - Field Test/Evaluation/Demonstrat ion 1,200 7 ~ Documentation 500 Total 4,900 Estimated Materfals (wiring, instru- $20,000 mentation, and computer interfacing) The duration of this project is estimated to be 15 months. 4-104.1.2.6 Related Current Projects. A related project that has been identified 4s. the program at Southwestern Public Service that is continuing in this general direction. This project should be advised of their status and coordinated if the two projects proceed toward related goals. 4.1.3 Guidelines For Heat Rate Measurement 4.1.3.1 Motivation, Less than a dozen utilities are successfully monitoring unit heat rate with permanently installed instrumentation in existing computer systems today. Although the accuracy is in question, the techniques are valid and the information generated is useful. 0n the other hand, many utilities are just beginning to develop heat rate monitoring programs with relatively inexperienced engineers, Based on the extensive amount of information available today, it would. appear useful for the utilities establishing their own heat rate monitoring pro— grams now to have the benefit of the experience developed by other utilities. working for many years in this area, That experience should be documented in both written handbook form as well as videotape guidelines. It is believed that through this mechanism a large number of utilities can begin improving their performance in @ mich shorter period of tine. 4.1.3.2 Objectives. The objective of this project is to develop and test a handbook for heat rate performance monitoring and a videotape presentation of that handbook. 4.1.3.3 Scope, The handbook should address coal-fired cycling and baseload power plants, Both supercritical and subcritical boilers with various turbine configurations should be included, It should address al1 major elements of a net. unit heat rate calculation, This includes boiler efficiency, turbine feedwater train cycle efficiency, condenser efficiency, and all major auxiliary power uses. Furthermore, the handbook should include reconmended standard forms for calculating information as well as the theoretical background for each of the calculations required. 4.1.3.4 Task Descriptions, The objectives of this task will be achieved through the following four projects. Task 1 - Prepare Draft Handbook An outline of the handbook shall be prepared and reviewed with se- lected industry advisors. The advisors shall have extensive experi- ence in heat rate monitoring and instrumentation, allTask Task The handbook shall address not only the monitoring instrumentat ion and calculations, but shall also include recommended operational checks and administrative procedures such as listed below: (1) Losses from traps, leaky valves, etc., can be fairly signi ft- cant. System and cycle loss checks can be developed and im- plemented, (2) Reducing electrical auxiliaries can be significant in heat rate improvement. Areas for potential savings should be identified and included in the heat rate manual; i.e., fly ash hopper heaters and circ water pumps can be taken out of service when not needed, (3) system heat rate improvement design reviews should be con- ducted periodically; i.e, changing the extraction point for plant heating steam under certain conditions may be cost- effective. Many times on older units, it is assumed that the above items have been optimized, It is not unusual for long-term problems to go un- noticed unless a comprehensive isolation check or system review is initiated, Based on the resultant outline a draft handbook shall be prepared. The handbook shall include a description of all the required calcu- Vations and a theoretical explanation, The instrumentation required to support the calculations and the appropriate instrument calibra~ tion procedures shall be described, Standard forms for heat rate calculations and diagnostic calculations shall be prepared along with. examples of their use on a specific type unit. All standard engi- neering handbook data required for heat rate calculations shall be defined and, if possible, included in this handbook. Furthermore, the use of existing modeling codes for performance measuring shall be described and guidelines for their use included. The output of this task shall be the draft handbook. 2 - Test _at Host Sites To be effective, the handbook mst be understandable and useful to less experienced performance engineers at utility operating plants. Therefore, the draft handbook prepared in Task 1 shall be issued to the less experienced personnel at three host sites, These engineers shall attenpt to establish a heat rate monitoring program for their specific plants using the draft handbook. The contractor shall pro- vide guidance and clarification at four well defined one day meetings at each utility in order to document deficiencies in the draft hand- book. The output of this task shall be a revised draft of the hand- book. 3 - Finalize Handbook Based upon the success and problems encountered at the three test sites, the handbook will be mdified and finalized for distribution to the power industry. The output of this task shall be a final handbook in EPRI report ready format, 4-12Task 4 - Videotape of Handbook In order to encourage use of the handbook, a videotape version of the handbook shall be prepared, This tape shall describe the contents of ‘the handbook along with example anda description of the test at the three host sites. Experience with the handbook at the host sites will also be documented on the videotape. This shall be achieved by interviewing the host utility engineering staff involved and their management. The output of this task shall be a high quality video- tape ready for distribution. 4.1.3.5 Resources Required. The contractor for this project should have extensive experience in power plant heat rate calculations. Much of the input for this program will come from techniques currently in use by utilities. Therefore, the contractor mst have convenient access and several contacts within the utility monitoring community. 4.1.3.6 Cost. The estimated cost for the four tasks described are listed below: Task Descriptions Manhours 1 = Prepare Draft Handbook 1,200 2 - Test at Host Sites 1,000 3 = Finalize Handbook 1,000 4 - Videotape Version Handbook 1,200 Totel 4,400 ‘The duration of this project is estimated to be 16 months. 4.1.3.7 Related Current Projects. EPRI has contracted Wood-Leaver Associates to prepare @ heat rate monitoring handbook under RP-2180, This project funded by ‘the Coal Conbustion Division at EPRI is intended to prepare guidelines for setting up a heat rate monitoring program, It does not address the detailed theoretical Support or recommended forms and procedures for actually performing the monitoring. Any work on the project recommended above should be preceeded by a review of the Wood-Leaver handbook. 4.2 UMBRELLA PROGRAM B: SYSTEM CONTROL CENTER OPERATION The systen-wide performance improvement which this research seeks to obtain is de- Pendent upon the ability to make direct messurements of unit input and output or otherwise improve the modeling of unit performance, The ability to update the unit models with more precise and timely measurements of the individual units and to 4-13more rapidly and accurately schedule generation based on these models 1s the major goal of this study. This program addresses the utilization of improved information at the system control center to compare the economic operation of the units on the system and assign their generation for greatest system-wide economy. Advancement in economy of operation will require improved information exchange be- ‘tween computers and between people which will allow the people at the plant, as well as the dispatchers at company and power plant control centers to further re- fine and improve the methods developed here to obtain the desired improvements in econony of operation. Three projects have been identified under the System Control Center Operation pro- gram: © Generating unit models and dispatch algorithms © Volt /VAR dispatch considerations © Performance indices. 4.2.1 Generating Unit Models and Dispatch Algorithms 4.2.1.1 Motivation, Generating Unit Models of power input vs. power output have been used by utility control centers primarily for scheduling generat ion and interchange. The models have also been used for controlling generation to obtain “optimum” economy of operation. These generating unit models and the associated fuel cost for each generating unit provide the basic information which utilities have used in determining the cost of generation and in assigning generation between units on an economic basis. There are two basic problems with current generating unit models and dispatch algorithn: (1) Most of the models in use do not take into consideration changes in the hardware, ambient conditions and other factors which may signifi — cantly affect operating costs. Examples of model omissions include the effects of slagging, boiler tube deterioration, soot build-up and soot blowing, condenser deterioration, ambient conditions such as air and water temperature, and environmental constraints such as SO2, NOx, cooling water discharge temperature, and wind velocity and di- rection, Additionally, constraints brought about by the unavaila~ bility ‘of portions of the generating unit are not generally considered in the unit model. These include auxiliaries such as mills, pumps, and blowers.(2) The economic dispatch algorithm for nearly all utilities is currently based upon an incremental cost curve having a first or second order shape with positive coefficients. Although the slope of the curve representing output as a function of input is generally positive, it is known that near the valve points, the slope may become zero or even negative. Inasmuch as generating units are often operated near these valve points, the impact on cost, and hence scheduling and con~ trol of generation, may be significant, although the actual amount of error is not generally known, If the commonly used generating unit models are proven inaccurate, it will be necessary to determine the changes or the new algorithms which will be necessary to properly schedule and control generation from the utility and power pool control centers. Generating unit models must te developed to provide a correct representation of the units over their range of operation including constraints. When real-time measurements of fuel input, ervironmental conditions, and electric output become available it will be possible to update the unit model when the operating conditions change, Anew algorittm may be needed to contain the means, perhaps analogs of each major component, to properly represent the generating system, its environment and the optimal operating condition in a given state. 