Siemens TPP FLex Solutions

Flexibilization of thermal power plants - need of hour
CERC, 29th July 2019

Sandeep Chittora & Rajeev Rajdeva, Siemens Limited
Restricted © Siemens AG 2018

Market requirements:
Changed operational regimes require highly flexible products
Primary Secondary Peak Power
Fast Fast shut-
Frequency Frequency & Off- Part-load Prepare for start-up
Start-up down
Response Response Frequency
Power
Flex Operation Line Standard Operation Line Base
Load
Time
Power on Minimum
Grid Services Maintenance Flexibility
Demand Part Load
• ST Stress Controller • Advanced Fast Loading • HP Turbine with Last MS-Valve • Fast Preservation
• SPP Hot Start On The Fly • Primary Frequency Response • Partial Bypass Concept • Fast Cooling
• HP internal bypass cooling • Condensate throttling • Part Load Optimization Package • ST Hot Standby
• Advanced Fast Loading • Dispatch Control • Minimum Load Reduction • FMS
• ST EOH Counter 4.0 • Maximum Load Plus • Top Feedwater Heater
• Low Loss Start
• Fast Start / Hot Start
Page 2 19.03.2019 Sandeep Chittora Power Generation Services
Flexibility Road Map
Lifetime consumption &

Controls and Optimization Retrofit and Modernization
Monitoring
Advanced Process Control • Fatigue Monitoring • Steam Turbine

• Temperature Control • Equivalent Operating hours Modernization
Optimization • Performance Monitoring • Boiler Retrofit
• Soot Blower Optimization • Last Stage Blade Vibration • Fast Start
• Combustion Optimization
• Frequency Control
• Fast Ramp
Technical Minimum + Higher Ramps + Efficiency

Measures for fast load ramping
Overview
Power
1 ≈ 5 min
2 HP IP LP LP G
Steam Extraction Condenser

Generator Steam
Valves Fast control
butterfly Condensate
valves Pumps
Time
3 Fast condensate
5
control station
1 2 3 4 5
LP Feed Water
Feed Water Heaters 1 Throttling 4 HP heater
Pumps 2 Additional valve 5 Fuel increase
4 3 Condensate stop
HP Feed Water Heaters
100% HP Feed Water Heater Bypass

“Condensate throttling” controls storages
in the water steam cycle to increase ramp rates
Iskenderun,
Neurath, Luenen
and NTPC Dadri
HP IP LP LP G a. Enlarge storage volume
b. Fast condensate control valve
c. Fast control valves in LP extractions
Condenser
Enlarged Condenser
Fast control Hotwell
Butterfly Valves
Condensate
Enlarged Feed 3 Pumps
Water Tank Fast Condensate
Control Station
LP Feed Water
Heaters
Power
3 NTPC Dadri Stage II – Unit #6 490 MW

Time
Let P3000 Condensate Throttling increase your profitability
by providing state-of-the-art frequency response (2/3)
Frequency Response including

Frequency Response without P3000 Condensate Throttling
P3000 Condensate Throttling : (Efficiency):
Power Power
1 3 1 2 3
Time Time

Let P3000 Condensate Throttling increase your profitability
by providing state-of-the-art frequency response (3/3)
Frequency Response including Frequency Response including

P3000 Condensate Throttling P3000 Condensate Throttling
(Efficiency): (Load Additional):
Power
Additional Load
Power
1 2 3 1 2 3
Time Time

SPPA-P3000 Minimum Load Reduction
Reduced minimum load level
Task Minimum Load Reduction

To upgrade the plant so that the specified minimum load
level can be reduced and to make the plant capable of fast
and low-stress load increases on demand in accordance Load
with market requirements.
Old minimum
Solution sustainable load
• Use of robust state space controller for unit control
• Adaptation, optimization and setting of lower-level controls for
new minimum load level
• Adaptation or addition of control sequences, burner and
mill scheduler
SPPA-P3000
• Provision of additional instrumentation where necessary Savings NEW, minimum
sustainable load
Time
Benefit e.g. 500,000 €/a  Benefit calculation
• Reduced financial losses during off-peak periods
• Faster response to increased load demands as unit does not
need to be shut down The Minimum Load Reduction solution results in savings for minimum load operation through
optimization of lower-level controls.
• Avoidance of unnecessary startups and shutdowns

40% Technical Minimum is Possible
UNIT LOAD
550
500
450
400
350
300
250
200
150
100
50
0
3:00
3:30
4:00
4:30
5:00
5:30
6:00
6:30
7:00
7:30
8:00
8:30
9:00
9:30
10:00
10:30
11:00
11:30
12:00
12:30
13:00
13:30
14:00
14:30
15:00
15:30
16:00
16:30
17:00
17:30
18:00
18:30
19:00
19:30
GCV (kcal/kg) VM% Ash %

