Performance Monitoring Methodology

Modeling Application

To make a Complete Heat and Mass

Balance

Establishing current performance level of

individual components and total system

Establishing the benchmark for the

individual component and for total system

Set targets for improvement/maintenance

ACTSYS Process Management Consultants

 Power Plant Components Quantification
Feed Water Heaters
 Individual Heater TTD
and DCA – Their impact on
overall heat rate.
Boiler
 Boiler Efficiency Steam Turbine
 Individual Loss Streams  HP Turbine Power
 Convective SH effectiveness  IP Turbine Power
 Eco/AH Effectiveness  LP Turbine Power
 Air Heater Leakage  HP/IP/LP Turbine Eff

Thermal
Power
Station
Condenser
Distribution
 Valve passing  Condenser Water Flow
 Condenser Duty
 Line Loss
 Condenser effectiveness
Auxiliaries
 CWP Performance
 BFP Performance
 CEP Performance
 FD/PA/ID Performance

ACTSYS Process Management Consultants

 Thermal Power Station Modeling

ACTSYS Process Management Consultants

 Heat & Mass Balance
 Complete quantification of all streams in a power plant eg
flue gas, cooling water, steam and fuel flows
 Establish the present performance level of the individual
equipment eg efficiency, heat transfer coefficients,
leakages
 Enables data validation
 Measured values can be compared against the heat balance
output for validating the accuracy of measurement.

ACTSYS Process Management Consultants

 Heat Balance Quantification
 Steam Plant
 Coal energy release / calorific value
 Superheater spray flow
 Air Heater leakage
 Boiler efficiency
 Feedwater heaters TTD Terminal Temp Diff and DCA Drain
Cooler Approach
 ST extraction flows to Feed water heaters
 Condensor Cooling water flow
 Plant efficiency / heatrate
 Steam Turbine Heatrate
 Steam Turbine HP/IP/LP outputs

ACTSYS Process Management Consultants

 Overall Plant Performance

ACTSYS Process Management Consultants

 Boiler Performance

ACTSYS Process Management Consultants

 Steam Turbine Performance

ACTSYS Process Management Consultants

 Performance Result – Air Heater

ACTSYS Process Management Consultants

 Performance Result – Cooling Water Flow

ACTSYS Process Management Consultants

 Excess O2 & Boiler Efficiency

ACTSYS Process Management Consultants

 Performance Monitoring Methodology
Modeling Application

To make a Complete Heat and Mass

Balance

Establishing current performance level of

individual components and total system

Establishing the benchmark for the

individual component and for total system

Set targets for improvement/maintenance

ACTSYS Process Management Consultants

 Steam Turbine New & Clean Model

ACTSYS Process Management Consultants

 HPST N&C Model Tuning

ACTSYS Process Management Consultants

 IPST N&C Model Tuning

ACTSYS Process Management Consultants

 LPST N&C Model Tuning - 1

ACTSYS Process Management Consultants

 LPST N&C Model Tuning - 2

ACTSYS Process Management Consultants

 Individual Steam Turbine Performance

ACTSYS Process Management Consultants

 Individual Steam Turbine Performance

ACTSYS Process Management Consultants

 Deposit on LPST Blades

ACTSYS Process Management Consultants

 Feed Water Heater New & Clean Model

ACTSYS Process Management Consultants

 HPHT 1 & 2 N&C Model Tuning

ACTSYS Process Management Consultants

 HPHT 3 & LPHT 5 N&C Model Tuning

ACTSYS Process Management Consultants

 LPHT 6 N&C Model Tuning

ACTSYS Process Management Consultants

 Individual Heater Performance

ACTSYS Process Management Consultants

 Individual Heater Performance

ACTSYS Process Management Consultants

 Cooling Water Flow Model

ACTSYS Process Management Consultants

 CW Flow Issue

ACTSYS Process Management Consultants

 Condenser N&C Model
22 July 1993 Condensor Performance Data

2.64E08
0.07 P T 39.46
Duty kcal/h
534.61 W H 532.38
LPST

1.20 P T 28.99
47628 W H 28.95
COND
CWIN

CWOUT

1.20 P T 34.54
47628 W H 34.48

CNDPMP
0.07 P T 39.46
534.61 W H 39.40

ACTSYS Process Management Consultants

 Condensor N&C Model

Gresik Steam
Model Simulation 3/4 Condenser
of Condenser Performance Curves
Performance
100

90
Des36
80
Des33
70 Des30
mmHg

Des27
60
Cal36
50 Cal33
Cal30
40
Cal27
30

20
0 20 40 60 80 100 120 140
% Design Heat Duty

ACTSYS Process Management Consultants

 0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
2-Aug-07
13-Aug-07
15-Aug-07
16-Aug-07
20-Aug-07
23-Aug-07
3-Sep-07
13-Sep-07
17-Sep-07

ACTSYS Process Management Consultants

19-Sep-07
21-Sep-07
3-Oct-07
8-Oct-07
Condenser performance

12-Oct-07
19-Oct-07
22-Oct-07
24-Oct-07
5-Nov-07
11-Nov-07
18-Nov-07
Condenser Exit pressure

29-Nov-07
1-Dec-07
1-Dec-07
5-Dec-07
Condenser (Actual/N&C)

8-Dec-07
12-Dec-07
16-Dec-07
15-Feb-08
Condenser performance is better than the new and clean performance.

20-Feb-08
22-Feb-08
26-Feb-08
26-Feb-08
28-Feb-08
 Condensor performance benchmarking ..

CCP2 Condenser Pressure (Actual/N&C)

1.19
1.17 CCP2 40K CI
1.15 22th~30th May
1.13
1.11
1.09
1.07
1.05
1.03
1.01
0.99

2-Jul
1-Jan

4-Jun

16-Jul

30-Jul
15-Jan

18-Jun
7-May
29-Jan

26-Feb
12-Feb

12-Mar

26-Mar

21-May
9-Apr

13-Aug

27-Aug
23-Apr

ACTSYS Process Management Consultants

 What do we do for you ?
Plant Info System

Plant
Plant
Data Data Reconciliation
Data
Heat Balances
Performance Models

Theoretical Analysis
Historical Archive &
Interpretation

Reports

Operations & Decision Discussion Points

Maintenance Support Presentation &
Discussion of Results

ACTSYS Process Management Consultants

 Thank you – Looking forward to work with you

AUXILIARY POWER (0.22%)

SHAFT POWER

GT SHAFT POWER (34.23%)

ROTOR COOLING LOSS (2.09%)
WORK (….% of GT

HP TURB POWER (2.18%)

COMBUSTOR LOSS (0.49%)
COMPRESSOR

Shaft Power)

)
%
.08
(0
INL

SS
ET

LO
A IR
(1. IP TURB POWER (6.68%)

PE
45

)
LP TURB POWER (10.87%)

PI
%)

35

SS
CONDENSER LOSS 33.53%
.
(0

04 LO
SS
SS
RADIATION LOSS (0.06%)

09 LO

(0. ION
LO

%)
RADIATION LOSS
T

(0. ION
%)

AT
C

CHEMICAL (0.34%)
U

DI
D

AT
ENERGY

RA
DI
(97.32%) HP STEAM (34.39%)

RA
IP STEAM (8.6%)
LP STEAM (4.03%)
STACK LOSS (8.97%)
T
EA
H
% E
00 BL
1. SI
N
SE
EL
FU

ACTSYS Process Management Consultants