1.

Overview of Performance Monitoring
1.1 Concept of Performance Monitoring

1.1.1

"Where You Are" Versus "Where You Should Be"

Performance monitoring is the process of continuously evaluating the production capability and efficiency of a power plant and its equipment over time using measured plant data. Performance monitoring evaluations are repeated at regular intervals using data readily available from on-line instrumentation. This differs from a performance test, a one-time event that relies on precision instrumentation installed specifically for that test. The objective of performance monitoring is to continuously evaluate the degradation (decrease in performance) of the plant and its equipment in order to provide plant operators additional information to help them identify problems, improve performance, and make economic decisions about scheduling maintenance and optimizing plant operation. A successful performance monitoring system can tell plant operators how much the plant performance has changed and how much each piece of equipment in the plant contributed to that change. This information enables operators to localize performance problems within the plant and to estimate the operational cost incurred because of the performance deficits. While it is expected that performance monitoring will help operators diagnose and repair faults in plant equipment, the diagnostic procedures to accomplish this are beyond the scope of this book. To answer the question "How good is my performance?" one must compare the current capability of the power plant and its equipment to its expected capability. Thus, performance monitoring is a comparison of the current capability, "Where You Are", to the expected capability, "Where You Should Be". Production capability is a measure of the ability of equipment to produce the output that the equipment is designed to produce; it is not the current production. In other words, a plant that is designed to generate (produce) 600 MW, might only be able to generate 550 MW on a hot day, but still be capable of generating 600 MW when operating at its design conditions. The objective of performance monitoring is to continuously evaluate this capability and monitor its change over time. Degradation is defined as the shortfall in equipment performance caused by mechanical problems in the equipment (such as wear, fouling, and

Abu Bader

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1. Concept of Performance Monitoring

oxidation), but not by changes to set points under the control of the plant operators. For example, if plant operators increase the excess oxygen on a coal-fired boiler to reduce CO emissions when burning low quality fuel, the boiler efficiency will decrease. The boiler capability has not changed: if the fuel and excess oxygen level were returned to their original value, the boiler efficiency would also improve to its original value. Thus, the observed efficiency decrease in this example is not degradation, but is instead an opportunity for economic optimization. A second example is a gas turbine whose water-to-fuel injection ratio must be increased to meet more restrictive NOX emissions requirements. The engine power would increase and the heat rate would get worse (increase). These changes in performance do not represent degradation, just a change in operating conditions. Economic optimization is concerned with finding the plant operating mode and control set points that meet all constraints on plant operation (such as equipment protection and emissions limits) and maximize plant profits. The current degradation of plant equipment is an important input to optimization analysis and the current plant control set points are important inputs to degradation analysis, but the two are separate evaluations. Performance monitoring involves two calculations: current production and expected production. The evaluation of performance degradation is a comparison between these two values. For example, a plant designed to produce 600 MW on a 59 F day may be expected to produce 550 MW on a 100 F day. If the plant meets its expected production of 550 MW on the 100 F day, then its performance is as expected (zero degradation) even though it did not perform at its design production level of 600 MW. Table 1-1 lists the plant equipment types discussed in this book, the production objective(s) of each equipment type, and an output parameter that is a measure of each production objective. Any performance evaluation of the equipment listed in the table must relate the cur r ent production capability of the equipment to the expect ed production capability. Notice that the equipment types that consume fuel have two production objectives, and hence two measurements of performance. This is because output and efficiency are independent parameters for these equipment types. For fuel-consuming equipment, efficiency needs to be evaluated along with output production capability because it may be possible to achieve higher output by simply consuming more fuel. For other equipment types (non-fuel-consuming types such as heat exchangers and steam turbines), the input source of energy is fixed (that is, not determined by the performance of the equipment type being monitored)

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1. Concept of Performance Monitoring

and therefore higher efficiency causes higher output. Thus, for these equipment types output and efficiency are not independent performance parameters.

Table 1-1 List of equipment types and their production objectives Equipment
Power Plant Gas Turbine Boiler

Production Objective
Electricity Efficiency Electricity Efficiency Steam Generation

Measured Output
Net Power (MW) Net Heat Rate Power Heat Rate Steam Flow(s), Temperature(s) and Pressure(s) Boiler Efficiency Steam Flow(s), Temperature(s) and Pressure(s) Power Condenser Shell Pressure Cooling Water Temperature to Condenser Feedwater Outlet Temperature

Efficiency Heat Recovery Steam Generator Steam Generation Steam Turbine Condenser Cooling Tower Feedwater Heater Electricity Vacuum Energy Rejection Feedwater Heating

The performance of a power plant has two measures: power and heat rate. They are independent measures of performance in that the highest power is not necessarily achieved at the best (lowest) heat rate. A plant operator generally has the option to control the plant for maximum power output or to control for maximum efficiency. A performance evaluation of a power plant must include evaluations of both the power generation capability and the heat rate capability.

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1. Concept of Performance Monitoring

A gas turbine is like a power plant; in fact, a simple-cycle gas turbine is a power plant. Thus, both power and heat rate are independent performance parameters that must be evaluated when monitoring a gas turbine. A boiler consumes fuel to generate steam. Both the steam generation capability and the boiler efficiency are important parameters of boiler performance, and both must be evaluated. The job of a heat recovery steam generator (HRSG) is to convert the available exhaust gas energy into as much steam as possible. When the plant is operating at full load, the temperature and pressure of the steam are controlled by the plant, and therefore are not independent parameters of HRSG performance. They represent requirements that the HRSG must meet. Improved HRSG effectiveness or efficiency results in increased steam generation. There is no opportunity to increase steam generation capability without increasing HRSG efficiency; thus, efficiency and steam generation are not independent parameters of performance. A performance monitoring system must compare the current value of HRSG steam generation or efficiency to its expected value. A condenser's job is to condense all of the steam exhausted from the steam turbine at a pressure as low as possible. The need to condense all of the steam is a requirement that must be met. Condenser pressure is the measure of condenser performance: the lower the pressure the better the performance. A performance monitoring system must compare the current value of this pressure to its expected value. Other parameters of condenser performance, such as cleanliness, are only important because they are an indication of the ability of a condenser to reduce steam turbine exhaust (condenser) pressure to its expected value. A cooling tower must reject all of the steam condensation energy (condenser duty) to the cooling media (air or water). The quantity of energy to reject is a requirement that the cooling tower must meet. The measure of performance of a cooling tower is the cooling water temperature at the exit of the cooling tower (or at the inlet to the condenser). A lower value of this temperature indicates better performance. A performance monitoring system must compare the current value of this temperature to its expected value.

1.1.2

Performance Calculation Procedure

Performance monitoring involves a calculational procedure that is repeated at regular time intervals. The details of the calculation vary greatly from plant to plant, depending upon the measured data that is available, the plant type, and the degree of sophistication of the calculations. However, a

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1. Concept of Performance Monitoring

performance monitoring calculational procedure always involves some or all of the following steps:

1. Acquire measured data. 2. Review, check and/or validate the raw measured data to find errors and omissions. 3. If possible, fix errors or omissions identified in the measured data. 4. Improve precision of the measured data by averaging and/or other techniques. 5. Compute fluid thermal properties, such as enthalpy and entropy, from measurements. 6. Use mass, energy and/or chemical balances to calculate data that is not measured, but can be
computed from the measurements that do exist.