3000 22% 35%

Transient Operation (Ramp Up / Ramp Down)
increased temperature gradient results increased life consumption
Main steam valve
Crack depth: 50%

wall thickness

Influence on Ramps on Temperature Transient
MS TEMP
570
DT = 1 K/min
560
550
540
530
520
510
7:00
7:30
8:00
8:30
9:00
9:30
10:00
10:30
11:00
11:30
12:00
12:30
13:00
13:30
14:00
14:30
15:00
570
HRH TEMP
DT = 1.5 K/min
560
550
540
530
520
510
500
7:00
7:30
8:00
8:30
9:00
9:30
10:00
10:30
11:00
11:30
12:00
12:30
13:00
13:30
14:00
14:30
15:00
SPPA-P3000 Temperature Optimizer
Increased steam temperatures
Task Temperature Optimizer

To achieve maximum steam temperature without violation of
material limits
Conventional steam
Temperature optimization
temperature control
Solution Steam temperature Steam temperature
• Robust, easy to parameterize and adaptive state space controller Material limit Material limit
with observer
• Where needed, use of entire control range through to injection
into saturated steam Set point
• Use on startup/shutdown and over the entire load range Set point
• Use of flue gas recirculation and biflux or triflux valves to control
reheat steam temperature
Benefit, e.g. 180,000 €/a  Benefit calculation Time [min] Time [min]
Increased efficiency thanks to

• Higher steam temperatures
• Reduction in reheater attemperation The Temperature Optimizer solution increases the efficiency through higher steam temperatures
and the use of appropriate control elements for reheater temperature.

Power on Demand
Reduction of Wall Thickness to Improve Start Up & Cycling Capabilities
100
Example: Reduced Casing thickness & reduced thermal
piston loading by HP bypass cooling 80
Design with
internal bypass
Significant improvement in LCF cooling
Load in %
60
Interstage Design without
admission cooling internal bypass
steam main steam 40 cooling
mixed steam
20
0
Time

Measures to improve transient operation
ST Warm Standby Operation to prepare for fast start-up
Technology
• Electrical heating system for ST in turning gear
• Maintains rotor shaft temperature at warm startup
conditions
Benefit
• Significant reduction of startup time
• > 60 min. earlier power production
• Reduction of EOH consumption per start
• Less energy is bypassed to condenser
• Reduced costs per start up
Electric heating coils to keep HP/ IP Turbine casing and shaft in warm start conditions
Key Takeaway
• Lower Technical Minimum is better operation than two shift

operation
• Subcritical fleet is more suitable for flexible operation with respect
to loss in performance
• Lower Technical Minimum with advanced control systems is
possible, unit specific changes needs to be applied
• Means of improving part load efficiency by upto 1% are available
• Maintenance planning is to be adapted based on actual life
consumption during flexible operation
• Thermal power utilities will play a key role in Indian grid for
renewable grid

Further I&C solutions for flexible operation
Selected references
Frequency & Dispatch Control Reliable and efficient start-ups

Franken I, Germany
Altbach, Germany 383MW, gas, built 1973:
420 MW, hard coal: 20% reduction of start-up costs
5% in 30 s up to 100% load
(with turbine & condensate throttling +
partial deactivation of HP preheaters)
Reduced minimum load

Dingzhou, China
600 MW, hard coal: Steag Voerde, Germany
700 MW, hard coal, built 1985:
Boiler delay reduced from 180s to 40s for
Minimum sustainable load w/o oil support
load ramps up to 4%/min (with throttling)
and bypass reduced
from 280 (40%) to 140 MW (20 %)
Dadri, India Increased Maximum Load

490 MW Callide, Australia
35 MW (~7%) in 20 s 420 MW, hard coal:
(with condensate throttling + HP reserve) Max. load +10 %
1,400 h/year max. load through
controlled HP bypass deactivation

Siemens TPP FLex Solutions

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Flexibilization of thermal power plants - need of hour

CERC, 29th July 2019

Restricted © Siemens AG 2018

Lifetime consumption &

Advanced Process Control • Fatigue Monitoring • Steam Turbine

Technical Minimum + Higher Ramps + Efficiency

Restricted © Siemens AG 2018

Steam Extraction Condenser

100% HP Feed Water Heater Bypass

Restricted © Siemens AG 2018

3 NTPC Dadri Stage II – Unit #6 490 MW

Frequency Response including

Restricted © Siemens AG 2018

Frequency Response including Frequency Response including

Restricted © Siemens AG 2018

Task Minimum Load Reduction

Restricted © Siemens AG 2018

GCV (kcal/kg) VM% Ash %

Restricted © Siemens AG 2018

Main steam valve

Crack depth: 50%

Restricted © Siemens AG 2018

Task Temperature Optimizer

Solution Steam temperature Steam temperature

Increased efficiency thanks to

Restricted © Siemens AG 2018

Restricted © Siemens AG 2018

• Lower Technical Minimum is better operation than two shift

Restricted © Siemens AG 2018

Frequency & Dispatch Control Reliable and efficient start-ups

Reduced minimum load

Dadri, India Increased Maximum Load

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