4.2.1.2 Objectives. The primary objectives of this project are to quantify the benefits which could be realized from improved accuracy of generating unit models and dispatch algorithms, identify the most effective parameters to be in~ cluded, define and develop an enhanced generating unit model, define and develop improved scheduling and control algorithms and communicate the results to the in- dustry. These models and algorithms should be significantly more complete than those currently in use. 4.2.1.3 Scope. The generating unit model project is organized into eight tasks which will identify the extent of present inaccuracies and the value of in provement as well as develop enhanced models and algorithms and determine how they can best be utilized in the utility and power pool control centers. The results are to be tested on an existing system, examined for usefulness to unit operators, and documented for written and video presentation. It is anticipated that this research will be applicable to all utilities which have steam generation, It may be particularly beneficial to utilities which have coal- fired generation,4.2.14 Task Descriptions. The cbjectives of this project are addressed by the eight tasks described below: Task 1 - Determine Impact of Incremental Heat Rate Curve Shape Present practice assumes a positive slope of the incremental heat rate curve at all generating levels. Determine the extent to which ‘the shape of the incremental heat rate curve deviates from present. assumptions in generating unit models and its impact on cost. The result of this task shall be a determination of the percent error in output, as a function of input, which can be eliminated by proper re- presentation of the unit, | In addition, the expected reduction in cost which would result from correctly representing the unit heat. rate curves near the valve points shall be determined, Task 2 - Develop an Improved Generating Unit Model Define and develop the improved generating unit model which will take into consideration the effects of all significant influencing factors of generating unit performance which are identified in this project and the associated projects and programs. The research must identi fy what factors should be included, how often the model should be up- dated, and the method by which it is updated. For instance, should the representation be a single curve or should it be a composite of several curves representing various parts of the generating unit? How often does this curve need to be updated, or if it is a com~ posite, how often does each component need to be updated? Care must be taken to define the general model or the model of vari- ous components with sufficient latitude to accommodate not only the different slopes which may be encountered, but also to provide the degree of resolution which may be necessary for modeling other units with significantly different characteristics. ‘The result of this task shall be the definition of a generating unit model which will not only represent the unit heat rate in a correct fashion through valve points, but also with various changes in unit and plant components and environmental operating constraints. Task 3 - Determine Benefits of Improved Generating Unit Models for Pre-Dispatch Algorithms Determine how the improved, more accurate and periodically updated generating unit model can be properly utilized and incorporated into Pre-dispatch algorithms such as generation and interchange sched- uling. "Determine the required update periodicity and the impact of ‘the improved model, the scheduling periods and the techniques on the overall system operating cost. Determine the methods for presenting the information to the dispatcher taking into consideration the human factors involved in his need to access the proper information for negotiating short-term power purchases/sales in the minimum time. The result of this task shall be a presentation of the expected savings through inproved scheduling in a host utility control area, a a result of reducing the errors determined in Task 1. 4-16Task Task Task 4 - Determine Benefits of Improved Generating Unit Models for Dispatch Algorithms Determine the impact of the improved and periodically updated gener- ating unit models or direct measurenent of unit input/output. and other parameters on dispatch functions such as Automatic Generation Control/Economic Dispatch. Determine the required update periodicity and determine the impact of improvements on system operating costs as well as the methods for incorporazing the models into the dispatch algorithms and presenting the information to the dispatcher, The re- sult of this task shall be the presentation of expected reductions in cost as a result of reducing the error determined in Tasks 1, 2 and 3. The improved automatic generation control/economic dispatch algorithms are to be developed for che same control area considered in Tasks 1, 2 and 3. 5 - Develop Inproved Dispatch Algorithms Plan and develop improved scheduling and contro? algorithms which will utilize the improved generating unit model of Task 2, and re- alize the error improvements and cost reductions determined” in Tasks 1, 3 and 4. The means of incorporating the changes to accommodate the required update periodicity determined in Tasks 3 and 4 must be taken into consideration. The question of where each bit of infor- mation required for update resides, (plant or dispatch office) and where and how manual entries may be injected until such time as auto- matic measurement and updating is achieved, shall be addressed, The result of this task shall be improved and perhaps totally new algori- thns for generation scheduling, interchange scheduling, and gene- ration control such as may be used in utility and power pool control centers. This task shall also include identification of the source, means, and frequency of update of the various parameters in the algo- rithms. 6 - Field Testing Incorporate the improved generating unit model and associated dis- patcher interfaces into an existing control system for extended use and test. The generation normally under control by the host dispatch center should include three or more coal-fired generating units whose unit models can be expected to incorporate the variables and factors under study in this project. It would be desirable that the host dispatch center be the Same center responsible for the control area considered in Tasks 3 and 4, Means must be provided for running both the old and the new algo- rithms simultaneously while documenting systen and unit parameters and algorithm outputs for each algorithm to a common time base. In- asmuch as these tests mst demonstrate the difference in unit genera tion level at or near valve points, through component degredat ion cycles, and also improvements in systen cost, it is important that. automatic means of collecting, calculating and presenting the re- quired information for both the old and new algorithms be utilized. Since only one system can be in control at any time, the strategy for comparing one algorithm against the other mist be carefully designedto produce valid results. It is expected that the field test should run at least one full year. During this time comparison of actual fuel burn to predicted fuel burn shall be made to help verify the the model. The result of this task shall be a well documented and auditable pre sentation of the differences in unit generation level and system costs utilizing both the old and new algorithms for interchange scheduling generation scheduling, and generation control. Task 7 - Determine Information Flow to Generating Unit Operators Examine the information developed and determine its usefulness to plant generating unit operators. Improvements to the unit model and periodic updating or direct Input/Output measurements should produce ‘information which will be more useful to the unit operator in. monitoring and improving efficiency. Determine the resolution, perdiodicity and presentation method by which this information should be made available to the unit operator, The results of this task shall include the recommended information content, method of pre- sentation, format, update perfodicity and resolution for each item which is to be presented, Task 8 - Documentation Develop an explanation of the research, its findings, and its de- velopments for use in a video presentation. The video presentation should be directed to plant managers, engineers, technicians, unit operators and control center power dispatchers, Results of this task shall be a video presentation of approximately 30 minutes duration. 4.2.1.5 Resources Required, This project will require investigators knowl - edgeable in the details of unit performance, performance testing, plant measure- ments, plant computer unit operation, control center computer applications/ algori- thns, display compilation, information presentation (human factors) and system operations. A computer will be required for modeling the unit and for production cost studies to determine the effect cf model improvements on overall operating costs, For these studies, it is anticipated that a large computer system such as is frequently found in utility corporate computer centers or engineering computer centers should be utilized, The host utility should not only have such a system, but should have run production cost studies for its control area. Additionally, @ host dispatch center which presently employs heat rate curves in performing scheduling, interchange scheduling and economic dispatch will be required to test the results of the research, The host dispatch computer system should have theability to both the old driven by the same real-time data base. run and should not cause the old algorithms to run however, must be This implies running the new new algorithm, capable periodicity. new algorithms each The incorporation simultaneously, of the new algorithms The newly reconmended any less frequent than in the past. of the algorithms in a back-up control computer execution at or interfacing a separate computer for this purpose. 