7. Compute current values for equipment parameters of performance such as heat rates, efficiencies,
effectiveness's, temperature differences, and cleanliness.

8. Predict expected values for equipment parameters of performance. 9. Compute the corrected performance of the plant equipment 10. Calculate the shortfall in performance (degradation), based upon the difference between the
expected and current values of the performance parameters.

11. Estimate the effect (impact) that the equipment degradation has on plant performance and plant
operating cost.

12. Perform plant optimization calculations to predict the most cost-effective way to run the degraded
plant equipment. A given performance monitoring system often will not perform all of these calculational steps, but the list is a fairly complete compilation of the calculations that can be and probably should be done in a comprehensive and successful performance monitoring system.

1.1.3

Expected Performance: "Where You Should Be"

For performance monitoring to be meaningful, one must compare current performance to expected performance, and track that comparison over time. This process is equivalent to tracking degradation (the difference between expected and current performance) over time. Since performance monitoring is a continuous process, as opposed to a one-time event like a

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1. Concept of Performance Monitoring

This makes the evaluation of expected performance the most challenging aspect of performance monitoring. the performance evaluation will be performed over a variety of plant operating conditions. as illustrated by the expected power line in this figure. such as table look-ups. Gas turbine vendors typically provide performance curves which show how performance will change with environmental conditions. The model(s) of equipment performance can be very simple. The baseload power of a gas turbine engine varies with inlet air temperature. The procedure to calculate expected performance is to start with the expected performance at the reference operating conditions (the rated performance). which occurs at only one air inlet temperature (shown as TRererence in Figure 1-1). as illustrated in Figure 1-1. Figure 1-1 illustrates the concept of expected versus actual (degraded) power for a gas turbine engine. The cor r ect ed power is the power that the actual (degraded) engine would produce if operated at the reference temperature. such as a physically based computer code. The difference between the rated and corrected power is the degradation of the engine from rated. the measured gas turbine power levels will likely be along a line below the expected power line. When a degraded gas turbine is operated over a range of inlet air temperatures.performance test. and then use a model or models of equipment performance to predict the change in equipment performance when the equipment is operated at conditions different from the reference operating conditions. Notice that one point on the expected power line is the r at ed power. A vendor performance curve can be used to compute the expected power line. or very complex. Page 18 1. It is assumed for the purposes of this discussion that ambient temperature is the only environmental parameter that is changing. Concept of Performance Monitoring .

fuel properties. Since these are independent parameters of gas turbine performance. Using curves to evaluate equipment performance is discussed later in this chapter under "Curve-Based Methods". expected. Of course. inlet relative humidity. Page 19 1. Concept of Performance Monitoring . any gas turbine performance monitoring system must also account for changes in other reference operating conditions such as inlet pressure loss. steam/water injection. inlet pressure. separate models can be used for each condition. and the total power change is the product of the power changes predicted from the changes in each reference operating condition. This line could be converted into a table look-up as part of a computerized performance model.Performance Evaluation Terms Figure 1-1 Comparison of rated. exhaust pressure loss. inlet guide vane angle and firing temperature. measured and corrected power for a gas turbine The expected performance line in Figure 1-1 is actually a simple example of a performance model of a gas turbine. This line shows how gas turbine power will change as the gas turbine inlet temperature changes.

Table 1-1 lists all of the specifications that are required to state the rating of a gas turbine. The values of the reference operating conditions are called the r ef er ence data. There are several ways to obtain the rating data for a plant and its equipment. the choice is somewhat arbitrary since a monitoring system tracks changes in performance or degradation over time. It would be necessary to adjust (tune) such a computer code so that it accurately predicts the gas turbine rated performance at the reference operating conditions. Then the performance monitoring system could input measured data into the computer code to predict the expected performance at the current measured operating conditions. the absolute value of the rating cancels out. 1.4 Equipment Ratings The rated performance of plant equipment must include a specification of all the external conditions and control settings that change equipment performance but are not part of the equipment itself. combustor and expander. For performance monitoring purposes. All of the data in Table 1-2 are related.Table 1-20 Typical rating specifications for a gas turbine engine An alternative model of gas turbine performance is a computer code that includes physically based mathematical models of the compressor. If the monitoring system defines degradation as the fall-off in performance over time.1. Such a code would take the operating conditions as inputs and predict the gas turbine power and heat rate at those operating conditions. . Using physically based computer models to evaluate equipment performance is described later in this chapter under "Model-Based Performance Analysis". and the power and heat rate of the engine will change (from rated). Several ways to define equipment ratings are: • • • • Use vendor guarantees Use acceptance test (as-built) data for the plant and equipment Use plant measured data at the time the monitoring system is installed Baseline (tune) the ratings on a regular basis using plant measured data A gas turbine will produce its rated power and heat rate only at the reference operating conditions listed. Change any of the operating conditions (from their reference values).

Table 1 -3 lists the rating specifications for a typical heat recovery steam venerator.Table 1-2 Typical rating specifications for a steam turbine/generator Gas Turbine Rating Specifications RATING: Gross Power Gross Heat Rate Example Data 170 MW 9400 Btu/KW-hr 59 deg-F 14.0065 lbm H20/lbm air 4 in H20 12 in H20 none Natural Gas 20200 Btu/lbm 86 deg 2300 deg-F none REFERENCE OPERATING CONDITIONS: Ambient Temperature Ambient Pressure Ambient Specific Humidity Inlet Pressure Loss Exhaust Pressure Loss Steam Water Injection Fuel Type Fuel Lower Heating Value Inlet Guide Vane Angle Firing Temperature Inlet Cooling or Heating The expected performance prediction for a gas turbine.65 psia 0. plus a model of performance that predicts how performance changes as the operating conditions change. Concept of Performance Monitoring . Page 21 1. or for any equipment type. requires both a set of rating specifications (which includes both the rated performance and the reference operating conditions).

000 lb/hr 70.Table 1-3 Typical rating specifications for a heat recovery steam generator (HRSGj Heat Recovery Steam Generator Rating Specification RATING: HP Steam Flow IP Steam Flow Example Data 415. Page 22 1.250. Concept of Performance Monitoring .000 lb/hr REFERENCE OPERATING CONDITIONS: Exhaust Gas Flow Exhaust Gas Temperature Exhaust Gas Composition HP Drum Pressure IP Drum Pressure LP Drum Pressure Inlet Feedwater Temperature HP Steam Temperature Duct Burner Fuel Flow Steam Extraction to Process Water Extraction to Process Once again. the rating specifications for an HRSG indicate that the HRSG will produce the rated steam flows only if it is operating at the reference operating conditions.000 lb/hr 30. a monitoring system must be able to predict the change in HRSG performance as operating conditions change from their reference values. To predict HRSG expected performance.000 lb/hr 3.000 lb/hr 1138 F 3% H20 1900 psia 400 psia 100 psia 140 F HOOF none 20.

