Power Solutions

PPI-CCP-CTG-PRF:Combustion Gas Turbine Performance Monitor & Plant Heat Rates

This module provides real-time compressor efficiencies, expected generator capacity, and expected heat rates based upon compressor inlet temperature and humidity.  This information can be useful in determining loss of turbine efficiency or other problems.  Curves are customizable and can be easily adjusted anytime afterward.  Expected values calculations require the availability of appropriate curves (from the manufacturer or actual historical data).  This tool makes it easy to identify problems with turbine performance early.  This solution also provides corrected load and heat rate at base load which provides the best indication of turbine condition since all environmental factors are removed and turbine performance is measured at the same base conditions at all times so any step change in the performance is easily detected.  This module also includes real-time heat rates of each gas turbine as well as both net and gross heat rates of the combined cycle plant.  This information can be useful in determining loss of turbine efficiency or other problems. 

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PPI-CCP-PLT-FRC:Combined Cycle Model with Weather-based Capacity Forecast

A separate AF database is used for a detailed plant model.  Process Plugins regularly reads the weather forecast, and inserts hourly forecasted ambient conditions into the model.  Any parameter may be included in the forecasted model report which is automatically emailed at any frequency desired (usually daily).  Internet access is required for at least one associated computer for weather inputs.  Process Plugins supports weather feeds from weather.gov (U.S. 7-day by latitude/longitude) and wunderground.com (International 10-day by city name). 

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PPI-CCP-OPR-PMW:Combined Cycle Plant Power Market Wise

This solution built entirely in AF with a web-based front end provides a complete package for market based power plants to effectively manage their assets.  The solution includes a weather based capacity forecaster, power 

purchase rules manager with daily and monthly invoicing capability.  Operators or others can enter availability data and then provide real time feedback to power purchasers as an option

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PPI-CCP-UNT-OCA:Combined Cycle Plant Operations Cost Analysis

Operational parameters are compared to expected values and corresponding effects on unit heat rate (or efficiency) and corresponding fuel costs/savings are calculated realtime and displayed.  Manufacturer’s design curves are customized upon installation and can be easily adjusted anytime afterward.  Parameters include GT Inlet Filter Pressure Drop, GT Inlet Temperature, Compressor Section Efficiency and Cleanliness, Exhaust Temperature, HRSG Efficiency, & Condenser Pressure.  This tool calculates real time financial losses or savings (in $/hour) based upon given operational parameters in comparison to the target values.  This tool is extremely valuable in identifying means of immediate savings.

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PPI-CCP-CTG-ETP:Combustion Gas Turbine Exhaust Temperature Profile

Provides a real-time calculation and polar plot of exhaust gas temperatures, and maps to originating combustion chamber. The exhaust swirl angle will be used to correct the combustion chamber position so that each exhaust thermocouple points to the correct combustion chamber.  This tool provides a visual map of exhaust temperatures, making it easy to identify uneven temperature distributions, and the source combustion chamber associated with the given downstream thermocouples

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PPI-CCP-HRS-PRF:HRSG Condition Monitor

Provides real-time Heat Recovery Steam Generator (HRSG) efficiency and effectiveness (HP and LP as applicable) and tracks these parameters. NIST-JANAF tables are used to formulate flue gas enthalpies which are used to perform the necessary gas-side energy balances. This information can be useful in determining loss of HRSG integrity due to corrosion or other problems

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More Power

PPI-GNL-STB-PRF:Steam Turbine Condition Monitor

This module provides real-time turbine section efficiencies and power output and tracks these parameters.  Formulations are based upon ASME A Method for Predicting the Performance of Steam Turbine Generators (by R.C. Spencer, K.C. Cotton, C.N. Cannon).  Real time calculations include actual and expected efficiencies of each individual steam turbine, steam power extracted from each individual turbine, and electrical and mechanical losses.  All steam turbine leakages are calculated and accounted for.  Calculations are in accordance with ASME PTC 6/6s and utilize properties of water and steam calculated in accordance with the ASME 1997 formulations. This information can be useful in determining loss of turbine efficiency or other problemsI

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PPI-GNL-GEN-RCP:Generator Reactive Capability

The generator reactive capability curve is displayed in a dynamic real time display.  This display is unique in that the hydrogen pressure (or temperature where applicable) D-curve accurately moves real-time with actual hydrogen pressure (or temperature) and reactive/real power is plotted within.  The D-curve is plotted with extreme accuracy using true polar coordinates so that the entire limit curve is displayed dynamically around the entire 180 degree plot.  This tool provides a very handy visualization of real time operation compared to the limitations. 

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PPI-RCP-BAH-PRF:Boiler & Air Heater Efficiencies (PTC 4.1) & Rankine Cycle Heat Rates

Gross turbine cycle heat rate is provided based upon the boiler’s steam-side heat input to the turbine cycle. Boiler Efficiency is calculated by the loss method, which is the most accurate way of ultimately calculating real-time coal flow and net unit heat rate.  Boiler Losses are calculated real-time (in accordance with ASME PTC 4.1) and compared to expected losses and overall boiler efficiency.  Air heater exit gas temperature (corrected to zero leakage), gas side efficiency, and x-ratio are calculated and compared to expected real-time values.  This solution includes a custom display of the boiler side view and air heater when diagram is provided.  Boiler Efficiencies (Actual and Expected) and Steam Temperatures are trended to provide a visual display of Boiler Key Performance Indicators.

