combustion@max boilers@max · combustion@max & boiler@max 16 introduction benefits (approx)...
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Combustion@Max & Boiler@Max 1
Combustion@Max
&
Boilers@Max
Combustion@Max & Boiler@Max 3
PAST FUTURE
Y2(t)
U1(t)
Y1(t)
Y1(t)U1(t)PLANT
Y2,3(t)U2(t)
Y1(t)U1(t)Model
Y2,3(t)U2(t)
^
^
U2(t)
Safety
Quality
Heat rate
NOx
Pressure
BFW
Steam Valve
Ambient T
INCA MPC
Principle of MPCAmbient T
Y3(t)
FuelU3(t)
Combustion@Max & Boiler@Max 4
MV2
MV1
CV2
CV1
time
CV2
DV1MV2
time
CV1
MV1
time
time time
time
time
calculate a model which
minimizes the between models output
and observed output
DV1
INCA MPC
Advanced Process Control -
How to get the models
Combustion@Max & Boiler@Max 5
INCA MPC
Performance = f(model quality)
Your feed forward performance will not be optimal…,
and a lot of feed-back action is needed to compensate for the differences!
if this is your model… and this is reality….
Combustion@Max & Boiler@Max 6
Prediction:Predict the future of CV’s based on past and assumed future inputs and the measured CV’s
Receding horizon [samples]
+5
5.1
5.2MV
t-400 t-200 t t+200 t+400 t+600
469.2
469.4CV
Past horizon Prediction (or future) horizon
HuPast
Ideal
TuFuture
prediction
ym(t)
yp(t)
d(t)=yp(t)-ym(t) yprediction
Current time instant t
INCA MPC
Basic MPC concepts prediction
Combustion@Max & Boiler@Max 7
TECHNOLOGY
INTERFACES
Engine
Pre CalcPre CalcPost CalcPost Calc
DCS Network
DCS OPC Server
Engineering Station
OPC Server
Exchange
Pre Calc
Engine
Post Calc
View
Scheduler
Test
Discovery Configurator Test
Combustion@Max & Boiler@Max 8
INCA MPC
Integration of INCA in Automation
Systems: e.g. via PID
Combustion@Max & Boiler@Max 9
• Dynamic process model-based predictive control technology based on INCA MPC
• Process know-how from IPCOS [and OPSYS] engineers
• Proven technology (references in China: Beihai, Datang, Shanghai Power, QinZhou, National power)
Introduction
What is it?
Combustion@Max & Boiler@Max 10
Introduction
MPC vs. PID
• MPC can offer significantly better control than PID (at least a 50% improvement in regulation over PID control)
• Looks at boiler efficiency (BE)
• Cost effective to implement (payback << 12 months)
• MPC is also scalable
• Integrated in DCS (as with PID).
Combustion@Max & Boiler@Max 11
Introduction
MPC Process
• Phase One – Audit
• Phase Two – Data Collection and Model Design
• Phase Three – Implementation and Commissioning
• Phase Three – Maintenance and Support
Combustion@Max & Boiler@Max 12
introduction
Benefits (1)
• 0.3 – 0.7% improvement in Boiler efficiency
• Coal Savings
• Better Temperature control of furnace exit gas temperatures
• 5-10% NOx reduction
• Reduced Nox going into your Nox reduction system (load)
• Possible extension of catalyst life
• Possible reduction of ammonia or urea
Combustion@Max & Boiler@Max 13
Introduction
Benefits (2)
• Better control of Carbon in Ash (CIA)
– Use CIA as a driver to make advantage of ash
– If your ash is dumped, perhaps you will be able to sell it
– If you need quality consistency – this can give it to you
Combustion@Max & Boiler@Max 14
Introduction
Benefits (3)
• Better knowledge of boiler
– Helps understand boiler operation due to the amount of mathematical models available
– Helps understand what is really happening inside the boiler
– Which controls are actually helping your boiler
– Maintain the controls which create the better value
Combustion@Max & Boiler@Max 15
Introduction
Benefits (4)
• Automatic Operation is tighter
– As if your best operator is on the job 24 hours a day, every day.
– Like Auto-Pilot on an airplane
– Ensures consistency in operation
– All priority functions can be monitored
• Which operator is taking what in and out of service
• Which operator is getting the best from the system
Combustion@Max & Boiler@Max 16
Introduction
Benefits (approx)
Benefit Numbers (Chinese market conditions)
• Coal Savings 200-300,000 Euros per year
• Nox reduction 20-30,000 Euros per year
• Boiler Knowledge 20-100,000 Euros per year
• Better Operation 20-100,000 Euros per year
• Carbon in Ash 20 - 100,000 Euros per year
• Better control of Temperatures 20 – 50,000 Euros per year
Combustion@Max & Boiler@Max 17
Introduction
Power plant Layoutfurnace exit
gas
temperature
selective non
catalytic
reduction
Selective
catalytic
reduction
electrostatic
precipitator
continuous
emission
monitoring
system
flue-gas
desulphurisation
Relative
Accuracy Test
Audits
Combustion@Max & Boiler@Max 18
Confidential
Introduction
What does the APC Control?