Concept of Performance Monitoring .000 lb/hr 1137 F 1800 psia 0.Table 1-4 gives typical rating specifications for a steam turbine.8 psia 1000 F none 160.000 lb/hr REFERENCE OPERATING CONDITIONS: Throttle Steam Flow Throttle Steam Temperature Throttle Steam Pressure Condenser Back Pressure Reheat Steam Temperature HP Extraction Flow LP Admission Flow A steam turbine will generate its rated power only at the rated steam flow conditions and condenser pressure. Any change in these flow conditions or pressures will cause the steam turbine power to change. Steam Turbine Rating Specification Example Data RATING: Gross Power 190 MW 930. Page 23 1.

Any change in the inlet steam or water flows will be expected to change the condenser pressure. The condenser is designed to achieve its rated pressure at a given (reference) set of inlet flow conditions. Concept of Performance Monitoring .000 lb/hr 1000 Btu/lb 6.000.Table 1-5 Typical rating specifications for a condenser Condenser Rating Specification RATING: Shell (Steam) Pressure REFERENCE OPERATING CONDITIONS: Inlet Steam Flow Inlet Steam Enthalpy Cooling Water Flow Cooling Water Inlet Temperature Example Data 0. Page 24 1.8 psia 930. the cooling water flow and the cooling water inlet temperature are imposed upon the condenser by the performance of other equipment in the plant (external to the condenser). The condenser duty.000 lb/hr 80 F A condenser is required to condense all of the incoming steam and transfer the energy released from condensation to the cooling water.

4.2.0. H:0. S.000 lb/hr 89.2. Ash) Inlet Feedwater Temperature Inlet Air Temperature Inlet Air Relative Humidity 3374 mmBtu hr 2800 psig 1005 F 1005 F 2. H. Concept of Performance Monitoring page 26 .Table 1-25 Typical rating specifications for a feedwater heater Table 1-6 Typical rating specifications for a COAL-FIRED BOILER Boiler Rating Specification RATING: Main Steam Generation Boiler Efficiency Example Data 2.59% REFERENCE OPERATING CONDITIONS: Fuel Input Energy Steam Drum Pressure Steam Temperature Reheat Steam Temperature Reheat Steam Flow Reheat Steam Inlet Pressure Fuel Higher Heating Value Fuel Composition (C.4.19.1.5.1.495 Btu/lb (64. N.560.8.000 lb/hr 592 psig 11.9) 475 F 80 F 60 % 1.4.275.4.

Table 1-7 Typical rating specifications for a feedwater heater Feedwater Heater Rating Specification RATING: Outlet Feedwater Temperature Outlet Drain Water Temperature Example Data 420 F 380 F 120. Concept of Performance Monitoring .000 lb/hr 890 F REFERENCE OPERATING CONDITIONS: Inlet Steam Flow Inlet Steam Temperature Page 26 1.

600.5 Corrected Performance: The Indicator of Degradation For combined-cycle power plants. The virtue of corrected performance is that its expected value remains constant and equal to the rated value. To cor r ect the performance means to account for the performance variations that would be expected due to the changes in environmental conditions and control set points. This makes it difficult to track changes in performance.000 lb/hr 460 F 1. 1.Table 1-27 Typical rating specifications for a feedwater heater Inlet Steam Pressure Inlet Feedwater Flow Feedwater Inlet Temperature Inlet Drain Water Flow Inlet Drain Water Temperature 320 psia 2. the expected performance varies greatly over time. usually the reference operating conditions. One methodology to make the identification of performance changes over time easier is to "correct" the current performance to a standard operating condition. Concept of Performance Monitoring page 26 . The corrected performance is the performance that would be expected if the current (degraded) engine were operating at the reference operating conditions. any change in a corrected value represents a change in equipment performance capability. Thus.1.000 lb/hr 370 F 150. as the measured values of most performance parameters vary due to changes in plant operating conditions.

If changes in the engine operating conditions were to cause changes in gas turbine power. In fact. The measured power is shown on the plot only when the engine was operating at or above 99% percent of baseload power. the degradation in performance from one point in time to another is equal to the change in corrected performance over that time range. An overhaul was performed on the gas turbine during October 2002. Concept of Performance Monitoring . It goes down when degradation increases and it goes up when degradation decreases. ambient conditions. the corrected power would not change. Figure 1-2 is an actual trend of gas turbine measured and corrected power. Notice that measured Page 28 1. and exhaust delta-P). Figure 1-2 Measured and corrected gas turbine power over a nine-month time period. water/steam injection. Corrected gas turbine power accounts for changes in engine operating conditions and predicts the equipment performance if the equipment were to operate at the reference operating conditions (including inlet filter delta-P. fuel heating value. load level. this time period is evident on the plot as the time during which there is no measured data.Corrected power is a barometer of engine performance.

but gives the viewer little information about degradation. When the tubes and Page 29 1. or it is a prediction of the power the engine would achieve in a performance test at reference operating conditions. Cooling water flow through the tubes also decreased about 4° o during this time period (not shown on the figure). In other words. The trend display of measured power is a history of operation. a loss of approximately 3 MW over a three-month period. Notice the slow increase in corrected pressure over 150 days. It is essentially the current rating of the engine. this plot shows that the overhaul improved the engine's power capability by 3 MW to 4 MW.baseload power vanes during each day. The engine overhaul in October improved the corrected power back up to approximately 162 MW. Notice that the engine corrected power started at over 161 MW in July and degraded to approximately 158 MW by October. Each corrected power point shown in Figure 1 -2 is an average of calculated corrected power over a time period of approximately two hours. Concept of Performance Monitoring . Figure 1-3 shows corrected condenser pressure at a combined-cycle power plant in the United Kingdom. Corrected power is a prediction of the power that the engine would generate if operating at reference operating conditions. and is higher in the winter months than in the summer months. indicating fouling of the condenser tubes and/or blockage in the waterboxes. The corrected power is a convenient plotting parameter because it shows degradation in the engine.

