Siemens Power Plant Advanced Automation Applications

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Siemens Power Plant Advanced Automation Applications Adapting Existing Generation for the ‘New Normal’ with Digital Applications

Unrestricted © Siemens Energy, 2020Siemens Energy is a registered trademark licensed by Siemens AG.

“Chasing the Wind”Driving Traditional Fossil Power Plant Operations

Reliable Power Supply

Economic Efficiency

Flexible Generation

Resource Efficiency

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September 2020

The Change in Generating Plant Priorities?

2020-08-15

Past Plant Operating Priorities• Availability• Reliability• Consistency• Life Cycle costs• Efficiency

Todays Generating Markets• Capacity and Energy Market Payments• Renewable Portfolio Standards• Grid Stability and Ancillary Services

• Regulation• Reserve• Frequency*

Even Regulated Power Markets have Changed their Generating Priorities: • Cycling Fossil Units (Partial or Full Unit on/off) • Reduced Minimum Loads• Operational Flexibility

(Faster Starts, Low Cost Starts, Fast Ramps, Extended Load Range)• Expanding Ancillary Services Markets

Renewable Energy and Open Markets have changed generation priorities• Grid stability increasingly impacted by rapid growth of Wind and Solar

generation• Renewables displacing fossil base load generation in some areas

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September 2020

Regional ISO’s Using Ancillary Services to Handle Integration of Renewable Energy

• ISO’s implement Ancillary Services (AS) to support grid stability through Regulation, Frequency Support, and Reserve services.

• ISO’s have grown Ancillary Services in both “Day-ahead” and “Real-time” markets.• Marginal price markets for Ancillary Services, (Regulation/Reserve) have reportedly doubled

since 2010 with PJM and SPP showing the most aggressive growth since 2014 (400%)

Source: U.S. Department of Energy, Office of Energy Policy and Systems Analysis, January 2019 Source: U.S. Department of Energy, Office of Energy Policy and Systems Analysis, January 2019

2009 2012 2015 2018 2012 2015 2018

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September 2020

The ‘New Normal’Plant Operational Flexibility, Reliability and Availability

§ Improved, Repeatable Startups• Faster Starts & Shutdowns• Reduced Hurdle Costs

§ Higher Ramp Rates§ Expanded AGC (AR) Performance

• Increased Range• Improved Accuracy

§ Increased Maximum Output (Peak Load)§ Reduced Min-Load (LLTD)§ Improved Frequency Control Services

• Primary Frequency Response (PFR)• Secondary Frequency Response (SFR)

§ Improved Spinning Reserve§ Emissions Reduction (Full & Part Load)

Digital Applications that Enable Traditional Generation to meet new Market Flexibility

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September 2020

Maximized Asset Utilization with Digital Applications that Enable Fossil Generation Plant ‘Power’

Peak PowerFaster,

Repeatable Startups

Higher Ramp Rates

Reduced Minimum

Load

Improved Frequency

Control

Maximized Reserves Support

Expanded Regulation

(AGC)

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September 2020

The Layered Approach to Plant ‘Optimal’ Automation

• Equipment Automation

• Sub System Automation

• Automatic Sequencing

• Engineered Applications

• Dynamic Adjustments

• Controls De-Coupling

• Feed Forwards

• Adaptive Controls

• Mathematical Modeling

• Stress Modeling

• Predictive Algorithms

• Self Learning Algorithms

• System & Equipment Modeling

• Unit Control Coordination

• Neural Network

• Equipment Performance Adaptation

Layer 1Improved Automation

Layer 2Advanced Controls

Layer 3Optimization

Layer 4Advanced Unit Coordination

Automation ResponseControl

Process Optimization

AdvancedUnit Control

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September 2020

Advanced Control Applications for Enhanced CCPP OperationStartup, Fast Ramp and Expanded Ancillary Services

Steam Press. & Temp. Raising Rate Coordination

Steam TurbineStart Criteria. & Method

CT M&U Flexibility Mod’s. Software

CT/HRSG Dynamic Ramp Rate Coordination w/ Stress

Advanced Steam Temp. Startup Control

Steam Drain & Vents Sequenc. for S/U & Shutdown

Advanced HP/IP/LP Drum Level Controls

HP/IP/LP Bypass Control Coordination

Steam Press. & Temp. Trajectory-Stress control

HRSG Stress Modeling (PLMC)

Advanced SCR Control Algorithm

SH / HRH Temp. Optimal Balancing

CT / Duct. Bnr Load Coordination

Duct Bnr. AGC Extension

Startup OptimizationCT Improved unloading & Shutdown Sequencing

Automatic Unit Coupling

Unit Coordination and Startup Sequencing

Efficient use of Steam Margins

Improved Automation Sub-Group Control

Eliminate LFC

Startup Estimator

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September 2020

Advanced Control Applications for Enhanced Fossil Steam Plant OperationStartup, Fast Ramp and Expanded Ancillary Services

