Proppgosal for Mongolian Power Station using Joint ......(2)The boiler and turbine arenot coordinated. → The plant is not stable by the mutual interference. • Improvement Inorder

Proposal for Mongolian Power Stationp gusing Joint Operation System(JOS)

Dec., 2013

© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

◆Contents

(1) What’s Joint Operation System (JOS) Actual Performance Functions and Features of JOS Functions and Features of JOS JOS for Paper manufacturing System Configuration Example S i C fi i System Function Configuration How to calculate optimization Calculation Examplep

(2) Proposal for Ulaanbaatar No. 3 and 4 Power Station using JOS Optimizing item ALR & MW Optimizing ALR & MW Optimizing Turbine Optimizing Boiler Demand & Optimizing Boiler Master Controller & Optimizing Boiler Feed Pump Inverter control & Optimizing Conclusions

1© 2013 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.

Conclusions

(1) What’s Joint Operation system(JOS)

What’s JOS ?JOS optimizes the plant status for a minimization of total energy.

H ?How ? • Each boiler, turbine and equipment has a high efficiency

operation band.operation band.• As a practical matter, all equipment can not be operated

on the high efficiency area in the plant.

JOS can coordinate the operation point both the boiler and turbine The operator can lead the plant to the minimizationturbine. The operator can lead the plant to the minimization of total energy using JOS.


◆Actual performance of JOS

T t f JOS ?Target of JOS ?The plant has a number of boiler and turbine with common header.Boiler uses some fuel for combustion.Turbine has some extraction line for process steam.

W h d li d JOS tWe have delivered JOS tothe following plant,• Paper manufacturing

for 3 companiesfor 3 companies = 3Bx7T+16Bx9T, 3T, 6Bx7T

• Iron manufacturingfor 2 companiesp

= 3Bx4T, 5Bx5T• Joint Thermal Power Plant

for 1 company = 3Bx3T


Figure 1. System diagram of paper manufacturing plant.

◆Functions and Features of JOS

Online real-time optimizationJOS calculates the optimal operation demand according to the mass balance of the steam and the power balance when the plant status changed.

Offli ti i tiOffline optimizationJOS can simulate the future plan to determine the running number of boilers and turbines.

Calculation of equipment operation characteristics modelJOS uses the model of boilers and turbines with the actual characteristicsJOS uses the model of boilers and turbines with the actual characteristics .Economical operation demandJOS calculates the total generating cost using nonlinear optimizing solver.Automatic update the nonlinear model using identificationp g fThe model is corrected using the present plant condition.Pattern setting of the utility power and its calendarThe operator can define when the utility power cost is decided and/or renewed by contract .Estimation of the statusJOS estimates the actual value using mass balance because the flow sensor has an error under low flow status.

D d t lDemand controlJOS can selectively warn the operator operating the shutdown of auxiliary machine before the utility power reaches the limit of its contract at the end of a demand cycle.


◆JOS for Paper manufacturing

JOS

( Economical load dispatch )Boiler Input Demand

JOS Input Signals JOS Output Signals

Set point of Extraction Steam Flow

S t i t f M i St Fl

Plant Optimization Function ( p )

Monitoring whole plant status FunctionDemand monitoring /control Function

Main Steam FlowMW Demand

Set point of Main Steam Flow

ControllerController

(DCS)

発電機発電機タービンタービンTurbine G

GOV

GOV

GOV

(DCS)(DCS)



GOV

Boiler

Boiler

Boiler

Boiler

Figure 2. Ex. of JOS for Paper manufacturing Plant


出典：火原協入門講座「計測と制御」

Plant.

◆System Configuration Example

Operation Schedule (Daily,

Weekly)

Operation Plan (Power generation, Air supply)

Case studiesCurrent demand setting

OperationOperator

Optimal operation balance display

Offline Real-time JOS instructionsOffline optimization calculation

Real time optimization calculation

Controller(DCS)

JOS instructions

Current values

Status assumption

Economical operation

model

Logs

GOV

Control & Monitoring

Model d

Equipment operation Operation




GOV

GOV

JOS consists of latest personal computer.

updatecharacteristics modelOperationdatabase

BoilerBoiler


BoilerFigure 3. Ex. of system configuration.

◆System Function Configuration

Statistical Data•MW•Steam flow

Cost Data•Power Cost•Fuel Cost

Demand Data•MW•Steam flow

OperationGuidance

OperationCondition

OperatorSteam flow

OptimizationpSystem

CostCost Data Cost CalculationDatabase

OperationSchedule

Optimization

C t i tInstrumentDatabase

Cost

ConstraintCondition

DatabaseP&I

Database


Figure 4. System function configuration.

