Power Plant - Performance Analysis
Diagnosis & Optimization (PADO)
Performance Monitoring System
AVEVA Team
03. July.2019
The Concept of PADO (Performance Analysis
Diagnostic & Optimization)
PADO is divided into sub-features:
1. Performance Monitoring System (PMS)
2. Predictive Emission Monitoring System (PEMS)
3. Boiler Combustion Optimization System (BCOS)
01 PMS OVERVIEW
Performance Monitoring
Monitoring Performance means:
Knowing actual and expected performance for current ambient and
operating conditions.
Knowing where inefficiencies are and their impact on financial
performance.
Understanding the impact of performance deficiencies on current and
future operations.
Objective:
Having real-time and historical performance information available to the
entire power generating enterprise in a concise and visual manner.
How is performance monitored?
• Performance Modules (efficiencies & other calculations – ASME PTC codes)
• Plant thermodynamic model (data validation & “what-if” analysis)
• Diagnostics
• Applies to both conventional fossil power and CCGT installations
• Uses AVEVA Wonderware IT architecture for easy integration
• Multi-unit, multi-site or fleet-wide deployment
• Calculation frequency – typically hourly
Overview Of Performance Monitoring System
Inputs/Outputs Graphic symbols
PMS
Server
Logic/Scripting Diagnostics
Historical Information
Alarms and events
Security
PMS - Capabilities
Controllable Parameters
• Provides BEST ACHIEVABLE and
DESIGN- based targets that
automatically adjust with load and
ambient conditions
• Provides real-time economic
feedback on operating decisions
“Provides real-time feedback to operations on
plant economy.”
Plant Analysis Model (PAM)
PAM is based on thermodynamic model
Plant Analysis Model (PAM)
Plant Analysis Model (PAM)
Plant Analysis Model (PAM)
Plant Analysis Model (PAM)
Plant Analysis Model (PAM)
Model Configuration & What-if Analysis
Plant Analysis Model
• Power cycle modeling framework that provides a robust steady state model of the entire
power plant.
High accuracy due to rigorous first principles thermodynamic basis.
Ease of use – intuitive graphical modeling approach (GUI based)
Detailed design for multiple design cases VWO, TMCR, BMCR etc.,
System level what-if analysis and Component level what-if analysis.
Supports entering missing values based on engineering judgment.
02 PMS – SYSTEM ARCHITECTURE
Typical Performance Monitoring System Architecture
Software requirement
Plant Data
•PMS server (per unit)
•WW InSQL Historian
(approx 5000 tags license
depending on tag
configuration)
Unit 1
Any Vendor’s DCS Wonderware InSQL
Historian
Typical Hardware
requirement
•1 server grade machine for
PMS server and 1
workstation for PMS Client
Unit1 Unit1
PMS Server PMS Client
03 PMS- Modules
Typical Coal Fired Power Plant
(Conventional Rankine Cycle)
1 Reductant injection
Waste gas
2 Catalytic converter modules
3 Air preheater
4 Blower Denitrification
(DeNOX) plant
5 Mill air
6 Pulverized coal conduits 1
Chimney
7 Coal bunker Flue gas
8 Burner
2
9 Coal mills
Steam
10 Feedwater pump 3
11 Turbo set Flue gas
Feedwater desulphurization
12 Generator 380 kV line
Boiler plant (FGD))
4 Electrostatic filter
13 Condensers
Power house
14 Flash vessel 6 5 7 Cleaned gas
Flue gas 18
15 Ash extractor 12
11 8
16 District heating 10 Ashes 19
17 Cooling water pipe PROCESS DATA, Gypsum
DCS
9
18 Limestone slurry 17 13 14 Controller via OPC
19 Fan 16 15
Typical Combined Cycle Power Plant
Fluidized Bed Combustion Boiler
Boiler Performance
Calculates Boiler Efficiency as per ASME PTC 4.1
standards
Useful for Combustion optimization with A/F
ratio calculations
Calculates the expected Boiler efficiency, A/F
Ratio, which guides the operating team to run
the plant in optimum condition
“Calculates the Expected Boiler efficiency as well as guides in improving combustion
efficiency”
Boiler Cleanliness
Based on Heat and Material balance calculations
Monitors Individual heat transfer section &
Trends tube fouling
Provides Optimized Values for the Boiler controls
Provides insight into the Boiler Operations and
the furnace exit gas temperature
“Provides insight into boiler heat transfer patterns and sootblowing effectiveness.”