Advanced Model Based Unit Coordinator Control

EmissionsReduction

Combustion Optimization

Optimized Soot blowing

Seq. Valve Management

Aux. LoadOptimization

Cooling System Optimization

Dynamic Sliding Pressure

Feed Water Optimization

Steam Temperatures

Excess Air Optimization

Heatrate Modeling

Stress Evaluation

Condensate Throttling

Peak Power

TOE

Startup Optimization

Capacity Maximization

Lower Min. Load Operation

Ramps & Ancillary Svcs.

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September 2020

Modernization and Optimization of Dual Unit 550MW 2on1 Combined Cycle Power Blocks

Plant• 2, 550MW 2on1 CCPP• GE-7FA CT’s and D11 STG’s • Nooter Eriksen HRSG’s with Duct Firing • Operated by Ethos Energy

Project Scope• Plant DCS Modernization (T3000) w/ New Operator Console• Integrated CT/ST operations through DCS HMI Workbench• Upgrade and integration of Duct Burner Controls from PLC• Thermal Performance Monitoring• Startup Optimization with PLMC for HRSG Stress Modeling• Advanced AGC w/ Duct Burners Flex Firing • Cooling Tower & CW Optimization

Project Resultsü 2on1 Starts reduced by 50%ü 1on1 Starts reduced by 45%ü Average Fuels Savings on starts > 50%ü Integrated Alarming and Operator HMI

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September 2020

Optimization of a Gas Fired Steam Power Plant“Phased Optimization Extends Plant Life”

Plant• 2, 215MW Gas Fired, Steam Drum Unit• CE Tangential Fired, GE Cross-Compound Steam Turbine• Minimum load relatively high• Unit operation changed to cycling duty• Startup cost far to high to compete in market• Unit response to slow for California AR market

Project Scope• Plant Performance Assessment• Optimizer on Unit 2 connected to existing ABB DCS• Boiler Controls Upgrade on one unit• Re-engineer, and partially automate Startup Process• Start-up Optimization w/ Startup Evaluator• Applied PLMC Boiler Stress Modeling• Min. Load Reduction• Improved ramp rates for AR participation

Lower Minimum Loadfrom 20MW to 10MW (5%MCR)

Faster Startup

50% reduction of time and costs

Minimized StressIncreased Repeatability

Faster Ramps

from 5MW/min to 15MW/min (7%/min)

Improved Stability

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September 2020

Modernization and Optimization of Dual Unit 550MW 2on1 Combined Cycle Power Blocks

Plant• Vales Point Units 5&6 Station• New South Wales, Australia• 2 x 660 MW Coal fired, Drum Boiler• TOSHIBA STGs, CE Boilers

Project Results• Scheduled change-over time reduced by two weeks (from

scheduled outages)• Superheat temperature at steady state +/- 2oF• Superheat temperature at load swing +/- 5oF • Reduction of minimum load to 200MW • Reduction of governor throttling losses with sliding pressure.• Load ramp improved from 18 MW/min to 40 MW/min

Project Scope• Modernization of DCS• Flexibility Optimization

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September 2020

Power Plant Operational Flexibly Enhancement Summary –(Historical Project Results)

Improved Operating Flexibility (Steam)• Faster Load Ramp Rates (~10% of MCR/min)• Improved AGC Dispatch• Lower Minimum Load (5%-8% MCR)• Higher Max Peak Load (2%-4%)• Startup Improvements:

• Faster Starts (20%-30%)• Startup Fuel Savings (30%-40%)

• Reliable, Repeatable Starts

• Reduced Boiler Wear and Tube Wastage• Reduced Thermal Stress• Improved Unit Response to Upsets

Improved Operating Flexibility (CCPP)• Faster Load Ramp Rates (1% to 3%)• Improved, Extended AGC Dispatch• Enhanced Ancillary Services• Startup Improvements:

• Faster Starts (30%-40%)• Startup Fuel Savings (35%-45%)• Reliable, Repeatable Starts

• Reduced HRSG Thermal Stress• Minimization of Low-Frequency-Cycling• Coordinated Steam Turbine Coupling• Improved Unit Response to Upsets

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September 2020

Thank you

Galen GeorgeSiemens Energy Business Development/Marketing Director1345 Ridgeland ParkwayAlpharetta, GA 30004, USA

Mobile: +1 404 915-4250

E-mail: [email protected]

www.siemens.com/sppa-t3000