Optimisation Tools for Power Plants

7/30/2019 Optimisation Tools for Power Plants

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About us

STEAG encotec (India) Pvt. Ltd.(SeI) is wholly owned

subsidiary of STEAG encotec GmbH, Germany.

SeI offers services in the field of:

Engineering Consulting Services

Power Generation

Operation and Maintenance

Renovation & Modernization Information Technology for Power Plants

New Technologies for Power Plants

SeI has offered services in recent time to: IOCL, MSEB, GSEG,BHEL, HPGCL, NLC, etc.


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_________________________________________________

Energy Management Systems

SRSystematicEnergyManagement


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SRIntelligentIT-Solutionsfor EnergySuppliers

SRvData

Validation

SR1Lifetime

MonitoringSR2Energy

Management

SR3Energy

Controlling

SR4Power Plant

OptimizationSR5

Power Trade

System

SRkPower Cycle

Evaluation

SRpStatistic

Forecast

SRxEnergy Data

Management

SR4 Compact

Power PlantOptimization


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SR1 LifetimeMonitoringin PowerPlants

Current Demands Components of power plants exposed to high temperatures andpressures suffer serious material degradation during their lifetime.

This degradation indicates a need for component exchange or atleast its repair.

The accumulated material degradation is not proportional tooperating time, for which reason a regular monitoring of the plantoperation is recommended.

Such a monitoring must be carried out by continuously operating adata logger together with a data evaluation system.

SR1 is the solution ...

for continuously recording operating temperatures and pressuresaround all the critical components of a power plant

for calculating the creep and the fatigue

for keeping the operator well-informed about the current status ofhis plant

for reducing the cost for routine maintenance inspections as well asadditional tests


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SR1 Saving themeasuredvalues


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SR1 Calculatingthe creepdamage

1)+vs

d(

2

p=

a

ir

100[%]X

x=Cfp/T

Actualstress:

Fatigue inthe time x:


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SR1 Saving thestress cycles


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You have a varying demand of electricity, steam,

hot and chilled water, compressed air, etc. ?

You have alternative means of generating andsupplying these energies ?

SR2 helps to cut your energybill significantly!

And pays back shortly!

You have various buying and selling contracts

for your moving energies ?

SR2 EnergyManagementSystem


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SR2

Online Application Offline Application

1/2 hour Day

OnlineData

Forecasts

What / If? Year

EnergyPlant

Closed LoopControl

EnergyPlants

EnergyContracts

EnergyDemands

System Parameters

SR2 EngineeringLogic


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M M

M M

Flue Gas Desulfurizationand DeNOx Plant

Boiler 185 t/h

Oil/Gas

Deaerator

District HeatSteam 170C

Process HeatSteam 250 C

Live Steam 60 bar/500 C

175 C

138 C

G

12,5 MW

G

12,5 MW

G

12,5 MW

G

15 MW

ST 1

Air Compr. 3

Boiler 275 t/h

Coal/Gas

Boiler 375 t/h

Coal/Gas

Boiler 885 t/h

Oil/Gas

Boiler 785 t/h

Oil

ST 3 ST 4 ST 5

Air Compr. 1

SR2 Optimizationin IndustrialCogen Plant


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General Motors Germany: Daily Energy Cost Profile at Beginning of SR2 Installation

5

7

9

11

13

3

5

7

9

11

13

0 3 6 9 12 15 18 21 24

further potentialfor optimization

Hour

TDM

/h

TDM/

h

Actual Costwithout SR2

Difference7,500 US$/day

Actual Costwith SR2

Optimized Cost

Optimized Cost

Difference3,500 US$/day

Daily Energy Cost Profile after 12 Months from SR2 Installation

Verified Savings: 4,000 US$/day,equivalent to 4 % of variable cost

SR2 VerifiedSavings inIndustrialCogen Plant


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SR2 Optimizationin MunicipalHeat/PowerPlant


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2,500 US$/day

Difference Actual to Optimized Cost

Actual Variable Cost

5,000 US$/day

April 98 March 99

SR2 VerifiedSavings fromOptimizationinMunicipality

Savings afterone year:

equivalent to 8 %of variable cost


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every 15 min

every h 1st step

2nd step

every 15 min

24 h operation plan

Fine Tuning

Balancing all thevariable costs

DemandForecasts

OnlinePlant Data

Load Distribution(24h Forecast)