For the value of degradation to be meaningful. If the degradation is defined as the change from guarantee (a level of performance that the equipment may never have actually operated at). If no time range is stated. Degradation will be defined throughout this book as the difference between corrected and rated performance.1. Thus. the corrected condenser pressure improved back to approximately the same level as the beginning of the trend. Since degradation is defined as a change in performance over time. this definition of degradation is only true if the equipment actually achieved its rated performance at some point in time. indicating that the equipment is performing better than the guarantee level. the equipment may not have ever operated at its rated performance. Thus. and the cooling water flow rate also recovered (not shown on the figure). the difference in corrected power from one point in time to another is the degradation that has occurred over the time period. but if sufficient plant data is not available it may be set equal to the vendor guarantee. some plant equipment may show may show negative degradation. Rated performance is often set equal to the vendor guarantee as opposed to a performance test at the beginning of equipment life. This is equal to the difference between the rated performance and the corrected performance. it compares equipment capability at one point in time to that at another time. 1. It is a relative parameter. the start time and end time of the degradation must be stated.6 What is My Degradation? Degradation is the reduction in equipment performance capability that has occurred over time. Concept of Performance Monitoring . Page 30 1. it is usually assumed that the degradation is over the operational lifetime of the equipment. degradation may be stated as the difference between the current equipment capability and its rated capability. Often when historical data is not available.waterboxes were cleaned during a plant outage. Since the corrected gas turbine power is a prediction of the current rating of the engine. Ideally. while a change from guarantee may be misleading. degradation may be defined as the change in corrected performance over time. which is from the time the equipment was put into service to the present. The definition of degradation as a change over time instead of the change from vendor guarantee is significant to the concept of performance monitoring because a change over time is an aid in identifying changes in equipment performance. the rated performance should be defined as the actual performance at some given point in time.

The impact of the condenser degradation on plant power is equal to the change in plant power caused by the degradation of the condenser. Therefore. is particularly important. One way to make a meaningful comparison is to calculate the impacts of the degradation on overall plant power.9 mbar). For example. The best that the operators can be expected to do is to maintain plant performance at a level that the plant actually operated in the past. For example. heat rate and operating cost. Concept of Performance Monitoring . Page 31 1. which is also a reduction in plant power. a condenser may have a degradation of 0. plant operators need to know how much the degradation is costing plant operation. The heat rate increase of the gas turbine will cause the plant to consume more fuel per MW-hr of power produced. but it's not the full story. Here is a situation where the definition of degradation as a change in performance over time. This makes it difficult to compare degradations calculated for different parts of the plant or for different equipment types. Once the plant is accepted and goes into commercial operation it is too late to worry about equipment guarantees. This degradation causes a reduction in steam turbine power.1. degradation is an estimate of the performance improvement that is possible.1. The power reduction in the gas turbine reduces plant power because both the gas turbine and the steam turbine power levels will change.1 psi (0.1 psia (6. These effects on plant power and heat rate can then be converted to operating costs by applying a fuel cost to the extra fuel being burned. Degradation normally is evaluated in different engineering units for each equipment type: gas turbine degradation is in MW while condenser degradation is in either psia or percent cleanliness. The definition of a plant impact is the change in plant performance that would be realized if the degradation were to be returned to zero by some maintenance action. The steam turbine power changes because the gas turbine exhaust flow and temperature normally change as a result of the gas turbine degradation. In order to make decisions about which maintenance to perform. which can be calculated using an overall plant model. as opposed to a change from vendor guarantee.7 How Much is Degradation Costing Me? Knowing the amount of degradation is important. This means that the condenser is operating at a pressure 0. and/or a MW-hr cost to the power which is not being sold because of the degradation. a reduction in gas turbine performance (power and heat rate) has an effect on overall combined-cycle plant performance. and any existing degradation can be looked upon as the source of an operational cost that is potentially avoidable.69 mbar) higher than it would operate if the degradation were zero.

Table 1-7 below illustrates the concept for a combined-cycle plant. which will reduce boiler fuel consumption. The change in plant heat rate caused by the degradation in the condenser is called the impact of condenser degradation on plant heat rate.3 2.1 16 75 41 31 25 13 191 46 294 169 84 56 22 671 Inlet Air Filter GAS Turbine HRSG Steam Turbine Condenser Cooling Tower Total Plant 1.000 lb/hr 0.1 psi 2. the plant power always decreases and heat rate always increases when condenser pressure increases.The reduction in plant power due to the condenser degradation increases plant heat rate since fuel flow is not changed. fuel flow in a Rankine cycle plant with condenser degradation may decrease slightly because the increased condenser pressure will lead to higher feedwater temperature entering the boiler.8 0. These changes in plant performance reduce electric sales revenues and increase fuel costs. even so. Then these degradations can be compared and evaluated on a consistent (apples to apples) basis.2 5. resulting in a net operating cost to the plant. Concept of Performance Monitoring . Table 1-8 Example of plant equipment degradations and their impacts on plant performance Equipment Degradation Impact on Plant Performance Power Heat Rate Operating Cost (MW) (Btu/kw-hr) ($/hr) 0.4 0.2 1.1 F Page 32 1. The idea behind the overall plant impacts is to convert all of the degradations in the plant to their respective costs on plant performance. The change in plant revenues minus fuel costs is called the impact of condenser degradation on plant costs.8 MW 0.9 MW 12.1 in-H20 1.2 0. Actually.

The inlet air filter in Table 1-8 has a pressure-loss degradation equal to 1.9 MW if operated at the plant reference operating conditions.9 MW) is called the corrected plant power. and the total power degradation from rated is 5. but optimization is concerned with actions the operator can take to improve performance without maintenance. In a similar manner.8 Optimization: "Where You Could Be" Once the degradation of the plant and its equipment is known. An example of calculated optimization outputs for a combined-cycle power plant with two gas turbines is illustrated in Table 1-9. Concept of Performance Monitoring . the total of the equipment impacts on plant power is equal to the degradation in plant power. which is defined as the impact of the air filter on plant power. The total plant power would increase by 0. Then. if the plant were rated at 400 MW.1. For example. The total plant power degradation is equal to the sum of the equipment impacts on plant power.1 in-H. resulting in a gas turbine power increase. The equipment degradation listed in Table 1-8 summarizes maintenance issues. 1. "Impacts of Degradation on Overall Plant Performance". If this degradation were eliminated by replacing the air filters. the plant operator is prepared to answer the question. when the degradation is calculated from rated.1 MW. Methods to calculate these impacts are reviewed in the chapter 6. the plant would be expected to now produce only 394. Page 33 1. This power (394.0. The steam turbine power would also increase because of the increase in gas turbine exhaust energy. Overall these changes in plant power and heat rate would yield a net increase of 46 $/hr in plant operating profits (electric sales revenues minus fuel costs).3 MW. The current plant operating costs (electric sales revenues minus fuel costs at the reference operating conditions) are $671/hr higher than they would be if the plant was performing as rated and was operating at the reference operating conditions. "What is the best way to operate the plant so as to maximize plant profits?" The idea is to adjust the plant set-points that are under the control of the operator to make as much money as possible for the plant. the gas turbine inlet pressure would increase. the corrected plant heat rate is equal to the rated plant heat rate plus the total of the equipment degradations in plant heat rate (191 Btu/kW-hr in Table 1-8). This plant power increase would cause a plant heat rate decrease equal to 16 Btu/kW-hr. In other words. which is equal to the rated plant power minus the corrected plant power.