18
Combustion@Max & Boiler@Max 19
Introduction
Datang Power
19
• One of the Big 5 Generating Utilities
• Over One Hundred Coal Fired Power plants in China
• One new power plant comes online every month.
Combustion@Max & Boiler@Max 20
Introduction
Unit Description
20
• 330MW
• CE T-Fired
• 5 Mills
• Lignite Coal
• Built in 2006
• Started Operation in
2007
Combustion@Max & Boiler@Max 21
Introduction
Project Description
21
• APC Scope:185MW(without oil)to full load
• APC Mode:Run-time Optimize by bias adjustment to DCS
• Target: Improved Boiler Efficiency by 0.3% above the base and keeping the steam quality
Combustion@Max & Boiler@Max 22
Results
Estimated Project Benefits
(coal savings alone)
22
• BE improvements above 0.3%,
• Calculated on 330MW unit: The Coal Consumption will be Reduced above 1.1g/kw
• If load rate 80% per year,and APC operating 5500h,
• Coal Saving by year = 330WM * 80% * 5.5kh * 1.1g/kw = 1600t
• Local Coal Price 80 Euros/t,Yearly benefit will be: 80 * 1600t ≈ 128,000 Euros
Combustion@Max & Boiler@Max 23
APC System
CONTROL MATRIX• The controller has the following sections:
• Fan Balancing:
– PAF (Prim air),
– IDF (induced),
– FDF (forced)
• Steam system: Gas Damper, Fsh/rh, Psh/rh, Tsh/rh,
• Mill Outlet Temperature: (hot – cold Prim Air)
• Carry-on air
• Secondary Air (-> NOx control)
• Tertiary Air (-> NOx control
• Oxygen
Combustion@Max & Boiler@Max 24
APC System
CONTROL MATRIXSafety Limits: 0 – 99
Furnace draft: zone
Total air flow: zone
Main Steam Temperature: zone and ideal
Reheat Temperature: zone and ideal
Carry On Damper Bias Sum: zone and ideal
Quality Limits: 100 – 199
CO: zone
Oxygen: zone and ideal
Economic Limits: 200 – 299
BE_q2: ideal, minimize
NOx: ideal, minimize
BE_q3: ideal, minimize
BE_q4: ideal, minimize
SH 2nd Spray Inlet Temperature: zone + ideal, maximize (minimize water flow)
SH 1st Spray Outlet Temperature: zone + ideal, minimize (maximize water flow)
PAF Balancing
FDF Balancing
IDF Balancing
Combustion@Max & Boiler@Max 25
APC System
CONTROL MATRIXMV tagname
1 APC O2 Bias
2 APC Mill A Outlet Temp SP
3 APC Mill B Outlet Temp SP
4 APC Mill C Outlet Temp SP
5 APC Mill D Outlet Temp SP
6 APC Mill A1 Carry-on Damper Bias
7 APC Mill A2 Carry-on Damper Bias
8 APC Mill B1 Carry-on Damper Bias
9 APC Mill B2 Carry-on Damper Bias
10 APC Mill C1 Carry-on Damper Bias
11 APC Mill C2 Carry-on Damper Bias
12 APC Mill D1 Carry-on Damper Bias
13 APC Mill D2 Carry-on Damper Bias
14 APC Secondary Air A12 Damper Bias
15 APC Secondary Air A34 Damper Bias
16 APC Secondary Air B12 Damper Bias
17 APC Secondary Air B34 Damper Bias
18 APC Secondary Air C12 Damper Bias
19 APC Secondary Air C34 Damper Bias
20 APC Secondary Air D12 Damper Bias
21 APC Secondary Air D34 Damper Bias
22 APC Tertiary Air A12 Damper Bias
23 APC Tertiary Air A34 Damper Bias
24 APC Tertiary Air B12 Damper Bias
25 APC Tertiary Air B34 Damper Bias
26 APC Tertiary Air C12 Damper Bias
27 APC Tertiary Air C34 Damper Bias
28 APC Tertiary Air D12 Damper Bias
29 APC Tertiary Air D34 Damper Bias
30 APC Gas Damper Bias
31 APC FSH Temp Bias
32 APC PSH Temp Bias
33 APC PAF Balance Bias
34 APC FDF Balance Bias