◆How to calculate optimization

V i bl d fi d f l l tiVariables are defined for calculation

Variable X for JOS ”Design Variable” Steam Steam flow of Turbine & ext. steam, oil & coal, etc.Feed back from demand of JOS MW, Steam flow of Boiler etc.,Condition for JOS MW demand, Steam flow demand, etc.

Equations are made from these relationship using system diagram

Equality constraint H :Mass balance of turbine, Characteristics （Flow vs. MW）

MW Demand＝ΣMW＋Utility power Mass Balance around header etcMW Demand＝ΣMW＋Utility power, Mass Balance around header, etc.Inequality constraint GG :MW of generator, Steam flow of boiler, etc.Limitation of variable X :Operation boundary of boiler and turbine, Utility power of contract

Object function of optimizing FF :Total Fuel cost and Utility power cost

Optimization using nonlinear programming method

Object function of optimizing FF :Total Fuel cost and Utility power cost

H=0, G<0 & F→minAnswer is X

x1 x2y

x1 x2yＦ

JOS solves X so as to be minimization of F.


x1x1Figure 5. Solver image of JOS.

◆ Calculation Example

Characteristics of 1T Demand

Minimization for Steam flow

Characteristics of 1T

35MW

10t/h

Ext. Steam0t/h X3(t/h)X1(MW)

Demand

MW = 65MWProc. Steam = 20t/h

● 20t/h

17MW

25MW 30t/h Initial balance●Necessary Steam

= 390t/h

▲

■

HP Header

Boiler150t/h 200t/h

X4( /h)

390t/h

∥

Ext. Steam0 /h

Optimizing

S1(t/h)

Optimizing Characteristics of 2T

～～1T 2TX1 X2

48MW40MW

10t/h

20t/h

X4(t/h)

MW after optimizing ■Necessary Steam

= 380t/h■

●

▲

30MW

0t/hX2(MW)

LP HeaderProc. Steam

Cond. Cond.Ｘ３

Ｘ４

30t/h = 380t/h

Ext. steam aft. opt.▲Necessary Steam

= 378t/h

●30MW

demand

MWDemand

378t/h

∥190t/h 230t/h

228t/h

whereDesign variable is X1～X4Obj t f ti S1+S2

S2 (t/h)


Object function S1+S2Figure 6. Calculation example of JOS.

(2) Proposal for Ulaanbaatar Power Station using JOS

National Dispatching Center

No. 3 Power Station

148MW

No. 4 Power Station

580MWRussia

Boiler

1〜 6B= 75t/h

7〜13B=220t/h

Turbine/Generator

1〜4T=12MW

5〜8T=25MW

Boiler

1,3〜8B=420t/h

2B =500t/h

Turbine/Generator1T = 80MW

2〜6T=100MW

•Problem(1)The operation is manual for Turbine/generator.→ The generating response is delay for the grid.

Figure 7. Ulaanbaatar power station.

(2)The boiler and turbine are not coordinated. → The plant is not stable by the mutual interference.• Improvement

In order to stabilize steam pressure/temperature, improvement of boiler control itself should be required.(1)Stable and optimizing → (2)Reducing an over fuel → (3)Reducing the fuel cost and CO2 emission(1)Stable and optimizing → (2)Reducing an over fuel → (3)Reducing the fuel cost and CO2 emission

•Action(1)The controller of Boilers and turbines should be improved using a proposed control method and a

optimizing solver.(2)The power plant shall be optimized to minimization of total energy using JOS.


(2)The power plant shall be optimized to minimization of total energy using JOS.

◆Optimizing itemJOSJOS

Optimizing of Boiler Control(1)Steam Pressure setting(2)St T t tti

Optimizing of Boiler Control(1)Steam Pressure setting(2)St T t tti

JOS(1) Boiler optimization demand(2) Turbine optimization demand(3) Hot water optimization demand

JOS(1) Boiler optimization demand(2) Turbine optimization demand(3) Hot water optimization demand

6B

(2)Steam Temperature setting(2)Steam Temperature setting ( ) p( ) p

Steam pressureSteam temperatureGovernor position

4T3B4B

5B6B Governor position

Fuel flow, etc.

3T

4T

1B2B

3B

1T

2T

Optimizing of Turbine control(1)I d llOptimizing of Turbine control(1)I d ll(1)Improved governor controller(2)Add ALR logic(3)Optimizing Governing point

(1)Improved governor controller(2)Add ALR logic(3)Optimizing Governing point

Optimizing of Hot water productionOptimizing of Hot water production


Optimizing of Hot water productionOptimizing of Hot water productionFigure 8. Optimization item.