and the Opt i mal Val ue column shows where the plant could operate if the operator took the appropriate control actions. and the optimal operating conditions are achievable by operator action. These displays are most often used for Rankine cycle plants where the expected or target values of plant performance parameters do not vary widely with plant operating conditions. Concept of Performance Monitoring .Table 1-9 Example optimization outputs for a combined cycle power plant Controllable Set-point GT l Power GT 2 Power Inlet Chiller #1 Inlet Chiller #2 Duct Burner #1 Duct Burner #2 Number of Cooling Tower Fans On Total Savings Possible Current Value 170 MW 150 MW On On Off Off 7 Optimal Value 161 MW 159 MW Off Off Off Off 6 Cost Savings ($/hr) 90 88 12 11 0 0 21 222 The C ur r ent Val ue column shows current plant operating data. Controllable loss displays show the current value of selected plant performance parameters. 1. This screen is different from the degradation screen in Table 1-8 in that no maintenance actions are required. Finally the C os t Savi ngs column estimates the increase in plant operational profit that would be achieved if the operator took the suggested actions. No one knows if the degradation in Table 1-8 is fully recoverable. Page 34 1. but the control actions suggested in Table 1-9 can be taken (assuming no environment or other operational limit on plant operation is violated). and the cost incurred by not operating the plant at these target values. their target values.9 Controllable Loss Displays Controllable loss displays are an alternate way to present the degradation and optimization data of tables 1-7 and 1-8.1. and the cost savings achieved.

controllable loss parameters do not report degradation specific to individual plant equipment. the economizers. degradation in one area of the plant will likely show up as deviations in several controllable loss parameters calculated from measured data in other areas of the plant. Due to the regenerative nature of a Rankine cycle. Thus. For example. and the feedwater heaters must all Page 35 1. but instead report a departure in overall plant performance from the values that the performance parameters would have if the entire plant were "new and clean". in order to achieve the target main steam temperature in a boiler. If there is no degradation in plant equipment. Controllable loss displays are a very useful way to summarize plant status: they inform the operator if there is a plant performance problem. the air preheater.Figure 1-4 Example controllable loss display for a fossil (Rankine cycle) plant The advantage of controllable loss displays is that they are readily understandable summary of the plant performance status. The target values for controllable loss displays are generally based upon expected overall plant performance with no equipment degradation anywhere in the plant. Concept of Performance Monitoring . the controllable loss display will show small losses and vice versa. The disadvantage is that they give little information as to the location of plant performance problems.

Concept of Performance Monitoring . A change in the steam temperature may change the throttle pressure. and several will likely change when one of them changes. calculation methods. The test procedures were developed by balanced committees of professional individuals representing all concerned interests.2 ASME Test Codes ASME Performance Test Codes provide test procedures that yield results of the highest level of accuracy consistent with the best engineering knowledge and practice currently available. The target values used in controllable loss displays are a very different concept from the equipment degradation calculations described above where the expected performance of each equipment type depends upon the operational conditions that the equipment is exposed to and is independent of the degradation of other equipment in the plant. The focus of the ASME test codes is to provide test specifications appropriate for verification of compliance with guarantee or warranty performance. Page 36 1. 1. The test codes specify procedures. the absolute accuracy of measured performance is stressed as opposed to ease of testing. instrumentation. As such. When tests are run in accordance with an ASME code. Thus. In general it is very difficult to implement the AMSE test code procedures as the basis of performance monitoring at an operating power plant. and uncertainty analysis. Degradation in any of these may cause the steam temperature to change. equipment operating requirements.operate with their target performance. the test results will be of the highest quality and the lowest uncertainty available. The following table lists the test codes that are most closely related to power plant performance monitoring. which might change the steam turbine efficiency and the condenser pressure. many of the controllable loss parameters are related to each other.

1993 Description General Instructions Code on Definitions and Values Air Heaters Gas Turbine Heat Recovery Steam Generators Steam Turbines Appendix to PTC 6 Evaluation of Measurement Uncertainty in Performance Tests of Steam Turbines Procedures for Routine Performance Test of Steam Turbines Centrifugal Pumps Fans Closed Feedwater Heaters Steam Surface Condensers Deaerators Test Uncertainty Performance Test Code on Gas Turbines Atmospheric Water Cooling Equipment Overall Plant Performance Performance Monitoring Guidelines for Steam Power Plants page 3" 1 .2 .1999 PTC 2 .3 .1981 (R2003) PTC 6 .4.1997 PTC 19.2000 PTC 6 Report 1985 (R1997) PTC 6S.1 -2000 PTC 12.1 .1984(R1995) PTC 12.1968 (R1991) PTC 4. C o n c e p t o f P e r f o r m a n c e Nlonitoring .1996 PTC 6A .1998 PTC 12.1997 PTC 23 .2 .1998 PTC 22.1990 PTC 11 .1986 (R197) PTC 46.1997 PTC PM.1980(R1997) PTC 4.3 .1988 (R1995) PTC 8.Table 1-10 ASME Performance Test Codes closely related to performance Monitoring ASME Test Code PTC l .

The fact that monitoring evaluations are repeated many times gives the engineer the opportunity to reject results that are not consistent with longterm trends. The absolute value of performance is not necessarily important to performance monitoring. but is usually acceptable for tracking changes in equipment degradation. Concept of Performance Monitoring . so that changes over time can be evaluated. monitoring data is usually not adequate for vendor guarantee testing. As such. The objective of performance monitoring is to detect changes in equipment performance (degradation) so that proper corrective action can be taken. Page 38 1. The principal differences between testing and monitoring are summarized in Table l-l l below.1. The equipment being tested is operated at conditions as close to design and. The objective of a performance test is to measure the absolute capability of the equipment.3 Performance Testing versus Online Monitoring A performance test is a one-time evaluation of equipment performance that relies on precision instrumentation installed specifically for that test. The tests are often done to verify vendor guarantees on new or upgraded equipment. Table 1-11 Comparison of performance testing and online monitoring Performance Test Objective Instrumentation Type Measurement Requirement Test Interval Test Conditions Absolute Performance Precision Test Instruments Accuracy One Time Event Equipment Isolated and at Full Load Online Monitoring Detect Degradation Whatever Is Available Repeatability Repeated Often Normal Plant Operation The basic difference between performance monitoring and performance testing is that monitoring uses whatever instrumentation is continuously available at the plant to give the operators an indication of plant performance status. or guarantee as possible. repeatability of results is most important. instead.

The current performance is usually directly measured or is calculated from measured data. Curve based methods are a simple and reliable method to predict equipment performance changes as long as the operating conditions have not changed too much from the reference conditions. The total equipment performance fractional change is then computed by multiplying together the fractional changes for each operating condition.4 Curve Based Methods 1. repeatability is the long-term variation in bias error. Page 39 1. the repeatability of performance monitoring results often approaches the accuracy of precision tests. Rating specification for the equipment that includes both the rated performance and the reference operating conditions at which the rating applies. This means that degradation (change in performance) can be measured more accurately than absolute performance.The uncertainty of a measurement is considered to be the sum of two components called the bias and the random uncertainties. However. heat rate or efficiency) when one of the operating conditions changes. the ASME Performance Test Code Committee has estimated the repeatability as one-half the overall instrument uncertainty. where each multiplying factor is generated using a separate correction curve. Accuracy is achieved only if both the bias and random uncertainties are small.4. Although the relative contributions of random and bias errors are unknown for most instruments. The basic concept behind curve based methods is to assemble a set of performance or correction curves that plot the variation in a specific equipment performance parameter (such as power. Two equipment characteristics must be known in order to predict the expected performance of any plant equipment: l. Concept of Performance Monitoring . The conclusion is that even though installed plant instrumentation may not be adequate for precision tests. The prediction of expected equipment performance requires both a measurement of equipment operating conditions and a method or model to use to predict how the equipment performance changes as operating conditions change.1 Performance Curves Performance monitoring involves a comparison of the expected (new and clean) equipment performance to its current (measured) performance. 1.