35 APC IDF Balance Bias
DV tagname
1 UNIT_LOAD
2 MS_PRESS
2 SH 1st Spray Inlet Temperature
3 SH 2nd Spray Inlet Temperature
4 SH_1SPRAY Valve
5 SH_2SPRAY_Valve
6 RH InletTemperature
7 RH_SPRAY_FLOW
8 INLET_AIR_TEMP
9 HeatID(Total Fuel/Total Air)
10 Gas Temp
11 BE
CV tagname
1 BE_q2 (dry gas losses) %
2 BE_q3 (Chemical, e.g. CO) %
3 BE_q4 (Carbon in Ash) %
4 Corr_Nox mg/Nm3
5 Corr_CO
6 MS_Temp C
7 SH 2nd Spray Inlet Temperature C
8
SH 1st Spray Outlet
Temperature C
9 RH_Temp C
10 O2 %
11 Total Air Flow Pa
12 O2_Diff %
13 Furnace Draft %
14 PAF A/B Current Diff A
15 PAF A/B Outlet Press Diff kPa
16 FDF A/B Current Diff A
17 FDF A/B Outlet Press Diff kPa
18 FDF A/B Outlet Flow Diff t/h
19 IDF A/B Current Diff A
20 IDF A/B Inlet Press Diff kPa
21 CA BIAS SUM
Combustion@Max & Boiler@Max 26
APC System
CONTROL MATRIX
干烟气损失
飞灰含碳
炉膛出口平均氧量
大风箱与炉膛差压
总风量
炉膛
(A/B
)烟温偏差
引风机
(A/B
)电流差
引风机
(A/B
)入口压差
送风机
(A/B
)电流差
送风机
(A/B
)风量差
送风机
(A/B
)出口压差
过热器温度
再热器温度
过热器区间
1金属温度
过热器区间
2金属温度
过热器区间
3金属温度
过热器区间
4金属温度
再热器区间
1金属温度
再热器区间
2金属温度
氧量偏置 X X X X X X X X X X X
给煤机(A/B/C/D/E)偏置 X X X X X X X X X X
二次风(AA/AB/BB/DD/DE)偏置 X X X X X X X X X X X X
二次风CC偏置 X X X X
周界风组(A/B/C/D/E)偏置 X X X X X X
过燃风EF层偏置 X X X X X X X X X X X X X X
过燃风F层偏置 X X X X X X X X X X X X X X
引风机(A/B)平衡偏置 X X
送风机(A/B)平衡偏置 X X X
主蒸汽流量 X X X X X X X X X X X
过热器减温水流量 X
再热器减温水流量 X
大气温度 X
煤风比 X X X X X X
锅炉效率
机组负荷指令 X X
M
V
(
可
控
量
)
D
V
(
干
扰
量
)
Combustion@Max & Boiler@Max 27
APC System
DCS Console GUI
Combustion@Max & Boiler@Max 28
APC System
APC Alarm Page
Combustion@Max & Boiler@Max 29
Results
Additional Benefits
• Better control of Boiler (Efficiency)
• Better control of Steam quality (Pres and Temp)
• Better understanding of the operation of plant
• Better continuous Auto – Control
• Reduced Emissions
• Reduced Unburned Carbon in Ash
Combustion@Max & Boiler@Max 30
Results
Acceptance Tests @330MW
330WM APC Off APC On
DiffStart2008-05-30
13:302008-05-30
17:00
End2008-05-30
15:302008-05-30
19:59
LOAD MW 328.79 328.89
MS_FLOW T/H 952.74 945.93
BE_Q2 (Dry gas loss) % 6.01 5.66 0.35
BE % 92.95 93.32 0.37
Combustion@Max & Boiler@Max 31
Results
Acceptance Tests @270MW
270WM APC Off APC On
DiffStart2008-06-05
08:102008-06-05
10:30
End2008-06-05
09:402008-06-05
00:30
LOAD MW 269.84 269.75
MS_FLOW T/H 776.06 791.94
BE_Q2 (Dry gas loss)
% 5.10 4.81 0.30
BE % 93.89 94.21 0.32
Combustion@Max & Boiler@Max 32
Results
Acceptance Tests
Combustion@Max & Boiler@Max 33
Results
Total Solution
• Boiler Efficiency improved at least 0.5% (ARC +APC)
– Better PID’s
– Better Logic
– Better Operation Curves
• Aux Power saving above 0.15%
• Steam Quality closed near design value 2~3C
• 0.1% BE increase = 1750 Ton/Year (330MW unit)
• 0.5% BE increase = 8750Ton/Year (330MW unit)
Combustion@Max & Boiler@Max 34
FLUE GAS CONDITIONING
Challenges
• Maintaining emission levels at specifications (good enough?)
• Stabilizing process conditions having a positive effect on catalyst aging, thermal stress,…..
• Take care of disturbances (boiler load, Sulphur conditions, ambient air conditions, steam conditions,..)
• Operate at maximum conversion/efficiency (if measured).