4.2.1.6 Cost. The estimated hours for the recommended tasks are shown below: Task Descriptions Manhours 1 - Determine Inpact of Incremental Heat Rate Curve Shape 800 2 = Develop an Improved Generating Unit Model 4,000 3 = Determine Benefits of Improved Generating Unit Models for Pre-Dispatch Functions 1,000 4 = Determine Benefits of Improved Generating Unit Models for Dispatch Functions 1,000 5 = Develop Improved Dispatch Algorithms 5,000 6 - Field Testing 1,500 7 = Determine Information Flow to Generating Unit Operators 700 8 - Documentation 1,500 TOTAL 15,500 It is anticipated that the eight tasks wi'l be completed in 4.2.1.7 Related Current Projects. the Instrunentation Program, and the Volt/VAR dispatch and Performance System Control Center Operation Program are related and will benefit tion exchange, thirty-six months. ‘The On-line Heat Rate Measurement Program, ‘the Plant Controls and Operating Procedures Program in this from informa— Indices Projects, which follow4.2.2 Volt/VAR Dispatch Considerations 4.2.2.1 Motivation. The output of a generating unit is complex power (MVA). There are two components, the real power (Megawatts) and reactive power (MVAR). The megawatts are sold, but there is generally no direct charge for reactive power even though reactive power flow creates real power losses which can be costly. The quality and reliability of supplied energy is ensured by maintaining load bus volt~ ages within permissible limits, Any changes to the systen configuration or in power demands can result in load bus voltage excursions, Volt/VAR scheduling and dispatching can be used to reduce systen losses, as well as to maintain permissible voltage levels. Substantial research has been done concerning reactive power as it affects the ‘thermal ratings of power system elements and the transient stability of the entire bulk power system, Research is needed to determine the extent to which reactive power generation in active power gene-ating machines constrains the economy of power system generation and how it should be accommodated in scheduling algorithms. 4.2.2.2 Objectives. The primary objective of this research is to develop an ‘input or a module for the generating unit model such that the scheduled and actual unit megawatt output will properly reflect the effect of VAR output. The module must recognize all the constraints associated with VAR production such as real and reactive power limits of the generators, generator terminal voltage limits, and voltage limits on an external load bus. Given the ability to recognize a constraint from some bus external to the power plant, this research is not intended to examine overall power system effects of individual generating unit VAR productian. However, it will be appropriate to pur- sue overall power system effects as an extension or follow-on to this project. Additionally, the research is not intended to consider the solution algorithms for optimun VAR dispatch, nor is it to consider operating philosophy. It is intended to look at all possible effects of VAR production by a specific generating unit on real power production and efficiency of that unit. 4.2.2.3 Scope. The volt/VAR investigation is organized into four tasks which will identify costs and constraints imposed upon the generating unit by its own VAR generation, develop a model of the impact of VAR generation on unit megawatt pro~ duction for inclusion in the overall generating unit model, test the model and determine the information flow which my be required to other programs and other 4-20locations, The tests are to be documented for written and video training presen- tations, It is anticipated that this research will be applicable to most generating units. 4.2.2.4 Task Description: composed of the following tasks. The volt/VAR dispatch considerations project is Task 1 - Determine the Effect of VAR Gene-ation on Unit Megawatt Performance and Develop a VAR Impact Model Determine the impact of VAR generation on the megawatt generation of the individual generating unit. This shall include the determination of any effect on unit heat rate as well as the identification of specific constraints which must not de violated such as MVA, tenper- ature, and voltage. Define and develop a model of the impact of VAR generation and the associated constraints which impose upon megawatt production of the unit. The most desirable methods of presenting information from this mmodei to the improved generating unit model shall be taken into con- sideration. A unit may be called uson to produce maximum megawatts within certain voltage constraints aid there may be an optinun volt- age or VAR level which will accomplish this. The model should be constructed so this type of information is available. The result of this task shall be a quantitative presentation which shows clearly the effect of VAR generation on megawatt generation over the full range of each, Additionally, the constraints, their normal ranges of influences and the effect’ on megawatt generation shall be presented, Task 2 - Field Testing Incorporate the unit VAR impact model into the improved generat ing unit model of the foregoing project to demonstrate its effect. As in the foregoing project, means must be provided for collecting and pre- senting the differences in unit schedule and generation control level with and without the volt/VAR model, The result of this task shall be a well-documented and auditable pre- sentation of the differences in unit generation level and system costs utilizing the improved generating unit model with and without ‘the VAR impact model. 421Task 3 - Determine Information Flow to Generating Unit Operators and Others Examine the infornation which is available from the model and deter- mine its usefulness to generating unit operators, control center operators and schedule and control algorithms. The extent to which VAR output is limiting megawatt output may be of great interest to unit operators, Optimum levels nay be of interest as well as the specific constraint which is limiting either VAR or megawatt pro- duction, Determine the resolution, periodicity, and presentation method by which this information should be nade available. Task 4 - Documentat fon Develop an explanation of the VAR impact considerations which may be used in a video training presentation. The presentation should be directed to unit operators, power dispatchers, engineers and their supervisors. The final result of this task shall be a video presen- tation of approximately 30 minutes duration, 4.2.2.5 Resources Required. The primary resources required will be the time of a principal investigator knowledgeable in the volt/VAR aspects of power system and unit operation, It is anticipated that mich of the required information can be obtained from existing research published within EPRI, or in the public domain and the data available for a specific generating unit, preferably one which may ulti- mately receive control signals from the dispatch center which hosts the dispatch algorithms and generating unit models of the foregoing program, It is expected that the host system utilized in testing the generating unit models and dispatch algorithms of the foregoing project will also be utilized to test the VAR impact model. 4.2.2.6 Cost. The estimated hours for the recommended tasks are as fol lows: Task Descriptions Manhours 1 = Determine the Effect of VAR Generation on Unit Megawatt Performance and Develop a VAR Impact vodel 2,000 2 - Field Testing 1,000 3 = Determine Information Flow to Generating Unit Operators and Others 400 4 ~ Documentation 300 TOTAL 4,200 It is anticipated that the four tasks will be completed in 24 months. 4-224.2.2.7 Related Current Project: trols and Operating Procedures Program and the Generating Unit Model and Perform— ance Indices Projects of this System Control Center Operation program are related The Instrumentation Program, the Plant Con— and will benefit from information exchange. Additionally, EPRI Project 1724, Opti— mal Power Flow Research and Computer Code Cevelopment, addresses both active and reactive power dispatch and should provide valuable information as to the overall problem and the information needed, 4.2.3 Performance Indices 4.2.3.1 Motivation, There is a gereral belief that system generation dispatchers could improve the economic operation of the control area if they had available an indication of the current econcmic performance of each generator and the overall power systen. The ability of the generation dispatchers to forecast changes in performance would enhance economic operation, through better short-term Scheduling, and reliability, through more realistic reserve calculations, As a re— sult of this, there is a need to develop a performance index for system generation which will take into consideration the perfcrmance index for each generating unit and overall power system factors, At the system level, the present Incremental Operating Cost At The Load Center (Lambda) is used in the economic dispatch algort - thn at many existing control centers. Since Lambda includes transmission losses , it is not useful for the purpose of comparing the performance of each generating unit to the aggregate power system generaticn performance. Additionally, neither Lambda nor aggregate system heat rate provide a conplete indication of system per— formance, and neither provides the ability to forecast changes. Presently, unit incremental costs are obtained from a unit heat rate model which is rarely updated. (The Generating Unit Models and Dispatch Algorithms Project addresses this pro~ blem.) Calculation of performance indices for individual generating units and for the ag— gregate system generation requires information in addition to the cost per mega— watt. The impact of other units, power interchange and equipment, anbient, and environmental constraints need to be taken into consideration. Inasmuch as each factor affects the relationship of each unit as it relates to the aggregate poner system, the solutions for optimum power system economy (and to some extent reli — ability) becone iterative, To aid in these solutions at the contro} center, it has been suggested that a ‘unit state vector" be developed which will contain the de— sired information. 4-234.2.3.2 Objectives. The primary objective of this research will be to define means by which unit generation, aggregate system generation, and overall power system performance indices may be calculated and presented to unit operators and system generation dispatchers so that they may readily know how much improvement should be obtainable from the overall power system, the generating units from which improvements should be obtainable, the amount obtainable, units which are experi- fencing a change in performance, units which have constraints imposed, and any unit for which there is a predicted change in performance. The information set associ- ated with this determination will be called the “unit state vector". An aggregate system performance index will be created from the unit state vectors with appropri- ate weighing factors. It is anticipated that the unit rating would be one of the weighting factors, Type of fuel or fuel mix may also require weighting, An additional objective will be to define an overall system performance index which will include the information from the unit and aggregate generation vectors and other power system information, It is intended that the power system information would include al1 of the important factors related to power system operation. This objective is intended to contribute a major step toward the automatic determination and presentation of power system state. The generation dispatcher will utilize these unit and aggregate generation indices and the overall power system index to obtain more precise, real-time economic dis- patch allocation and to initiate "preventive" actions to forestall further econo- mic degradation, improve economic operation, and to some extent maintain reliabili- ty. It is anticipated that the overall system performance index will also aid the transmission dispatchers in maintaining system reliability. 