Page 40 1. Concept of Performance Monitoring . a computer model of the HRSG. Each curve shows how equipment performance will change if only one of the equipment operating conditions changes. and duct burner fuel flow) remain equal to their reference values as stated in Table 1-12. inlet feedwater temperature. drum pressures. These curves may come from vendor performance guarantee tables. and Figures 1-5 through 1-8 are example performance curves for that same heat recovery steam generator. of equipment performance that can predict how the performance changes when any of the reference operating conditions change. Thus.2. A method or model. or from measured data. HP steam temperature. exhaust gas composition. Table 1-12 is an example of the rating specifications for a heat recovery steam generator (HRSG). but only if the other operating conditions (exhaust gas flow. When generating a performance curve it is assumed that all other equipment-operating conditions remain constant and equal to their reference values. figure 1-5 shows the variation of HP steam flow and HRSG effectiveness as the gas turbine exhaust temperature varies. which could be in the form of performance curves.

Table 1-12 Ratings specification for the example heat recovery steam generator Heat Recovery Steam Generator Rating Specification RATING: HP Steam Flow LP Steam Flow Effectiveness Data 511.0 1900 psia 100 psia 136 F 1000 F 0.700 lb/hr 88.00 Page 41 1. Concept of Performance Monitoring .200.000 lb/hr 1135 F 10% H.4 REFERENCE OPERATING CONDITIONS: Exhaust Gas Flow Exhaust Gas Temperature Exhaust Gas Composition HP Drum Pressure LP Drum Pressure Inlet Feedwater Temperature HP Steam Temperature Duct Burner Fuel Flow 3.300 lb/hr 93.

Concept of Performance Monitoring page 42 .Figure 1-5 Example HRSG performance (HP steam flow and HRSG effectiveness) versus changes in gas turbine exhaust gas temperature I.

Concept of Performance Monitoring .Figure 1-6 Example HRSG performance (HP steam flow and HRSG effectiveness) versus changes in gas turbine exhaust gas flow rate Page 43 1.

Concept of Performance Monitoring ."igure 1-7 Example HRSG performance (HP steam flow and HRSG Effectiveness versus changes in highpressure steam drum pressure Page 44 1.

Figure 1-8 Example HRSG performance (HP steam flow and HRSG effectiveness) versus changes in duct burner fuel energy input 1. to some value is.4.2 Expected Performance from Curves The basic assumption behind the curve-based performance-prediction methodology is that the individual operating conditions impact equipment performance independently. the total impact in performance can be computed by combining the impacts of the individual parameters. The methodology used to combine the individual impacts into a net impact on performance is to convert all the individual impacts into a fractional or percentage change in the performance parameter. Concept of Performance Monitoring . The fractional change in HP steam flow when the exhaust temperature changes from the reference value. Fractional Change from to where Page 45 1. When this assumption is true.

which occurs at the reference exhaust temperature is the value read from the exhaust temperature performance curve at temperature is the value read from the exhaust temperature performance curve at temperature is the value from the exhaust flow rate performance curve at temperature is the value from the exhaust flow rate performance curve at temperature is the value from the drum pressure performance curve at temperature is the value from the drum pressure performance curve at temperature is the value from the duct burner fuel flow performance curve at temperature is the value from the duct burner fuel flow performance curve at temperature Page 46 1. Figure 1-5. Concept of Performance Monitoring . Expected HP Steam Flow from Performance Curves: where is the expected value of the HP steam flow. and duct burner fuel flow is the rated value of the HP steam flow.is the look-up value of the HP steam flow from the HRSG exhaust temperature performance curve. at temperature is the steam flow at the reference exhaust temperature from the same performance curve The expected HP steam flow is the combination of all the fractional changes from all of the parameters that affect the HP steam flow. drum pressure . at the exhaust temperature exhaust flow .

it would be Page 47 1. a given amount of water or steam injected into a gas turbine will increase the gas turbine power by an increment that is proportional to the amount of steam/water injected. For example. It would make little sense in this case to use a multiplier on the reference gas turbine power.3 Additive Performance Factors Some operational parameters are not best represented by fractional changes in performance. and the exhaust flow reduces from 3200 klb/hr to 2800 klb hr.4. consider what happens to the HRSG performance when the gas turbine exhaust conditions change. such as when the exhaust temperature into the sample HRSG changes from its reference value of 1135 F to 1100 F. i 1. Concept of Performance Monitoring . The expected HRSG effectiveness at the new gas turbine exhaust conditions would be calculated in the same manner. Thus.6 klb/hr at exhaust temperature equal to 1100 F. except that the calculation must use curve look-up values for the effectiveness instead of the steam flow. but is not closely related to the power level of the gas turbine without the steam/water injection. and 448. but instead by incremental changes in performance.7 klb/hr at the reference flow (3200 klb/hr).As an example. The exhaust temperature performance curve (Figure 1-5) gives HP steam flow values of 511.5 klb/hr at exhaust flow equal to 2800 klb/hr. In this situation. The exhaust flow performance curve (Figure 1-6) gives HP steam flow values of 511. the expected HP steam flow at the new exhaust conditions is equal to: Notice. and 480.7 klb/hr at the reference temperature (1135 F). An addition of a quantity of energy to a system will likely cause the outputs of the system to increase by an additive amount that is proportional to the quantity of energy added.0). only two terms out of four possible change factors are included in the calculation because the drum pressure and duct burner fuel flow did not change. and their contributions to the calculation would equal unity (1.

For example. The rated HRSG performance occurs at a duct burner firing level equal to the reference value. steam. this impact is better presented by adding an increment of power proportional to the amount of steam/water that is injected. This argument also applies to other situations such as adding duct burner fuel energy added to an HRSG. Concept of Performance Monitoring .C ur ve D B (0) } (1. If the duct burner in the example HRSG fires at a level equal to 200 mmBTU hr when all other operating conditions remain at their reference values. instead of firing at the reference duct burner firing level is: Per f or mance Incr ement = { C ur ve D B (w F ) . which equals zero. Instead. the expected HP steam flow would be: Page 48 1. Additive correction factors generally are only used to represent discrete quantities being added to or taken from the equipment or system. w F . and to admission or extraction from a steam turbine where the flow rate is not directly related to the throttle flow.n on-intuitive to express this impact as a multiplier on the reference gas turbine power. Thus. the performance effect would be multiplicative. the performance increment when the duct burner fires at level equal to some value. HRSG vendors have the same option on duct burner fuel energy. gas turbine vendors have the option of expressing the effect of water injection on gas turbine performance as an additive factor (when the amount of water injection is plotted versus gas turbine power) or as a multiplicative factor (when water to fuel ratio is plotted versus gas turbine power). then the effect on performance is better represented as a multiplicative factor. Thus.5) Where Cur ve D B (w F ) is the value from the HRSG performance versus duct burner firing curve (Figure 18) at the x-axis value equal to w F . This is because the water injection has been normalized back to rated conditions by dividing the quantity of water injection by the quantity of fuel flow. Additive changes in performance are computed by adding the increment in performance calculated from the performance curves to the reference performance value. Cur ve D B (0) is the HRSG performance at the reference duct burner firing level. If the duct burner fuel energy were expressed as a fraction of the input exhaust gas energy. Note also that if the impact of water injection on gas turbine power is expressed using the water-to-fuel ratio as the independent parameter instead of a specified water injection flow rate.