Load Comparison(Is/Should be)

Cost Comparison(Is/Should be)

every 15 min

every h

SR2 Howthe OnlineSystemworks


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Optimizing the annual budget (incl. maintenance dates)"What happens if?" simulations (incl. unexpected outage)

Cost efficient "In House" studies (incl. plant additions)

Identification of future bottlenecks

Optimizing energy contracts

SR2 Whatthe OfflineSystem

offers


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Injection Condense

GT Generator

Hot Water Generator

Sat. Steam Generator

Boiler with Superheater

Boiler with Reheater

WHSG

GT

Motor (Heat and Power)

Motor Generator

Steam Turbine (3 stages)

Steam Turbogenerator(3 stages)

Motor

Generator

Pump

Compressor

Water Turbine

E-Pump

Steam Driven Pump

Heat Exchanger

Cross Flow HE

Condenser

Cross Flow Condenser

Throtthing Valve (with Spray)

Spray Atemperator

Valve

Water Storage

Steam Storage

Fuel Storage

Heater Deaerator

Condensate Tank

Energy Source

Energy Sink

Black Box (general

Energy Line

SR2 PredesignedComponents


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Client Server Applications

SR2-ConfData Configuration Module

SR2-VisPresentation Module

Online DataInterface Module

External Programs(via API)

SR2-EditPlant Configuration Module

Optional for furtherSR applications

MIP-Solver

SRp

(Optimizer)

(Forecast Module)

Problemtransformer(MPS generator)

Archiveinternal

Archiveexternal

Data Server

SR2 SystemArchitecture


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Exteral

Data / FileServer

(e.g. Netware)

LAN

SR2 ClientOnlineControl Room

(Windows95/NT)

SR2 Application

Server incl. DataServer

(Windows NT)

SRxClientOnlineData

(variable)

Results

SR2 ClientOfflineOffice

(Windows95/NT)

Measurements

ParametersPlant Bus,Terminal Bus,Interface,etc.

SR2 Integrationin Clients

InformationSystem


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SR4 Optimizationof Power

PlantOperation

Current Demands More strict environmental regulations ask for better plant control and make

it even more important and more difficult to find the best point for

economic operation of the plant Competition, especially from a deregulated market and from a growing

number of Independent Power Producers, also requires knowledge of bestprice for power output

The more and more urgently needed economic production of electricity andheat asks for maximized efficiency

Maximum efficiency needs intelligent software tools implemented in the

PMS Using online measurements and system parameters these systems should

- reduce the costs of energy production !

- simulate current plant behavior for various boundary conditions !

SR4 is the solution ...

for highlighting the entire process

for maximizing economic and environmental efficiency

for comparing todays operation with its possible best

for simulating the power plant behavior of tomorrow


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Online BalancingCurrent behavior of all components and the

entire plant efficiency, performance, power output,

fouling

Online/Offline Simulation &Forecast

Results for various power plantparameter variations and the

related fuel consumptionfigures

Online Comparison Reference-to-Current / Best-to-Current

Reference : all components at guarantee point based oncurrentoperation and ambient conditions

Best : optimized operation based on currentcomponent

and ambient conditionsClose follow-up of all relevant componentcharacteristics, calculation of cost reduction potential

SR4 Results


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Ambient

Parameters(not controllable)

ambient temp,pressure, humidityCooling water temp, (load level,heating value,combustible), etc.

Forecast

SimulationsComponentEfficiencies

(controllable during downtime)

efficiency, spec. heat rate,

gain factor,effectivity,approach temp, etc.

Comparison

OperationalParameters

(controllable during operation)

Load factor GT/ST, Soot Blowing,Steam Parameters, Cold end,

Feed water split, etc.