Boiler Tube Stress Analysis
Steam Turbine Performance
Enthalpy-drop efficiencies
Corrected stage pressures
and flow coefficients
Expected section efficiencies modeled using
standard OEM procedures
IP turbine efficiencies corrected for N2 &
cooling steam flows
“Calculates steam turbine stage efficiencies for condition assessment.”
Condenser Performance
Expected condenser performance modeled using HEI
Standard and complies with ASME PTC 12.2
Achievable performance considers plugged tubes
Overall cleanliness calculated
Compares actual pressure, TTD, and CW temp rise to
expected values
“Calculates condenser cleanliness and expected condenser pressure for current
operating conditions.”
Pump Performance
Determines a pump performance factor based on
actual flow vs. expected flow with given power input
Detects pump degradation
Complies with ASME PTC 8.2 Centrifugal pumps
“Calculates actual and expected pump performance for current operating conditions.”
Gas Turbine Performance
Expected Power Output & Heat rate for
Operating conditions
Inlet Pressure drop effect on capacity & heat
rate
Compressor efficiency
“Calculates expected thermal performance of combustion turbines for current
conditions.”
HRSG Performance
Expected HP, IP and LP performance
Efficiency and Effectiveness are calculated
Complies with ASME PTC 4.4
“Calculates expected capacity and efficiency of heat recovery steam generator.”
Steady State Analysis using Trends
Alarms
Set Alert Limits
Set alarm &
historian high
& low
04 PMS- Diagnostic Tool & its Features
PMS Diagnostic Tool
• Developed by operations &
performance experts in Auto &
Manual mode
• Customized for each plant and unit
• Available for controllable
parameters & major equipment
Provides Operations and Technical personnel with expert
tools for diagnosing root causes of losses (for all the
identified Controllable parameters).
Diagnostic Chart (Typical tree structure)
Analyze Alerts
Manual decision • To identify the root cause problem for
deviation in the process value with
tree analysis / reference to Design value, the Operator
has to drill down the tree by checking &
Offline analysis comparing the actual plant/DCS values.
Automatic Decision • In this analysis, the DCS I/O’s present in
the decision tree is mapped directly to
tree analysis LIVE DCS system and it directly drills
down to root cause problem, without
/Online analysis any manual intervention.
Diagnostic Charts
DEVELOP DECISION TREES
Hot well level
Drum level
Deaerator level
SH temperature
Mill dp high
Furnace pressure
Condenser vacuum
Mill outlet temp
Mill electrical overload
O2% in flue gas
ID fan trip
Rotor winding temp
Boiler water Silica
Main steam Ph level
Diagnostic snapshots : Manual/ offline decision
tree analysis
Auto/ Online decision tree analysis
Recap: How is performance monitored?
• Performance Modules (efficiencies & other calculations – ASME PTC codes)
• Plant thermodynamic model (data validation & “what-if” analysis)
• Diagnostics
• Applies to both conventional fossil power and CCGT installations
• Uses AVEVA Wonderware IT architecture for easy information visualization and
integration
• Multi-unit, multi-site or fleet-wide deployment
• Calculation frequency – typically hourly, to have instant health check of plant key
process/equipment, diagnosis, “What-if” studies, performance reporting to various
management functions/levels;
Reference List (APAC)
• HHI Hanju, Korea
• TTCL IRPC CHP, Thailand (combined cycle unit)
• SWCC Yanbu Ph-3, Saudi Arabia
• SKS PADO, India
Key Differentiators!
• Unique and Core Competency with Thermal Performance (thermodynamic model - PAM)
for equipment actual and expected performance under multiple normal and abnormal
operation conditions
• Unique and Core Competency in sophisticated Data Validation and comprehensive
Diagnostics
• 130+ Fossil Power Specialists & Engineers with deep knowledge and experience of both
conventional fossil fuel (generic drum, supercritical, CFBC) & combined cycle power
plants (no all software solution vendors are specialized in Power)
• Extensive Fleet-wide Monitoring Experience (Enterprise-wide reporting/monitoring
capabilities)
Thank you!
And any questions?
This presentation may include predictions, estimates, intentions, beliefs and other statements
that are or may be construed as being forward-looking. While these forward-looking statements
represent our current judgment on what the future holds, they are subject to risks and
uncertainties that could result in actual outcomes differing materially from those projected in
these statements. No statement contained herein constitutes a commitment by AVEVA to
perform any particular action or to deliver any particular product or product features. Readers
are cautioned not to place undue reliance on these forward-looking statements, which reflect
our opinions only as of the date of this presentation.
The Company shall not be obliged to disclose any revision to these forward-looking statements
to reflect events or circumstances occurring after the date on which they are made or to reflect
the occurrence of future events.