◆ALR & MW Optimizing

ALR ti i ti i i lALR operation using optimizing solverNDC

DemandNDC

Demand1G〜nGMW

1G〜nGMW

△△ΣΣ

WW

OptimizingSignal

OptimizingSignal

PIPI

ΣΣ ΣΣ

△△1G

MW1G

MW △△nGMWnG

MW

Automatic Load Regulator (ALR)

PIPI PIPI


1T GV Motor nT GV MotorFigure 9. Block diagram of ALR.

◆Turbine Optimizing(1/3)

Specifications of Turbine governor Case Study 1Specifications of Turbine governor

60

80

100ift

(%)

100

If Total output=200MW by 3 generatorsCase Study 1

20

40

60

Val

ve L

i

20406080

60

80

100

w (%

)

0020

0 20 40 60 80 100Optimizing

0

20

40

60

Ste

am F

low

2 Generators output=50MWx2

1 Generator output=100MW

p g

0

6080100

oss

of G

V

)

Good operating point 6080100

02040

Pres

sure

Lo

(%

02040

0 20 40 60 80 100


0 20 40 60 80 100Turbine GV Demand(%)

P 0 20 40 60 80 100Turbine GV Demand(%)

Figure 10. Turbine optimizing.



60

80

100ift

(%)

80100


20

40

60

Val

ve L

i

20406080

60

80

100

w (%

)

0020

0 20 40 60 80 100Optimizing

0

20

40

60

Ste

am F

low

Reducing turbines inlet pressure set point

p g

0

6080100

oss

of G

V

)


02040

Pres

sure

Lo

(%

02040

0 20 40 60 80 100






60

80

100ift

(%)

80100


20

40

60

Val

ve L

i

20406080

60

80

100

w (%

)

0020

0 20 40 60 80 100Optimizing

0

20

40

60

Ste

am F

low

Increase turbines inlet temperature set point

p g

0

6080100

oss

of G

V

)


02040

Pres

sure

Lo

(%

02040

0 20 40 60 80 100




◆Boiler Demand & OptimizingTurbine inlet Turbine 1st stage

Target Valve Lift (GV)

Target Valve Lift (GV)

P1P1PTPT

steam pressureg

steam pressure

△△÷÷ KK

PIPIKK

> <> <

PI controllerwith limit (High, Low)

△△

Target pressure> <> <

PIDPIDΣΣOptimizing

SignalOptimizing

SignalBoiler master

controller

※Ex. Turbine Optimizing(2/3)ΣΣ


Boiler DemandFigure 11. Block diagram of boiler demand.

◆Boiler Master Controller & Optimizing

OptimizingOptimizingSteam header

Set point bySet point by

PPOptimizing

SignalOptimizing

SignalSteam header pressure

△△

Set point by manual

Set point by manual

ΣΣ

Steam Header

PP1B 5B

△△

PIPI1T 5T

FF FF

1B fuel flow 5B fuel flow

PIPI

※

ΣΣ △△ ΣΣ △△

※Steam header pressure can be stable because each fuel controller of boiler receives from one Boiler master controller.

PIPI PIPIOptimizingSignal

OptimizingSignal

OptimizingSignal

OptimizingSignal


1B Fuel 5B Fuel Figure 12. Block diagram of boiler master.

◆Boiler Feed Pump Inverter control & Optimizing

OptimizingOptimizing

BFP outlet feed water pressure

SPBPPBP

OptimizingSignal

OptimizingSignalSuper

HeaterTo Steam Header

Set point by manual

Set point by manual

ΣΣSteam Drum

△△

Speed demand to

PIPI

Feed water control valve(FWC)

※Differential pressure between FWC inlet and outlet shall be controlled by BFP speed .

FWC l b il d l l b i 1 l 3 l

pInverter


FWC controls boiler drum level by using 1 element or 3elements signal . Figure 13. Block diagram of BFP inverter

control.

◆Conclusions

The Plant shall be optimized to minimization of total energy using JOS.The manager can predict total cost using offline mode.The operator can get the most economical and safety operation

using online mode.

Investigation of the following characteristics,(1)Turbine mass/heat balance(2)Characteristics of Turbine GV (3)Boiler mass/heat balance(4)Fuel consumptions and cost(4)BFP Q−H characteristics


(5)FW CV, flow, diff. Press., position, etc.

Thank you for your attention.


Documents

Proppgosal for Mongolian Power Station using Joint ......(2)The boiler and turbine arenot coordinated. → The plant is not stable by the mutual interference. • Improvement Inorder