Optimization

SR4 TheTriangle ofSimulations


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Balancing

Higher quality of relevant measured and calculated values

Compact summary of process information allows more detailed evaluation

Reference-to-Current evaluation

Continuous evaluation of components and the entire unit

Identification of faults and slowly increasing deviations

Savings of up to some 100 $/h per unit

Optimization

Optimization of components, the unit or even the entire site

Savings of up to 1 Mio $ per year

Forecast

Configurable parameter variation for different load conditions Forecast of plant efficiency deviations up to 2-3% supports the plant operation

strategy

SR4 OptimizationPotential


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Continuous monitoring of plant efficiency

Balancing, optimization and simulation tool

Cost analysis of component deficiencies

Complete thermodynamic boiler model

Suitable to answer market needs by parameter variationsthe power plant behavior of tomorrow

Graphical configuration leads to a transparent online and offlineapplication with proven data management

Extendable from SR4 Compact to a detailed, large SR4 system

SR4 TheSystemBenefits


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Basic version: SR4 Compact

Scope of Calculation:Online BalancingOnline Best-to-Current Comparison and Simulation

Main Steam Boiler: efficiency, fouling, oxygen content flue gasAir heater: pressure and oxygen content before/after heater, foulingSteam turbine: spec. heat consumption (net/gross), evaluation of water/steam-cycleCondenser / cold end: temperature, pressure, efficiencyEntire unit simulations: reference point, best point, maximum power output, other

boundary conditions

Data Preparation: Plausibility checkData Management: Data base SRxInterfaces / Hardware: PC as SR4/SRx-Server and integration in Customer-LAN

Options SR4

Standard objects : Cooling tower, blower/fans, pumps, exhaust gas cleaning, a.s.o.

Special objects : Boiler with detailed heat exchange model, optimization Cold End,a.s.o.

Optional Data Preparation

Plausibility check of input values with neural networksData reconciliation of relevant values

SR4 TheBasic System


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Main Steam Boiler + Air Heater + Flue Gas Cleaning

Net/gross boiler efficiency (current/reference), effective thermal power, heat balance,

indirect coal flow calculation, pulverizer performance, gas temperatures and interstagevelocities along the boiler,

Superheater and reheater sprays, (T/p) of live steam and hot reheat, reheater steamsidepressure drop,

fouling of furnace chamber and boiler convection zones controlled by soot blowers, fouling andleakage of rotary air preheaters,

flue gas composition, pressure drop flue gas, efficiency flue gas blower, emission monitoringevaluation ( NOx, SO2, CO ),

delta of flue gas oxygen content over air heater (current/reference), delta of flue gas pressureair heater (current/reference),

boiler simulation taking into account: fuel characteristics, combustion conditions, water-steamcycle parameters, flue gas conditions,

Gas Turbine

Net/gross efficiency GT (current/reference), back pressure at turbine outlet,

efficiency air compressor (current/reference), flue gas mass flow / temperature / oxygencontent / composition,

gas turbine simulation taking all relevant influencing parameters into account

SR4 Examplesfor Optional

Results


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SR4 Examplesfor Optional

ResultsHeat Recovery Boiler

Net/gross boiler efficiency (current/reference), pressure drop flue gas, effective thermalpower, boiler simulation

Water-Steam-Cycle

Net/gross specific heat consumption (current/reference), delta costs (current/reference),feed heater performance/optimization,

water-steam-cycle simulation taking all relevant influencing parameters into account

Condenser

Pressure / temperature / degree of recovery / media temperature difference, cold endperformance/optimization,

condenser simulation

District heating system

District heat output, el. power output equivalent

Entire unit

Net/gross unit efficiency, gross unit efficiency + current el. power output equivalent,entire unit parameter variation by activating the simulations of all relevant sub-units, severaloptimization scenarios


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SystemParameters

Heating values, fixed

costs, soot blowingparameters, ...Plausibility / Reconciliation

Online Mode

Gas Turbine / Boiler / Steam Turbine / Condenser / Plant

Balancing :Current plant behavior, efficiency,fouling, ...

Ref.-to-Current Comparison : Boiler, heatcycle, ...

Optimization :Plant optimum regardingefficiency, costs,..

Offline Mode

Gas Turbine / Boiler / Steam Turbine / Condenser / Plant

Simulation : Various scenarios, forecasts, ...

Data Base

Measurements, Formulas

Plant Management System (PMS)

Visualization Online Mode process figures, color switch, diagrams, ...

Graphical interface( Configuration mode,

offline presentation )

ObjectConfiguration

Characteristic

values, TAG

numbers,

characteristic

curves, ...

SR4 TheProgramStructure


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For the connection of SR4 to the data acquisition system a suitable interface will be used.

Approximately 200-500 measurements per unit will be selected for transfer at 1 min intervals. Allthe results are stored in an integrated data base, they can be visualized in actual (on-line) modeand historically for any period of registered time.