4.2.3.3 Scope. The performance indices project is organized into nine (9) tasks. A unit state vector and index is to be developed, from that, an aggregate system generation state vector and index, and then an overall system performance index, Methods are to be developed for presenting the information contained in the vectors and indices to control center dispatchers, unit operators, and performance engineers. Written and video training presentations are to be prepared. While the unit state vectors will be spectfically applicable to coal-fired units, ‘the general methods and the overall system performance index should be applicable to utilities with all types of generation, While it is not the intent of this ef- fort to apply the unit state vector concept to nuclear, combustion turbines, or 4-24hydro units, the methods may be useful in tre computation of predicted capability for all units on the systen. 4.2.3.4 Task Descriptions, The objectives of this project are addressed in the following nine (9) tasks. Task 1 - Determine the Uses and Associated Benefits to be Derived from Performance Indices It is expected that control center ceneration dispatchers would be in a position to obtain benefits from the unit and aggregate generation vectors and indices and the Overall System Performance Index through better scheduling and economic dispatching, It is also expected that the transmission dispatcher and dispatch supervisors would utilize ‘the Overall System Performance Index to obtain improved reliability. Unit operators and plant performance people would likely use the unit and aggregate generation state vector information to improve unit performance. The result of this task shall be a cescription of the expected bene- Fits to be realized from the utilization of each vector and index at each operating position or job area where they may be used. Task 2 - Determine the Factors to be Included in the Unit Generation State Vector and the Aggregate Generation State Vector The unit state vector will contain all of the factors which will com. pletely describe the generating urit capability and current condi- tions. It will also contain a short term capability forecast based upon information which is available from the unit, unit computers, and unit operators. This information set is to include status and value information for all factors relevant to current conditions such as heat rate, incre mental operating costs, unit capatility, response rate, linits or other constraints, and reliability. The information set should also make provision for including the ideal and/or theoretically attain- able "status or value corresponding to each factor representing Current conditions. Provisions shall be made for entering predictive information, particularly impending constraints which may be imposed and which may impact factors such as generating cost, response rate, maximun capability, or reliability. Additionally, all of the factors included in the generating unit model project (4.2.1) and voltage/VAR considerations project (4.2.2) shall be fully considered for inclu sion. The aggregate generation state vectcr will be essentially a composite of the unit generation state vectors for all fossil-fired generating units on the power system, It must be determined if any of the unit factors are not appropriate for the aggregate, and if there are any additional factors which must be taken into consideration. The re- sults of this task shall be complete listing of the factors to be in- Cluded in unit generation state vectors and the aggregate generation state vector, 4-25Task 3 - Determine the Factors to be Included in the Overall system Performance Indes (0SPI) It 4s expected that the OSPI will include the factors in the unit and aggregate generation state vectors and other power systen factors which will affect performance, One of the goals is to provide system Operators with an indication of the state of the power system, in~ cluding a predictive element, The factors considered in “Human Factors Review of Electric Pover Dispatch Control Centers" EPRI EL~ 1960, Vol. 4, Sec. 3 shall be considered. The results of this task shall be a complete listing of factors to be ‘included in the Overall system Performance Index. Task 4 - Determine and Test the Weighting to be Assigned to Factors in the Unit State Vector The relative importance of each factor to be considered, whether it be of a status or analog natur2, must be determined. The fact that a mill, feed pump, or blower is unavailable needs to have an analog weighing value associated witn the event such that the information becomes meaningful in terms of unit capability, Each factor must be examined and a logical weighting assigned as well as a range of weightings which may be required in different circumstances. ach weighting factor must be tested for reasonability by observing the effect of the weighted factor on the indication of unit generation. state, Results of this task will be a list of the weightings, weighting ranges, and/or the means of determining the weighting for a specific unit for each factor in the unit state vector, Task 5 - Determine and Test the Weighting to be Assigned to Factors in the Compilation of the Aggregate Generation Vector This task will refine the aggregate information from the unit state vectors such that the aggregate generation state indication responds reasonably to changes in the individual unit state vectors. Addi- tionally, any other factors which are appropriate for the comparison. of unit vectors against the aggregate must be properly weighted. The results of this task will be a listing of factors which must be weighted for the aggregate generation vector and the weighting, range of weighting, and method of determining the weighting. Task 6 - Determine and Test the Weighting to be Assigned to Factors of the OSPI This task will be necessary to determine the weightings to be assign- ed to the information from the unit or aggregate generation state vectors and the other power system factors determined in Tasks 2 and 3. The differences in OSPI factor weighting for different utilities 4-26Task Task Task may be significantly greater than the differences in the weighting of factors for individual generating units. The methods of determining the weighting are therefore of great importance. The result of this task shall be a description of the method of determining the wei ght~ ing for each of the factors in the Overall System Performance Index. 7 ~ Field Testing Incorporate the unit and aggregate generation vectors and the overall system performance index computation into an existing control center for test. The host dispatch center should be the one used in pro- Jects 4.2.1 and 4.2.2, The information collected shall include the analog values and status of all of the factors, all of the weight- ings, and all of the output indicat-ons produced from the unit and aggregate generation vectors and the OSPI. Tests should run for ap- proximately one year, or a sufficient period of time to demonstrate results through a range of events encountered by the power system, such as unit trips, major inter-tie trips, peak days and lightly loaded days. The result of this task will be a presentation of the OSPI readings (information) and the corresponding data over a period of several hours under normal conditions and before, during, and after the events described above. 8 = Determine Information Flow Examine the information developed and determine its usefulness to any who may use it, including unit operators, plant performance engi- neers, generation dispatchers, system dispatchers, and dispatch Supervisors. At the minimum, plant people should be able to observe the state of their unit, compare it with past performance, compare it with the performance of the aggregate generation, and have an indi- cation of which factors are presenting the unit fron reaching full efficiency and/or capability. Control center generation dispatchers may be interested primarily in the relative performance of all units, comparison of the current aggregate with the best obtainable, and the recent past. Results of this task shall include the recomended in- formation content, the method of presentation, format, up-date periodicity, and resolution for each item which is to be presented, 9 - Documentation Develop an explanation of the research, its findings and its develop- ments for a video presentation. The unit generation state vector and index, the aggregate generation state vector and index, and the Over- all System Performance Index shall be fully described showing how each relates to the other, The information flow which comes from 4-27each vector to the other and to the various operating positions and work areas shall be described and illustrated. The video pre- sentation should be directed to managers, engineers, technicians, unit operators, power dispatchers, system dispatchers, and dispatch supervisors. The result of this task shall be a video presentation of approximately 60 minutes duration, 4.2.3.5 Resources Required. Eligible contractors should include people who are knowledgeable in generating unit performance determinations, generating unit operation, control center application support programs, generation dispatch, and power system dispatch, It is expected that a small computer "spread sheet" can be utilized in testing the weighting factors, and a host utility mst participate pro- viding data, testing, and the control system computer. 4.2.3.6 Cost. The estimated manhours for the nine tasks is shown below. Task Descriptions Manhours, 1 - Determine the Use and Asscciated Benefits to be Derived from Performance Indicies 200 2 = Determine the Factors to te Included in the Unit Generation State Vector and the Aggregate Generation State Vector 500 3 = Determine the Factors to be Included in the Overall System Performance Index 700 4 ~ Determine and Test the Heighting to be Assigned to Factors in the Unit State Vector 1,000 5 - Determine and Test the Weighting to be Assigned in the Compilation of the Aggregate Generation Vector 400 6 = Determine and Test the We"ghting to be Assigned to the Factors of the OSPI 2,000 7 ~ Field Testing 1,000 8 ~ Determine Information Flow 800 9 = Documentat fon TOTAL 8,600 The duration of this project is estimated at 40 months. 