4 Expected Performance from Curves In summary. one term for each additive performance increment until terms from all the additive performance increments are included in the final sum. one term for each performance curve until terms from all the performance curves are included in the final product. Expected Performance from Performance Curves: wher e Per f or mance e x p is the expected equipment performance at the actual operating conditions. Cur veVal ue(i ) is the value off the performance curve at operating condition i Note that the above formula can be used to predict the performance at any set of operating conditions when the performance is known at any other set Page 49 1. is a mathematical operator indicating that all the following terms are to be added together.4. Concept of Performance Monitoring . the expected equipment performance at actual operating conditions can be calculated from a set of performance curves of the equipment performance versus equipment operating conditions by the following formula.1. if the equipment performs with rated capability Per f or mance rated is the expected or rated equipment performance at the reference operating conditions (expected equals rated at the reference operating conditions) is a mathematical operator indicating that all the terms in the following parenthesis are to be multiplied together.

and the rated performance to be equal to that known performance value. Predicted Performance at ( 1 ) Given Test Performance at ( 2 ) : where Per f or mance(l ) is the predicted equipment performance at the operating conditions (1) if the equipment performs with the same capability as the known or test performance at conditions (2) Per f or mance(2) is the known or test equipment performance at the operating conditions (2) is a mathematical operator indicating that all the terms in the following parenthesis are to be multiplied together.of operating conditions. one term for each performance curve until terms from all the performance curves are included in the final product. and inlet gas flow rate of 2800 Klb/hr. Concept of Performance Monitoring . Simply define the reference conditions to be equal to the operating conditions where the performance is known. one term for each additive performance increment until terms from all the additive performance increments are included in the final sum. is a mathematical operator indicating that all the following terms are to be added together. and with the duct burner consuming 200 mmBtu/hr of fuel. the expected HP steam flow rate would be: Page 50 1. Cur veVal ue(i ) is the value off the performance curve at operating condition i If the example HRSG is operated at inlet exhaust gas temperature of 1100 F.

For example. This forces the Y-axis value to equal unity (1. The methodology is to apply independent correction factors for each operational and environmental effect. water injection rate and fuel type. The advantage of correction curves is that the value read directly from the plot is equal to the correction factor needed to predict performance at the reference conditions given performance at some other operating condition. Concept of Performance Monitoring . The disadvantage is that the absolute value of performance is not available from the curve. gas turbine base-load power is known to be dependent upon inlet air temperature. inlet pressure loss. A correction curve is simply a normalized performance curve. The basic assumption of this curve-based methodology is that the individual operating conditions have independent impacts on equipment performance. The gas turbine vendor would rate the engine power at a given set of these conditions. The equipment output parameter (Y axis on the performance curve) value is divided by its rated value.5 Correction Factors The traditional method to account for operational and environmental effects on equipment performance is the correction factor method. Page 51 1.4. inlet air pressure. and provide correction curves for each of these operational and environmental effects. Each correction curve would quantify the change or percent change in engine performance that would result when the given operational or environmental condition changes. inlet air humidity.0) at the X-axis value equal to the reference value. There is no need for the user to divide by the rated performance value to obtain a correction factor. and to avoid the need to provide the physically based computer models of equipment performance from which the curves are usually derived. This means that the total impact on performance can be computed by combining the individual parameter impacts. This method was developed by equipment vendors to enable their customers to predict the performance of the vendor's equipment at various operating conditions. exhaust pressure loss.1. steam injection rate.

Concept of Performance Monitoring . They are often used in performance testing to predict the equipment performance at the reference conditions when the performance was measured at conditions other than the reference conditions. Expected Performance at Test Conditions from Correction Factors: wher e is a mathematical operator indicating the product of all the following terms (each term multiplied by the next term) Page 52 1.Figure 1-9 Correction factor curve for the effect of exhaust gas temperature on HP steam flow. This predicted performance at reference conditions is called the corrected performance. this curve is equal to the curve in Figure 1-5 divided by the rated HP steam flow Correction factors are defined as the fractional change in performance from rated when an operational condition changes from the reference conditions.

just like performance curves. can be used to predict equipment performance at any operating condition given the performance at one other operating condition. Concept of Performance Monitoring . given known performance at operating condition (2) is below.is a mathematical operator indicating the sum of all the following terms (each term added to the next term) Performance Performance rated is the expected or rated performance at the reference operating conditions e x p is the expected performance at test operating conditions if the equipment performs with rated capability C or r ect i onFact or s are the values from the correction curves at the test operating conditions Addit i veC or r ect i ons are the values off the additive correction curves at the test operating conditions The correction factor curves. Predicted Performance at Operating Conditions (1): where Per f or mance ( I ) is the predicted performance at operating conditions (1). if the equipment performs with the same capability as the known or test performance at operating conditions (2) Per f or mance (2) is the known or test performance at operating conditions (2) Per f or mance rated is the rated performance at the reference operating conditions Cor r ect i onFacot r s (l ) are the values off the correction curves at operating conditions (1) Cor r ect i onFacot r s (2) are the values off the correction curves at operating conditions (2) Page 53 1. The formula for the predicted equipment performance at operating condition (1).