The SR4 Compact software should run exclusively on a PC application server so that sufficientcapacity is available to generate results of diagnosis and optimization every 5 minutes. The PC canbe linked to the clients PC LAN (TCP/IP) so that any authorized client (Windows NT) has access tothe online visualization of current and past operation. For this purpose the SR4 client software,available on the SR4 server is downloaded automatically when an authorized client of the LANrequires any information. The graphic and numeric presentation of SR4 Compact results includespresentation with automatic visual changes to indicate individual component deficiencies and trend

curves as well as x/y-presentations of any combination of variables (original data and results).

Testing and tuning of the system during on-line operation is to the major part done by remotecontrol of system operation. For this purpose an ISDN or telephone socket shall be supplied by theclient and the server PC will be connected to the suppliers offices. The general hardwarerequirements for SR4 Compact for the two units are specified as follows:

Trademark PC

Pentium IV, 800 MHz, 128 MB RAM; Raid 5 Array, 3x18,2 GByte HD;

CD ROM drive for Windows NT; MOD 5,2 Gbyte, with 2 storage media;

ISDN router ZyXel Prestige 100 including connection (for system tuning, trial run and for service);

Operating system Windows NT 4.0 Terminal Server (alt. Windows 2000 server);

Color monitor 19''; Color printer;

Interfaces to clients and the DCS for measuring data;

SR4 Thesystemrequirements


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SR4 Thedatarequirements

Approximately 200-500 measurements of operational data we need from your plant for balancing andoptimization

Relevant units: Gas Turbine;Boiler;Steam Turbine;Condenser;; Entire Plant

All technical specifications on boiler geometry, boiler efficiency definition, cycle calculations (design),soot blower characteristics, fuels, air preheaters, gas turbines, steam turbines, etc. have to besupplied by the customer and will be used exclusively to determine the parameters for the systemconfiguration.

Some documents in detail :

- Supply of the documents and information required for process modeling, according to ourrequirements;

- Lists of available measuring points including TAG numbers;

- P&I diagrams and flow schematics; - Functional descriptions;

- Design data and acceptance test data; - Fuel analysis; - Burner arrangement, firing sequence;

- Boiler drawing, including summary of boiler heating surface data (surface area, pitch, etc.);

- Number and arrangement of soot blowers, along with their steam or compressed air consumptioncharacteristics;

- Heat flow diagrams of the water/steam cycle and reheater mass flow data as a function of load.

- Information about operational cost factors as a basis for the determination of current operating costs;

- Information about plant-specific boundary conditions ( e.g. maximum allowable interval between twosoot blowing cycles )

- Check and approval of results.

Services to be Provided by the Purchaser

The Purchaser shall assign a project manager who shall be responsible for:

- Supply of the documents and information required for process modeling, according to ourrequirements.

- Information about operational cost factors as a basis for the determination of current operating costs;

- Information about plant-specific boundary conditions, e.g. maximum allowable interval between twosoot blowing cycles;

- Check and approval of results


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External

Data / File Server(e.g. Netware)

LAN

SR4 Client OnlineControl Room

Plant Load Schedules(WinNT / Win2000)

SR4 Application Serverincl. Data Server(WinNT / Win2000)

SRx ClientOnline Data

(WinNT /Win2000)

Results

SR4 ClientEngineering OfficeStudies & Parameters(WinNT / Win2000)

Measurements

Parameters

SR4 Integrationin Clients

InformationSystem


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Siemens : Teleperm XP, Teleperm XP-XU, WinTM (Teleperm ME)

ABB : XTC (ProControl Interface to PBS30), PIMS, GLINK

Hartmann&Braun (now ABB) : CONVISA, CONLINK

IDS : HIGH LEIT OS9, HIGH LEIT NT

B&R : DCS2000

OSI Software (Oil Systems) : PI System (via PI-API)