4-284.2.3.7 Related Current Programs. The On-line Heat Rate Measurement Program, ‘the Instrumentation Program, the Plant Controls and Operating Procedures Program, and the Generating Unit Model and Voltage/VAR Dispatch Consideration Projects of this System Control Center Operation Program are related and will benefit from in— formation exchange. The already completed EPRI EL-1960, Volume 4, Section 3 iden~ tifies factors pertinent to the state of the power system. Research by PEPCO and their subcontractors on RP 1681/2153 is also relevant and should be reviewed prior to initiation of this project. 4,3 UMBRELLA PROGRAM C: INSTRUMENTATION Without doubt the major cause for difficulty in measuring unit heat rate is the in— accuracy of installed instrumentation. For both performance monitoring and econo— mic dispatch objectives instrumentation accuracy of +1 percent of actual value or better is required. However, instrumentation as installed in plants typically has errors greater than 5 percent and sometimes as large as 15 percent. The reasons for the errors vary significantly from plant to plant. However, the primary causes are improper installation procedures, infrequent or improper calibration, and in herent limitations in sensors. When utilities are asked what the installed instru- mentation accuracy is at their plants, they simply quote the accuracy specifica tions from the instrumentation vendor, Unfortunately, these numbers are the result of testing under laboratory conditions and not in actual plant environments. The actual as-installed instrumentation accuracy is not well not known, Because the as-installed accuracy is uncertain, the quantitative impact of instrumentation inaccuracies is also not known. To address these major problems, three projects have been defined within this un- brella program, The first project 1s entitled Instrumentation Accuracy Analysis and is intended to quantitatively define the as-installed accuracy in a cross sec~ tion of fossil plants, This will provide data necessary to determine quantitatively what improvements can be made in performance monitoring via improved instrunenta- tion. The second project is, in fact, an unbrella project in itself, It is titled Sensor Development Projects and involves the development of eight sensors believed neces— sary for improved unit performance monitoring. Initiation of any of these eight instrument development projects is dependent upon the results of the instrument - ation accuracy analysis project and other projects within this entire recomended progran that will substantiate the need for the individual developments. 4-29The third project is, in fact, entitled Sensor Calibration/Validation and is in- tended to address the problem of instrumentation calibration, 4.3.1 Instrumentation Accuracy Analysis Projects 4.3.1.1 Motivation, Based on substantial review by industry instrumentation Personnel and utility management, it is believed that more accurate instruments would produce more accurate heat rate measurements on fossil-fired units. However, it is not currently known what the as-installed instrumentation accuracy is. As-installed accuracy refers to the accuracy of the entire instrument string, in- cluding sensor, transmitter, wiring, interfaces, and readout, in the actual plant environment. This is different than the accuracy specification by the vendor which is based on laboratory testing. Before development of a new or modified instrument can be justified, the installed accuracy of existing instrumentation mst be shown to be inadequate for performance monitoring purposes. Since this project is in- tended to provide that quantitative information required to justify additional pro- grams, it is the prerequisite to the remaining projects within this program. 4.3.1.2 Objectives, The objectives of this project are ti 1, Determine the as-installed accuracy of performance monitoring instru~ mentation. 2, Determine the cost impact of the as-installed instrumentation errors fon plant performance, and 3. Determine the cost impact of as-installed instrumentation errors. on economic dispatch. ‘The third objective should be based upon the assumption that the minimum cost dis- patching 1s possible by the economic dispatcher when given accurate unit perform ance information. 4.3.1.3 Scope, The following characteristics define the scope of this pro- Ject. @ Only those measurements identified by ASME testing codes for turbine cycle analysis and boiler performance analysis will be examined for as-installed accuracy. The most common instruments and the most State-of-the-art instruments used for these measurements will be ad- dressed. ¢ The complete instrument string from sensing element to readout device must be included in the accuracy analysis. 4-30@ The analysis will be limited to coal-fired units. © To get a representative sample of the fossil industry at least five different units will be analyzed, The units should be selected to represent some of the major differences such as supercritical versus subcritical units and different turbine configurations, Furthernore, different aged units should also be considered. © Major instrumentation deficiencies (i.e., missing sensors) should al- so be identified to help characterize the level of instrumentation actually existing in a cross section of plants. © Instrumentation repeatability over a six month period of time will also be determined quantitatively. 4.3.1.4 Task Descriptions. The objectives of this project will be accomp— lished through the seven tasks described below: Task 1 - Identify Sensor Set To Be Analyzed The set of sensors dened most critical for heat rate measurement on coal-fired units shall be identified from ASME test code procedures. The set of sensors shall include those required for both subcritical and supercritical units as well as various turbine combinations. The major variables shall include steam and feedwater temperatures, pres- sures, flows, fuel flows and Btu content, and electrical output meas- urement equipment, The output of tris task shall be a brief report defining the selected sensors and the selection criteria. Task 2 - Select Test Units Criteria for selecting test units shall will be developed based on the sensors identified in Task 1, Additional criteria shall include the age of the units, the design of the thermodynamic cycle, the tur- bine configurations and the cooperation of the utilities. Gnce these criteria are established at least five units shall be selected for testing, It is important that the criteria represent a cross section of the coal-fired units in the utility industry. The output of this task will be a report describing the selected test units and the criteria for selection. Task 3 - Develop Detailed Test Plan Once the test sites are identified, and agreements between the con- tractor and the utilities are completed, a detailed test plan for determining as installed sensor accuracy shall will be developed for each plant. The test plan shall include the actual procedures by which pressure, temperatures, flows, and electrical signals will be tested for accuracy. In many cases, additional high precision in- strumentation be installed or standard calibration equipnent shall be available for determining the accuracy. All necessary equipment to perform the testing shall be identified, 4-31Task Task Task The time period between tests shall be identified so that a measure- ment of sensor drift rate can be determined. This shall be accomp~ lished primarily by determining the sensor accuracy with three separate accuracy measurements spaced one to six months apart. The factual time period shall depend upon the sensor design and calibra- tion schedules previously used by the plant test sites. In developing the detailed test plan, specific attention shall be ad- dressed to fiow stratification problens. Water and gas temperatures in large ducts are not uniform. Furthermore, a significant amount of stratification occurs within those ducts. Frequently sensors are 10- cated near the duct wall and properties are assumed constant across the flow cross-section, The detailed test plan shall identify a means of confirming the temperature distribution across large conduc ‘tors. Where irregular tenperature profiles exist, the contribution of the irregular profile to heat rate measurement errors shall be determined, The output of this task shall be a detailed test plan document for internal project use. 4 - Procure Qualification Equipment Al] equipment necessary to perform the sensor accuracy testing shall be procured under this task. Calibration equipment available through utilities or vendors shall be identified and used where possible. Any equipment that must be purchased shall be identified along with additional instrumentation required to ascertain instrumentation ac- curacy. The output of this task shall be a list of all equipment required for testing. 5 - Measure Installed Accuracy ‘The tests developed under Task 3 shall be performed under this task. Each sensor shall be manually tested to determine the as-installed accuracy. Both contractor and utility personnel shall participate in the testing to assure validity of results. The test procedure and results shall be documented or forms prepared under Task 3. | The testing procedure shall be performed at all test units at the time periods specified in the test plan developed under Task 3. The out~ put of this task shall be a report listing the as-installed accuracy and the test procedures used. 6 - Determine Impact_on Heat Rate Measurement ‘The impact of the as-installed accuracy on heat rate measurement. shall be determined for each of the test sites. The impact shall be based on comparison of heat rate assuming no instrumentation errors with the heat rate calculation based on the as-installed accuracy. The most significant contributor to heat rate measurement error shall be determined, The impact of this error on economic dispatch al 1o~ cation shall also be determined, The output of this task shall be a report showing the analysis procedure, results, and conclusions. 4-32ion and Dissenination The results of the accuracy testing and the analysis of the impact of the instrumentation accuracy shall be documented ina report and video tape for dissemination to the power industry. The documenta~ tion and video tape shall describe the testing procedure, the re- sults, and the conclusions along with guidance on how to apply the conclusions to other plants. The output of this task shall be a Final report and videotape document irg the procedures used, results, conclusions, and recommendations. 