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PPI-RCP-UNT-OCA:Rankine Plant Operations Cost Analysis

Operational parameters are compared to expected values and corresponding effects on unit heat rate (or efficiency) and corresponding fuel costs/savings are calculated realtime and displayed.  Manufacturer’s design curves are customized upon installation and can be easily adjusted anytime afterward.  Parameters include Main Steam Pressure & Temperature, Reheat Temperature, Condenser Pressure, Cooling Tower Outlet Temperature (when Cooling Tower Performance is included), Feedwater Temperature, Hotwell Temperature, 


 

Appendix A-4 

Attemperation Spray Flows, & Auxiliary Station Service Power.  This tool calculates real time financial losses or savings (in $/hour) based upon given operational parameters in comparison to the target values.  This tool is extremely valuable in identifying means of immediate savings.

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PPI-RCP-FWH-PRF:Feedwater (& DA) Heater Condition Monitor

Each feedwater heater is modeled to predict the feedwater outlet temperature, terminal temperature difference (TTD), drain cooler approach (DCA), and steam extraction flow.  These parameters are compared real-time to the corresponding actual conditions which are also calculated.  Differences in expected results could indicate problems with heater operation or physical condition. 

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PPI-GNL-PLT-MDL:Detailed Thermodynamic “What If” Model

The detailed plant model is built in a PI-AF Database.  A customized interactive PI-ProcessBook display is integrated with this AF-based model.  The user may easily edit the value of any input parameter, and the edit automatically triggers the Process Plugins model function to recalculate a new set of results which are stored in PI tags.  Any parameter may be included in the model input/output display.  The display also includes a side-byside real vs. model set of parameters, making it convenient to enter actual input values, and compare modeled to actual values.  This is handy when tuning the model as is often needed to account for equipment degradation.  The ProcessBook display includes a handy form to edit the input data.  When opened, this form is automatically filled with actual plant values as the default, making it very handy to run the plant against real data with any number of edits to easily see “What If” any parameters are changed. 

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Other Industry and Power

PPI-GNL-CTR-PRF: Cooling Tower Condition Monitor

Provides real-time expected cooling tower outlet temperature based upon wet bulb temperature and range (circ-water temperature rise).  The Process Plugins™ toolset provides the calculation of wet bulb temperature from humidity or dew-point as necessary.  This information can be useful in determining problems with cooling tower operation or physical condition.  Curves are customized upon installation and can be easily adjusted anytime afterward. Expected values calculations require the availability of appropriate curves (from the manufacturer or actual historical data). 

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PPI-GNL-ACC-PRF:Air Cooled Condenser Condition Monitor

The air-cooled condenser is monitored using design specifications to predict target pressure (vacuum) and cleanliness. These parameters are compared real-time to the corresponding actual conditions which are also calculated.  Differences in expected results could indicate problems with condenser operation or physical condition, which often has a substantial impact on plant heat rate

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PPI-CCP-CHL-PRF:Chiller Performance Monitor & Advisor

This solution performs thermodynamic calculations on the chiller coils, calculating the real time chiller duty, heat exchanger effectiveness, heat transfer coefficient, and air moisture removal rate.  The chiller design specs are used to model the design conditions for real time comparison.  When incorporated in conjunction with PPI-CCP-CTGPRF (Combustion Gas Turbine Performance Monitor & Plant Heat Rates), chiller advisor will determine whether or not chiller operation is beneficial under current ambient conditions.  When incorporated in conjunction with PPICCP-CTG-FRC (Combustion Gas Turbine Weatherbased Forecast), chiller advisor will recommend chiller operation based upon future ambient weather conditions.

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PPI-SOL-STR-PRF: Solar String Condition Monitor

This solution monitors the condition and performance of the module DC output, axis trackers, string inverters, and transformers.  Real-time solar conditions (i.e. cloud cover) is imported from the internet in order to asses and historize output vs. ambient light irradiance. DC to AC “Performance Ratio” and lifetime system degradation is calculated, monitored, and historized.  For each string inverter, a real-time plot of output power and current vs. DC voltage is rendered with any available design curve. PI Notifications is leveraged to provide email alerts in the event of a performance reduction or any discernable condition requiring attention

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PPI-CCP-SOL-FRC:Solar Park Model with Weather-based Capacity Forecast

A separate AF database is used for a model of the photovoltaic power station.  Process Plugins regularly reads the weather forecast, and inserts hourly forecasted ambient conditions into the model.  Any parameter may be included in the forecasted model report which is automatically emailed at any frequency desired (usually 

daily).  Internet access is required for at least one associated computer for weather inputs.  Process Plugins supports weather feeds from weather.gov (U.S. 7-day by latitude/longitude) and wunderground.com (International 10-day by city name).

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PPI-WND-WTB-PRF:Wind Turbine Condition and Assets Monitor

Wind asset parameters are organized by Region, Site, Turbine, and Component within PI-AF.  A master display is provided with drill-down capabilities to support five levels of hierarchy: Executive, Regional, Site, Turbine, and Component screens.  Calculations include Availability, Capacity Factors, and totalizing functions.  Turbine status is monitored for any gear boxes, generator and overall performance issues.  Real time performance of the turbine compared to expected performance is displayed within Process Book of the PI Vision. 

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