Aspen Tech : Info Plus X

SEG : VLS2000

Others : OPC-Data-Interface, DDE-Server, Profibus, M-BUS, ODBC, SQL,

OLE, FTP, MS-Excel, Yokogawa

SR4 RealizedData

Communi-cation forInterfaces

S O FB D Software for the Power Industry


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EbsilonProfessional

Plant optimization

offline with

Our clients: more than 100 utilities and manufacturers

B I D

EPOS

Performance Monitoring

online with

Software for the Power Industry

ABB, ALSTOM, BABCOCK, BEWAG, Blohm + Voss, BMW, CEE, Colenco, DSD, ECH, Envi Con,E.ON, Electrowatt Hamburg und Zrich, enertech, ENERGOPROJEKT, EVH, EVT, GKWeser,GEW Rheinenergie, gtz China, gtz India, HEW, IBT, LAUBAG, Lurgi, Mannesmann Seiffert,Mitsubishi HI, Ramboll, MVV, NEM, Schering, PCE ENERTEC, PEF, RAB, Rheinbraun, RWE,Saarberg, Siemens, SIK, Stadtwerke Chemnitz, Stadtwerke Hannover, Standardkessel Lentjes-Fasel, STEAG, TEAG, Technip, TV Nord, VA TECH, VEAG, Weig GmbH, ZBP INWAT

Frankfurt

Zwingenberg

Frankfurt

Essen

EbsilonProfessional


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EPOS

total flexible from offline to online operation

actual by high calculation velocity

Optimal use of all potentials by realistic detaillingExact What-If-calculations by identical models for simulation and validation

High availability by reliable convergence behaviour

References and experiences of over 40 online installationsfrom 0,04 MW to 1460 MW for industrial plants and utilities since 1996

Coal,oil,gas fired Nuclear ppCCP plants Mixed plantsRepowering

Modellierung EbsilonProfessional

Offline process simulation


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Mills

Fluegas path

g

Graphical modelling with tool box

Standard libraries for fuels (coal, oil, gas) oxygen carrier gas turbines water-steam user defined and extensible

Error analyzer English, French, German, Spanish,

multilingual

Interactive offline process calculation EbsilonProfessional


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Interactive offline process calculation

Input ofprocess parameters

Input air temperatureDemo example CCPTotal power 10.382 MWEfficiency 38.09%

Start of the calculation


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Offline process simulation with actual,historical or manipulated data

EbsilonProfessionalEPOS


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Choice coal mixture

water-steam-circuitair pathmillsfluegas path

fluegas desulphurization unit

Determination overheads of a power plant

historical or manipulated data EPOS

In Ebsilon integrated optimizer EbsOptimize


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Input of optimization measures

Input of variation measures

Input constraints

EbsOptimizeOptimization objectivesdesign operation modes

In the model available measures


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SR4 UnitOverview


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SR4 BoilerSections


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SR4 BPOSCalculations


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SR4 BoilerMapping


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SR4 TurbineCycle


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SR4 TurbineSection


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SR4 CondenserSection


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SR4 HPHeaterSection


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SR4 LPHeaterSection


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SR4 Air andFlue GasSection


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SR4 AH- ASection

SR4 AH B


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SR4 AH- BSection

SR4 Mill C


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SR4 Mill C

SR4


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SR4 AuxiliaryPower

Consumers

SR4 Set


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SR4 SetPointOptimization

SR4 RH


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SR4 RHMetalTemperature

Calculation

SR4 SH


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SR4 SHPlaten MetalTemperature

Calculation

SR4


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SR4 ParameterEditor

SR4 What


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SR4 WhatIf Module

SRx Raw


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SRx RawData

SRx


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SRx PlausibleData

SRx


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ReconcillatedData

SRx


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SubstitutedData

SR4


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Trending

SR4


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Economic Lossfrom soon or late sootblowing

Optimal TimeforWaterwallSootblowing

Generator Power

Waterwall effectivity (fouling)

Optimum Waterwall

Sootbl. Signal


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SRNo Client Place SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx


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ReferencesNo. Client Place SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx

1 BMW Dingolfing (D) 1999 1998 1998 1998

2 Condea Moers (D), Studie 1998

3 Jebel Ali K Dubai (VAE) 2001 2001 2001 2001

4 Endesa Teruel 1,2,3 (E), 1993

5 Endesa As Pontes 1,2,3,4 (E) 1993

6 Endesa Compostilla 3,4,5 (E) 1992

7 EVN Duernrohr 2 (A) 1990 1998 1998

8 EVN Theiss (A) 1999 1999 1999

9 Henkel Dsseldorf (D) 2001 2001 2001

10 HEW Wedel (D) 1992 1999

11 HEW Moorburg (D) 1995

12 Hidroelectrica Abono (E) 1995 1996 1996

13 Iberdrola Guardo (E) 1994

14 Infracor Marl (D) 2000 2000

15 Kali & Salz Werra (D), Studie 1999

16 LG-Power Seoul (Korea) 2001 2001

17 LVR Bedburg Hau (D) 1992

18 LVR Dsseldorf (D) 1993

19 Mainfranken-Park Wrzburg (D) 1999 1999 1999 1999

20 MiRO Karlsruhe (D) 1999 1999 1999

21 Opel Rsselsheim (D) 1990 1991 1999

22 Petronas Kertih (MY) 1999 1999 199923 Petronas Gebeng (MY) 1999 1999 1999

24 Rethmann Lnen (D), Studie 1997

25 Roche Diagnostics Mannheim (D) 1998 1999

26 RWE Meppen (D) 1994

27 RWE Ibbenbren (D) 1997 1997

SRf

No. Client Place SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx


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Referencesp

28 RWE Neurath (D), Bl. D u. E 1999 1999

29 RWE Neurath (D), Bl. A, B, C 2000 2000

30 RWE Gowerk (D) 1998

31 RWE KEO (D) 2001 2001 2001

32 Salzburg AG Salzburg (A) 2001 2001 2001 2001

33 SAP St.Leon Roth (D) 1999 1999 1999

34 Schering Berlin (D) 2001 2001 2001

35 SESA Leuna (D) 1997 1999

36 Stadtwerke Chemnitz (D), Studie 2000

37 Stadtwerke Schwbisch Hall (D) 1996 1999 1997 1997

38 Stadtwerke Hamm (D) 1994 1999

39 Stadtwerke Kempen (D) 1993

40 Stadtwerke TW Ludwigshafen (D) 2000 2001 2000 200041 Stadtwerke Dsseldorf (D) 1999 1999

42 Stadtwerke Neustrelitz (D), Studie 1996

43 Stadtwerke Rosenheim (D) 1998 2000 1999 1999

44 Stadtwerke Salzburg (A) 1999 1999 1999

45 Stadtwerke EW Wels (A) 1999 1999 1999 1999

46 Steag Lnen (D) 1997 1997

47 Steag Herne (D), Bl. 4 1998 2000 1998

48 Steag Herne (D), Bl. 3 2000 2000

49 Steag Walsum (D) 1998 199850 Unin Fenosa La Robla (E) 1989

51 Unin Fenosa Narcea (E) 1990

52 Unin Fenosa Meirama (E) 1993

53 Unin Fenosa Sabn (E) 1992

54 Verbundkraft Duernrohr 1 (A) 1998 1998

55 Wienstrom Wien (A) 1999 1999 1999 1999

SRR f


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KW Lnen, Unit 6 (Steag AG, Essen, Germany); 1996

150 MW, high ash coal / oil, 2 Turbines

KW Drnrohr, Unit 2 (EVN, Maria Enzersdorf, Austria); 1996/97350 MW, Imported coal/gas

KW Drnrohr, Unit 1 (Verbundkraft, Vienna, Austria); 1996/97410 MW, Imported coal/gas

KW Ibbenbren, Unit B (RWE, Essen, Germany); 1996/97750 MW, Anthracite, wet bottom furnace

HKW Herne, Unit 4 (Steag AG, Essen, Germany); 1997500 MW, high ash coal, 400 MW district heating

KW Neurath, Unit E (RWE, Essen, Germany); 1998/1999600 MW

References

SRR f


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KW Simmering Unit 3 (Wiener Stadtwerke AG, Austria);

1999 Combined cycle, 487,3 MWel, District heating 350 MW,

KW Thei 2000 (EVN AG, Austria); 1999

Combined cycle, 454 MWel

KW Neurath, Unit D (RWE, Essen, Germany); 1999

600 MW

HKW Herne, Unit 3 (Steag AG, Essen, Germany); 2000

300 MW, high ash coal, 150 MW district heating

KW Neurath, Units A/B/C (RWE, Essen, Germany); 2000

300 MW each

KW1, Unit 4 und 5 (Infracor, Hls, Marl, Germany); 2000

150 MW each, coal/ chemical residues

References

Documents

Optimisation Tools for Power Plants