4.3.1.5 Resources Required. This project will require skilled technical man— Power and specialized equipment to achieve the objectives. Contractors interested in this project should be experienced in instrument string accuracy analysis as well as fossil power plant heat balance calculations, Furthermore, contractors should have available specialized field testing equipment to facilitate the mea— surement of as installed instrumentation accuracy equipment such as dead weight. pressure calibration equipment, temperature controlled heating chambers for ther— mocouple and RTD calibration, and high accuracy voltage, current, watthour meters will be required, 4.3.1.6 Cost. The estimated cost for the seven tasks are shown below. Task Description Manhours, 1 = Identify Sensor set 300 2 = Select Test Units 200 3 = Develop Detailed Test Plan 500 4 = Procure Qualifications Equ’ pment 600 5 - Measure Installed Accuracy 4000 6 - Determine Impact on H.R. 400 7 = Documentation and Dissemination 1000 Total 7000 Materials costs will depend on specific instrunents being developed, The costs for this project are estimated to be approximately 7,000 man-hours. The major contri- bution to this cost is the extensive testing required at five separate test sites. Because of the coordination required with several utilities this project is ex- pected to extend over an eighteen month period. However, significant technical output will be generated about 12 months into the project as the first round of testing is completed. This will provide the prerequisite information for sensor development tasks and autocalibration tasks described in the remaining two projects under this umbrella program, 4-334.3.1.7 Related Current Projects. One EPRI project, Power Plant Performance Instrumentation Systems - EPRI RP 1681/2153, currently underway is generating in- formation relevant to this project. The prime contractor is Potomac Electric Power Company (PEPCO) who is looking at the impact of instrumentation error on economic dispatching. Any activity on the above proposed project should be coordinated with the PEPCO project currently underway. 4.3.2 Sensor Development Projects Based on analysis of current heat rate reasurement problems and on recomendations from utility performance experts, several sensor development projects have been recommended. The generic tasks required to develop a specific sensor are basically the same regardless of the type of sensor being developed, Consequently, the pro- Ject descriptions for all eight sensor development projects are grouped under this one project description, The individual sensors identified by EPRI as a high pri- ority need are listed below: © — Moderate to low cost continuous BTU analyzer @ — Pulverized coal mass flow meter © Accurate boiler air flow methodology © Average fluid temperature in large pipes @ Stack and ash pit carbon losses © Stack acid dew point © Nonintrusive portable water flow © Water flow in large pipes 4.3.2.1 Motivation, Heat rate measurement today is believed to be plagued by poor measurements of some key variables. The reason for the inadequate measurement is due to various causes, Listed below are the primary motivating factors for each of the sensor developments reconmended by industry personnel and EPRI. Low Cost Continuous BTU Analyzer The measurement of coal BTU is currently done by sampling coal at the bunkers and transmitting the samples to the onsite or offsite labora- tory for BTU analysis. — This procedure introduces both a significant, time delay and the potential for selecting samples that do not repre- Sent the majority of the coal fed to the boiler. Furthermore, it does not provide a means of measuring variations in BTU released as the coal supply to the boiler is switched from one bunker or hopper to another, It is believed that a continuous measurement of coal BTU 4-34online is more desirable, A continuous coal analyzer called CONAC has been developed under EPRI sporsorship but is designed for ele- mental coal analysis upstream of the coal hoppers. Furthermore, it is far too expensive for the heat rate monitoring application dis- cussed herein. If a lower cost continuous analyzer could be developed that is accurate within one percent, then the method of determining boiler efficiency for the purpose of econonic dispatch would be greatly facilitated over the current techniques, Pulverized Coal Nass Flow Meter There is currently no measurement cf pulverized coal mass flow in a coal fired unit. Several techniques have been tried by many utili- ties but none have proven adequate for accurate pulverized coal ass flow measurement, As in the case cf coal BTU measurement, the meas- urement of fuel flow is essential to generate an online continuous measurement of boiler efficiency. There are additional reasons be~ yond heat rate monitoring for being able to measure coal flow parti- cularly if it can be measured at the outlet of the pulverizer, For example, it is desirable to maintain equal coal and air flow through all of the many lines leaving the pulverizer. Since the coal cannot Currently be measured, it is difficult to equalize the coal flow in each line. If a moderate/reasonable low cost coal mass flow meter could be developed, the flow to each line leading from the pulverizer to the burners could be controlled and the heat rate of the boiler could be more effectively measured for economic dispatch purposes. Accurate Boiler Air Flow Current difficulties with boiler air flow measurement are a result of ‘the large ducts in which the air is conducted to the boiler and the leakage and temperature profiles associated with these large ducts. It is believed that more accurate air flow measurements can be made by accounting for flow profiles in large ducts or by measuring the flow closer to the burners where the ducts are not as large. Again a more accurate air flow measurement will both contribute to the ac- curacy of the heat rate measurement as well as facilitate combustion efficiency control by more accurately controlling the air/fuel ratio. Average Fluid Temperature in Large Pipes The average fluid temperature in large conductors is difficult to measure because of irregular profiles across the flow path, In many cases, the flows are stratified, tiereby having temperature varia tions depending upon the introduction of flow streams upstream of the measuring point. The magnitude of the errors caused by assuming a flat profile across the conductor is unknown and is addressed in the previous project of this umbrella p-ogram. However, it is believed by experts in the utility industry that’ the imact’ of temperature stratifications and irregular temperature profiles are a significant contribution to errors in heat rate monitoring, 4-35Stack and Ash Pit Carbon Losses One of the potentially major losses in coal fired units is unburned carbon. Currently unburned carbon in the ash pit is determined by ash analysis and 1s not a continuous measurement, Most utilities do not measure carbon losses out the stack. With the extrene interest ‘in reducing excess air for combustion, the possibility of carbon losses out the stack is increased. Consequently, a means of meas uring carbon losses both in the ash pit and out the stack is needed. Stack Acid Dew Point The acid dew point has a significant effect on the life of the stack. As sulfuric acid condenses on the stack, it corrodes the liner which ultimately must be rebuilt. It 1s believed by the utility industry that current acid dew point monitoring methods are not adequate to protect the stack. Nonintrusive Portable Water Flow Meter Many water flows are not directly measured in fossil plants. These Flow streams have a contribution to the heat rate monitoring and either mst be estimated or calculated using iterative calculational schemes. It is believed by the utility industry that a nonintrusive accuraté portable water flow meter would provide a means of improving heat rate testing because it can provide more accurate measurement of auxiliary flows. Having a portable meter allows use of the meas- urement device on many plants thereby amortizing the cost of the device over several applications. Water Flow In Large Pipes As in the case of temperature in large conductors, water flow is also difficult to measure in large pipes because of the spatial differ- ences and the difficulty in calibrating large orifices or flow noz- zles. When temperature distributions are significant across the flow path, the density distributions are also varying. Consequently, a mass’ flow measurement cannot be calculated accurately unless the temperature density variations are accounted for. It is believed that a more accurate water flow measurement in large conductors which accounts for temperature variations will provide a more accurate measurement of heat rate. This is particularly true for condenser cooling water flow measurements. In addition to the above motivations identified by utility performance engineers, ‘the output of Project 1 Instrumentation Accuracy Analysis within this program will provide the quantitative justification for the sensor development projects recom- mended above. These justifications will be based upon the impact of the inaccu- Facies observed in the field instrumentation. None of the above projects should proceed prior to completion of the first round of analysis in the Instrumentation Accuracy Analysis Project. 4-364.3.2.2 Objectives. The general objeczive of this program is to develop and test the specific sensor identified. The specific objective of each development effort is to satisfy the motivations described in the section above, 4.3.2.3 Scope, For each individual sensor development the project will pro— ceed from an evaluation of alternative technical approaches through selection of a specific approach and to field testing the ulzimate design. 