Addi t i veFacot r s (l ) are the values off the additive correction curve at operating condition (1) Addit i veFacot r s (2) are the values off the additive correction curve at operating condition (2) Because the correction factor curves are based upon a rated performance value at reference operating conditions.4. .6 Percent Change Correction Factors Sometimes the variations in equipment performance with operating conditions are presented as a percentage change in performance versus the percentage change in the operating condition. These curves are fully normalized performance curves where the y-axis is equal to the change in equipment performance (equipment performance minus the rated performance) divided by the rated performance. and the x-axis is equal to the change in reference condition (current operating condition minus the reference operating condition) divided by the reference condition. the prediction of performance at some operating conditions (1) requires the knowledge of both the rated performance as well as the performance at operating conditions (2). An example of such a performance curve is shown in Figure 1-10. 1.

and are a convenient way for vendors to transmit the results of complex computer analysis to their customers. Why not use the computer codes directly to calculate expected and corrected performance? Computer software programs like GateCycleIM. contain complex. Pepse™ and GTMaster™. 1. it is not necessary to simplify the analysis into a few curves.5 Model-Based Performance Analysis The correction curves that equipment vendors supply to customers are based upon physically based computer models of the equipment performance.Figure 1-10 An HRSG percent change correction curve for the HP steam flow versus exhaust gas temperature The use of these percentage change correction curves is essentially the same as that for correction curves. physically based models of equipment performance that . However. except that the correction factor must be calculated from the curve look-up value in the following manner. in this time of powerful computers on every desk.

the assumption that the overall effect of changes in all the operating conditions can be computed by multiplying the correction factors together may is not valid over a wide range of operating conditions. Physically based models can allow wide variations (far from reference) in operating conditions. Computer models can compute corrections for parameters that the vendor may not have supplied correction curves for. In particular. Computer models can handle wide variations in environmental parameters and operational modes for which curves do not exist or do not accurately model. These changes are handled directly by computer models. Physically based models give detailed information about the expected performance. Page 56 1. but seldom accounted for in correction curves. the method words very well. As long as each correction factor is near unity. Some advantages of using the computer codes (model-based analysis) instead of performance or correction curves are listed below: • • • • Interaction of varying operating conditions can be modeled. equipment vendors often use these computer codes to create the correction curves. the interactions between environmental parameters become more and more important. For example. In fact. if the gas turbine uses varying amounts of water injection or switches from natural gas to oil fuel.0. The individual equipment operating conditions may not have independent effects on equipment performance. This additional information may help the engineer diagnose problems.can be used in place of correction curves. Physically based models can compute impacts of parameters for which no curves are available. as conditions change over a broad range. the exhaust gas compositions will change. their product may not represent the true performance change in the equipment. which is an assumption of the curve-based method. but when correction factors get far from 1. and computer codes are often built specifically to handle these interactions. Concept of Performance Monitoring . not available from curves. In other words.

1.The methodology for model-based performance analysis is. Concept of Performance Monitoring . Evaluate degradation by comparing the expected performance from the model to the measured performance. The actual surface areas of the tube bundles were obtained from vendor information and input into the computer model. Then the design-point heat transfer coefficient in each tube bank was adjusted so that the model prediction matches the rating specification for the HRSG. At each performance monitoring calculation interval input the measured equipment operating conditions into the model 4. 3. Build a computer model of the equipment being monitored. The following figures illustrate the use of physically based computer code analysis for the example heat recovery steam generator used in the chapter on performance curves. Run the model and obtain the expected equipment performance as a model output. The procedure to build such a model is specific to the software used. Correct the model where necessary. 2. Test the model versus vendor guarantee data and/or plant-measured data over a wide range of operating conditions. 5. Page 57 1. This resulted in a design point model of the HRSG. The computer model in Figure 1-11 was constructed to replicate the actual steam/water flow path in an existing HRSG.

corrections were made to the design-point model. the predictions (off-design mode in GateCycle™) of the HRSG model were compared to vendor warrantee data over a range of operating conditions to verify model accuracy.Next. Concept of Performance Monitoring . Page 58 1. and the verification process repeated until the predictions of the HRSG model matched the vendor data to within one percent over the entire operating range of the HRSG. Notice that the model predicts the rated steam flows to three digits of accuracy or better.gure 1-11 shows the output of the model when the reference operating conditions from Table 1-12 are input to the computer model. If necessary. Figure 1-12 is a plot of these temperature distributions. The resulting model can then be used to give predictions of the expected performance of the HRSG as operating conditions change. F-. the model also computes the complete temperature distributions within the HRSG. In addition to predicting the rated steam flows.

There is one steam/water straight line for each tube bundle modeled in the HRSG. the gas enters at a temperature of 1135 F. Notice on the left hand side of the plot (at zero on the x-axis). Concept of Performance Monitoring . The computer code only predicts the inlet and outlet conditions for each tube bundle. The closer the gas exit temperature is to the feedwater inlet temperature the higher the effectiveness of the HRSG. and does not predict temperature distributions within a tube bundle. while the inlet feedwater temperature is 136 F.Figure 1-12 Temperature profile from GateCycle™ for the example HRSG at reference conditions The upper straight line in Figure 1-12 is the exhaust gas temperature as the gas goes from the HRSG inlet to the stack. A straight line is drawn from one predicted point to another. On the right hand side of the plot the gas exit (stack) temperature is 206 F. The lower set of straight lines is the corresponding steam/water temperature distribution. Page 59 1. where the corresponding steam temperature is 1000 F.

Notice that when using model-based analysis. Table 1-13 Comparison of results between curve-based and modelbased methods for a change in HRSG inlet predicted Performance conditions after exhaust gas flow & temperature changeCurve-Based MethodModel Based Method HP Steam Flow (klb/hr) 420421HRSG Effectiveness (%)92. all operating conditions are input to the model and the output accounts for changes in all the operating conditions at once.9 Page 60 1. Figure 1-13 shows the model-based prediction of HP steam flow and effectiveness. How do these compare to the curve-based method? Table 1-13 below compares the model-based results to the curvebased results for the situation where the exhaust gas temperature and flow change from 1135 F and 3200 klb/hr to 1100 F and 2800 klb/hr respectively. and exhaust gas flow equal to 2800 Klb/hr Figure 1-13 shows the predicted HRSG performance when the exhaust gas inlet temperature and flow rate are changed to 1100 F and 2800 mmBtu/hr respectively.Figure 1-13 Model-based prediction (from GateCycle™) of the HRSG performance at exhaust gas temperature equal to 1100 F. Concept of Performance Monitoring .892. Interactions between the inputs can be predicted only if all changes in operating conditions are input to the model.

595. Changes in exhaust conditions of this size could be expected to occur as a result of ambient temperature changes on the order of 40 F. and duct burner fuel flow all change from reference Now let's add a significant change in duct burner firing level.1 Page 61 1. and once again compare the predictions of the curvebased method to the model based method. Concept of Performance Monitoring . Figure 1-14 Predicted HRSG performance (from GateCycle™) when exhaust gas temperature. the curve-based and the model-based methods yield approximated equal predicted performance values when exhaust gas temperature and flow change over a relatively narrow range.Thus. from zero at the reference conditions to the maximum possible for this HRSG (200 mmBtu/hr). Table 1-14 Comparison of results between curve-based and modelbased methods for high duct-burner firing situation Predicted Performance after exhaust gas flow & temperature & duct firing level all changeCurve-Based MethodModel Based MethodHP Steam Flow (klb/hr)612614HRSG Effectiveness (%)94. exhaust gas flow.

Since.Notice that differences between the curve-based method and the model-based method begin to become important. the curves for this example were calculated from the model. and is a simplification to the model that makes it possible to predict performance without needing to run the computer code. Concept of Performance Monitoring . at least for effectiveness. all of the differences in calculated results are due to the simplifying assumptions inherent in the curve-based method. as the changes in operating conditions get larger. the curve-based method is based upon the model. In other words. Page 62 1.

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