4.3.2.4 Task Descriptions. The objectives of this project will be achieved through the five tasks described below: Task 1 - Identify Alternative Design Approaches For each sensor under development alzernative design approaches shall be described, where several approaches are possible, a preliminary paper evaluation shall be performed to reduce the number of designs Under consideration to no more than four different approaches. A set of criteria shall be established upon which to perform the prelimi- nary evaluation and selection procedure. The criteria shall be established jointly by the contractor, two selected utilities, and EPRI. The Output of this task shall be a report showing the evalu- ation of alternatives and selection criteria used. Task 2 - Preliminary Design and Laboratory Test The preliminary design of the design approaches shall be tested ina laboratory environment. Based upon the laboratory tests one design approach shall be pursued further. The primary objectives of the laboratory tests are to determine tre ultimate costs, the technical feasibility, the environmental durability, and the overall perforn- ance, particularly including accuracy. The output of this task shall be a'report showing the evaluation rasults.. Task 3 - Prototype and Field Installation The selected design based on laboratary tests in Task 2 shall be pro- totyped using commercial grade equipment and packaging. This proto- type shall be installed at a selected host site for testing, A test Program be shall developed in conjunction with the utility and EPRI. The test program shall be designed to confirm that the instruments have met all the criteria established in Task 1, The output of this task shall be a working instrument ready for testing and a detailed test plan, Task 4 - Site Test The site test shall be conducted undar the host utility surveillance. Results documentation described unde> the test plan shall be prepared 4-37at the specified points in the testing. Continuous monitoring of the instrument performance shall be maintained to establish the reli- ability of the design. Frequent calibration checks shall be perform- ed to determine the accuracy and drift characteristics of the sensor. Evaluation of the sensor shall be based on the criteria established in Task i, The output of this task shall be a summary report of the test results and evaluations, Task 5 - Documentation A report written in EPRI format shall be prepared describing the de- Sign approaches considered, the ultimate design tested, the criteria and performance of the site test the conclusions of the test program, and. recommendations for any further research, 4.3.2.5 Resources Required. Instrumentation development requires rather specialized experience and laboratory facilities. Since several groups having these capabilities exist in the United States, EPRI should not be expected to pro- vide funding for laboratory construction. Consequently, the primary resource is a organization having both the manpower and laboratory facilities to perform the specific type of development and testing for the sensor under development, EPRI's role should be to define the instrumentation needs, provide initial research funding, to coordinate site testing, and to assure dissemination of results. 4.3.2.6 Cost, The estimated cost for the five tasks are shown below. Task Description Manhours 1 - Identify Alternative Design Approaches 400 2 = Preliminary Design and Laboratory Test 1500 3 - Prototype and Field Installation 1500 4 ~ Site Testing 600 5 ~ Docunentat ion 600 Total 4600 The cost of the sensor development programs are approximately 4,600 manhours per development. The majority of these costs Iie in the preliminary design and laboratory testing phases. The field installation and testing period will vary from one month to six months depending upon the specific instrument under de- velopment. However, the instrument will remain in the field unattended for a high percentage of this time. Consequently, the elapsed period of performance for the sensor development should be approximately 18 months. 4-384.3.2.7 Related Current Projects. Only one sensor development project is currently underway at EPRI, This is the development of a coal analyzer, CONAC, by SAI, under EPRI sponsorship. The CONAC is intended to develop a coal analyzer for many purposes other than heat rate measurement, The cost of the CONAC instrument is quite high and, consequently, it is not applicable to the specific objectives of the heat rate improvement program, Furthermore, its size requires that it be placed 8-16 hours upstream from coal burn, However, the technology may be condens — able into a lower cost device for continuous monitoring. 4.3.3 Sensor Validation and Auto-Calibration 4.3.3.1 Motivation, By far the most signficant contribution to error in and heat rate measurement using permanently installed instrumentation is the difficulty in keeping the instrumentation calibrated, This is because of the large nunber of sensors that require calibration and the higher priority work facing the instru- mentation crew. Given carefully calibrated instrumentation, accurate continuous online heat rate measurements may be possible without highly specialized and ex— pensive instrumentation and testing. However, to maintain this status the instru- mentation must be kept calibrated. Consequently, a means of detecting when sensors are out of calibration is believed to be a valuable tool because it will bring attention to those sensors requiring maintenance in a timely fashion. This will generate a sense of urgency for the maintenance of the faulty sensor and avoid the low priority syndrome of preventative maintenance that is currently practiced. 4.3.3.2 Objectives, The objective of this project is to develop a method— ology for detecting when sensors are out of calibration and develop a means for automatic calibration. 4.3.3.3 Scope. The scope of the sensor validation system should be limited to those variables identified under the instrumentation accuracy analysis project as being critical to heat rate monitoring accuracy. The sensors should be vali — dated for correct operation and calibration cver their full range. The validation schemes that are used to detect when an instrument is out of calibration must be valid during both steady state and transient operation, This is necessary since any of the plants operating on economic dispatch are cycling units and may have very short periods of steady state operation. The automatic calibration function should be operator initiated. It must advise the operator that the sensor has been removed from online operation while cali — bration is being performed. 4-394.3.3.4 Task Descriptions, The objectives of this project shall be addressed by the following seven tasks. Task 1 - Define Instrumentation Lists The list of instrumentation to be considered for validation and auto- matic calibration shall be based on the instrumentation accuracy analysis discussed under Project 1 of this umbrella program. There is one major criterion for instrumentation on this list. The typical instrument calibration errors mst have an impact of .25% or more on the heat rate measurement accuracy. The instrument list shall in= clude temperatures, pressures, flows, volts, current and watts. Sensors for supercritical and subcritical boilers as well as sensors for various turbine configurations shall be reviewed. The output of this task shall be a list of instruments to consider further for autocalibration. Task 2 - Identify Sensor Validation and Autocalibration Schemes The validation techniques and autocalibration techniques can be de- veloped separately in parallel. Both elenents can be achieved using various methods currently employed in other industries. The various Schenes that are applicable to the sensors identified in Task 1 above for both validation and automatic calibration shall be identified. These schemes shall include validation techniques used in the aero- space industry such as parity space and analytic redundancy as well aS conmon filtering methods and observer technology. Autocal ibrat ion Schenes shall include both analytical compensators as well as mechan- ical devices for physically correcting transmitters at their instal — Jed locations. The output fron this task shall be a description of the various schemes to be considered. Task 3 - Preliminary Evaluation of Alternative Schemes The validation and autocalibration schemes identified in Task 2 shall be reviewed with at least three of the utilities that participated in Project 1 (as-installed accuracy) to eliminate those methods which are inappropriate for the power industry. The impact of each scheme fon the control room operation, equipment requirements in the control room, and potential administrative problems shall be identified. The estimated cost to the utilities for the implementation of the various schemes shall also be estimated as a part of this preliminary evalu- ation. Task 4 - Design and Laboratory Tests The validation schemes and autocalibration schenes selected in Task 3 above shall be designed and tested in a laboratory environment. The 4-40Task Task Task laboratory tests shall provide a final evaluation of the renaining schemes so that the best validation and autocalibration system can be selected. The evaluation criteria shall be established prior to testing and reviewed by the three utilities, The laboratory tests shall include physical implementation of all analytical programs in a laboratory computer as well as installation of all hardware on flow test loops. Upon completion of the laboratory testing one validation and autocalibration scheme shall be recomended for field testing, The output of this task shall be a report showing the results of the laboratory testing and a recommendation of which schene(s) to pursue further. 5 - Field Testing The recommended validation and autocalibration scheme shall be imple- mented in field deployable hardware, This includes both conputer hardware as well as mechanical instrunentation and testing equipment, A test plan for both the validation system and calibration schemes shall be developed jointly with one of the three participating utili- ties. The test plan shall identify the various plant conditions under which the system shall be tested and the criteria for a suc~ cessful test. Additional criteria include the ability of the operator to understand and easily use a system. Of particular in- portance is the accuracy to which the validation system can detect calibration errors and the autocalibration systen can correct errors. This field test is a proof of principle tests. It is__not intended that this task confirma specific hardware design. The output of this task shall be a report showing the results and conclusions from the field test, 6 ~ Define Implementation Requirements Recommended methods of implementing the validation and calibration schemes tested under Task 5 shall be defined. The recommendations shall include alternative methods for implementing this system so that utilities can select the approach most suitable to their envi- Fonment and capabilities. The output from this task shall be a brief report on the above recommendations. 7 ~ Documentation Documentation shall be prepared in two forms. A written document, shall describe the details of the test program and the ultimate de- Sign of both the validation and autocalibration scheme. A video tape documentation shall describe how the system works, show the system in operation at the host site, and define the benefits obtained as a re- sult of the field test. 4414.3.3.5 Resources Required. This project requires a unique combination of, analytical capabilities as well as instrumentation and hardware capabilities. It will be necessary to have laboratory facilities that are capable of testing instru- mentation and sophisticated analytical algorithms as well as the ability to build field deployable test equipment. Although some of the mechanical methods for auto~ calibration must be fabricated by the contractor, all test loops and computer test equipment should be available and, consequently, not require EPRI funding. Even though the signal validation scheme and the autocalibration schemes are sig- nificantly independent and can be developed in parallel, there is sufficient com- munication required between the two schemes to reconmend the program be developed by one contractor. The prime contractor may use subcontractors for different por- tions of the work; however, communication is required between the two during oper ation. For example, the sensor validation scheme must initiate the autocalibration system, When autocalibration fs in operation the sensor validation scheme must be in standby mode, These types of interactions must be carefully designed into the system to avoid unnecessary operator interaction with resulting low confidence and lack of use. 4.3.3.6 Cost. The estimated cost for the seven tasks is shown below. Task Description Manhours 1 = Define Instrument List 200 2 ~ Identify Sensor Validation and Autocalibration Schemes 300 3 = Preliminary Evaluation 500 4 ~ Design and Laboratory Test 5000 5 - Field Testing 4000 6 - Define Implementation Requirements 200 7 = Documentation 1800 Total 12000 Material Costs $3500 In addition to manhour costs, this project will include fairly significant material cost because of the anticipated fabrication of physical devices for autocalibra- tion, The labor estimate is 12,000 manhours. There are three major contributions to this man-hour estimate, The laboratory design and test phase will include more than one scheme, It is estimated that at least three schemes will be tested re- sulting in nearly 5,000 manhours for this task. 4-42The field testing phase will require fabrication labor as well as design labor and negotiations with utilities for installation. Consequently, this task is expected to require about 4,000 manhours. The documentation task which requires both written and video tape documentation is estimated to require 1,800 manhours. These three tasks constitute the majority of ‘this project. The duration of this project is estimated to be 24 months. 4.3.3.7 Related Current Projects. EPRI Nuclear Power Division ts currently funding a signal validation project RP-2292, The intent of that program is to develop sensor validation schenes for use in nuclear power plants. The validation schemes under consideration are currently employed in the aerospace industry and are being applied to temperatures, pressures, flows and level measurements. A review of this project as results should be a prerequisite for initiation of the project. recommended above. Philadelphia Electric Company has developed strategies for validating signals through internally funded efforts [8]. Their approaches should be reviewed as part of the initial screening process. Research work has been performed by EG&G Idaho Inc. in the sensor validation area. A review of their results should be prerequisite reading for the initiation of the project reconmended above (71. 4.4 UMBRELLA PROGRAM D: DIAGNOSTICS If performance degradation can be detected, then the next step is to determine the root cause of the degradation, Algorithms designed to determine the root cause of performance problems are recommended for development under this umbrella program, The areas of primary concern expressed by the utility advisory committee and EPRI are the boiler, the generating unit control systems, and detection of impending failures throughout the turbine cycle. When root causes can be determined or in- cipient failures can be predicted, then maintenance schedules can be optimized to minimize the cost of operation. Another recommended project under this umbrella program is the optimization of the maintenance schedule given diagnostic informa- tion. 4-43Various diagnostics systens that attempt to predict the root cause of performance probiens are available throughout the industry today. Some are based on design codes while others are based on a system performance model. Most of these systems, however, are used only a cenand basis and are not used in maintenance schedule optimization, Furthermore, they are \inited to the boiler and turbine cycles and do not address the contro} systen. In addition, there is no attempt to predict ‘ailures thet will occur ir the near future. They attempt only to define the root cause of current performance deficiencies. This program is intended to develop algorithns that are integrated through the boiler, turbine, and control system in order to provide the comprehensive descrip- tion of the status of the generating unit. This information should then automati- cally be fed into the maintenance scheduling optimization program and a historical records file, This will establish a source for reliability information that can be maintained over a long period of time. The primary prerequisite for this program is the ability to measure performance with sufficient accuracy. Consequently, as indicated in the program overviews of Section 2 it is desirable to have completed Program A and relevant portions of Progran C prior to proceeding with Program D. Some work has been done by Babcock and Wilcox in the boiler diagnostics area pre- viously and has indicated where improvements may be possible in the industry with current instrumentation capabilities. Consequently, the boiler diagnostic project has @ more flexible project starting date. 4.4.1 Boiler Diagnostics 4.4.1.1 Motivation. Boiler diagnostics involves two major elements one of which is not considered under this program, The first element of boiler diagnos- tics is heat transfer effectiveness. Heat transfer effectiveness requires an analysis of several signals monitored within the boiler to determine where the heat transfer from hot gases to steam is being restricted, Slagging and soot build up can reach a point at which boiler performance begins to degrade. Furthermore, main steam and reheat steam temperatures begin to vary dramatically thereby effecting the entire cycle efficiency. When the boiler de- velops a significant siao or soot build up problem, the energy required to pump the air through the convection paths becomes greater, Furthermore, the gases leaving the stack are higher thereby increasing the stack losses. As the temperature 4-08distribution between reheat and superheat banks change because of soot build up, the reheat and superheat temperatures will change, thereby decreasing cycle effi- ciency in the turbine. Removing soot and slag requires significant auxiliary power in the form of steam or air extracted fromthe steam generation process or an auxiliary boiler. Furthermore, injection of steam in the gas path allows more heat to be carried out the stack. Therefore, it is not desirable to clean the boiler tubes continuously. In addition to efficiency losses, a continuous cleaning of the tubes will result in early tube failures. The second element is combustion optimization, which is addressed under Program C: Instrumentation, with measurement of stack and ash pit carbon losses (Section 4.3.2), Program E in the combustion optimization project. Combustion optimization is not addressed in this program because it requires direct measurement of com- bustion products and does not require any extensive algorithns to determine the root cause of deficiencies. 4.4.1.2 Objectives. This project is intended to develop algorithms that de- termine the boiler surface cleanliness and various heater banks throughout the boiler based on permanently installed instrumentation measurements. The algorithm will also provide recommended soot blowing cycles based on the cost of blowing soot and the cost because of inefficient cycle operation resulting from the slagging or soot build up conditions. 4.4.1.3 Scope. The scope of this project shall be limited to coal-fired Supercritical and subcritical units, The final algorithms should be applicable for all types of coal burned fn the United States including bituminous, sub-bitumtnous , and lignite. The algorithms should be written in an ANSI standard FORTRAN 77 sub~ routine format so they can be implemented on a wide variety of currently installed plant computers. 4.4.1.4 Task Descriptions, The objective of this project will be achieved through the five tasks described below: Task 1 - Quantify Potential savings The potential savings from optimum sootblowing scheduling shall be determined. Factors to consider in the potential savings include the tube wasteage due to excessive sootblowing, the cost of blowing soot, as well as the cost of inefficient operation because of soot and slag buildup. The analysis shall include steam, water, and air soot- blowing medium where appropriate. Continuation into the development 4-45Task Task Task Task ‘tasks that follow shall be dependent upon favorable prospects for economic improvement. The output of this task shall be a report identifying the potential improvenents. 2 - Develop and Test Analysis Equations Depending upon favorable results from Task 1, the equations required for determining the boiler cleanliness on a bank by bank basis and for optimizing the cleaning procedure shall be developed under this task. The complete FORTRAN algorithms required to implenent the analysis and optimization shall also be developed and implenented on a laboratory computer. Recorded field data fron a selected host utility shall provide the basis for testing the algorithms. The algorithms will be coded in a subset of FORTRAN 77 that is operable with FORTRAN 65, The output of this task shall be a report including ‘the FORTRAN algorithms and test results. 3 = Determine Instrumentation 2equirenents The instrumentation required to implement the analysis and optimi- zation procedures developed in Task 2 above shall be identified. Any special instrumentation not typically installed in fossil power plants shall be specifically noted, Furthermore, any special compu tational or output monitoring devices required for effective use of the analysis and optimization procedure shall also be specifically noted, "The output of this task shall be a brief report listing the required instrumentation and ssecial computational requirenents. 4 ~ Field Test A host unit shall be selected based on the instrumentation available as specified under Task 3. The algorithms developed under Task 2 shall be implemented in a field deployable conputer and installed on the host unit. A test procedure shall be developed which identifies ‘the various unit conditions under which the system mst be operable and a complete list of evaluation criteria, The analysis and optimi~ zation system will then be tested in the actual field environment. under the specified conditions, The clarity and usefulness to the plant operators is a significant factor to determine during this field test. The output of this task shall be a report showing the results of the field test. 5 - Docunentation Two types of documentation shall be prepared on this project. A written document shall describe the test procedures and results along with the detailed description of the algorithms used, The written material shall further recommend operating procedures to be followed when using the analysis and optimization system. A video tape of the actual field test showing the output formats and operator reactions to the system shall also be prepared. 4-46