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ACTSYS Process Management Consultants Pte Ltd. Seminar on Energy Efficiency for the Process Industry
Who are we ?
Established 2001 Principal ex Shell operational and technology senior management Based in Singapore, operating regionally Specialize in Plant Performance Monitoring methodology for Power Plants, Refineries and Petrochemicals Major Clients include Tuas Power Singapore, Power Seraya Singapore, PJB Indonesia, GE Energy, Gulf Electric Thailand, EGAT, Petronas Penapisan Trengganu, Petronas Central Utilities Gebeng, ThaiOil, Malakoff, Senoko Power Singapore
Energy Index
Time
ACTSYS Process Management Consultants
The performance of these equipment can be adversely affected by mechanical degradation or fouling.
Bypass Valve
V-1
Passing Valve
Pump 2 Pump 1
190 210 230 250 270
290
310
Flow (TPH)
230 220 Stack Temp C 210 200 190 180 170 160 150 10 15
Target Stack T
20
25
30 35 BFW Flow
40
45
50
MWh/Yr
Thermodynamic Models
Heat Balance model
Using existing measured operating conditions calculate all other unmeasured plant conditions Determine actual efficiencies of plant components
109848
S59 SP3 S37 S38 HPBYPS V1 PI3 S40 V2 HPST LPSTOT M6 CONDSR S39 S60 M3 CWS CWR HPSTOT S26 S55 S48
BFWSPP SP5
ST Power kW
IPST LPST BFWHDR S50 S51 S52 IPBFWP HPBFWP
HPBFW
MAKEUP PI1 HPBPSS S57 S58 S43 SP4 PI2 HPSDSH HPS IPS S35 S36 S24 S22 S29 S1 S3 RHTRS S34 HPSH2 S5 S6 S7 S8 S9 S10 S11 S12 RHDSH S25 S33 S32 S28 S13 HPECO1 S15 S27 S23 LPS S31 M5 S49 S44 S45 S46 PUMP1
M4
S30
COND
S17
S18
S19
S20
S21
STACK
S4
IPECO2
GTEXH
DUCT1 FUELGS
169298 GT Power kW
TURBIN GTTURB S41
AIR
SSGEN
INLFLT
LP STM
Bypass Valve
V-1
1-Jan-05 15-Jan-05 29-Jan-05 12-Feb-05 26-Feb-05 12-Mar-05 26-Mar-05 9-Apr-05 23-Apr-05 7-May-05 21-May-05 4-Jun-05 18-Jun-05 2-Jul-05 16-Jul-05 30-Jul-05 13-Aug-05 27-Aug-05 10-Sep-05 24-Sep-05 8-Oct-05 22-Oct-05 5-Nov-05 19-Nov-05 3-Dec-05 17-Dec-05 31-Dec-05
0.90
0.95
1.00
1.05
1.10
Stack (New Feedwater Preheater Temperature (Actual) /temp Vsand Clean Performance)
Valve Repaired
Plant Data
Plant Data
Historical Archive
Discussion Points
Typically power plants operate with at least 0.5% thermal efficiency loss, some as high as 1-3% !! Imperative to ensure Power Plants operate as near as possible to New & Clean all the time
That the Power Generators and Process Industry have to do something is clear
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Historical EI
Time
ACTSYS Process Management Consultants
SHAFT POWER
ROTOR COOLING LOSS (2.09%) COMPRESSOR WORK (.% of GT Shaft Power) COMBUSTOR LOSS (0.49%)
.3 5% )
FU EL
S EN 1. SI 00 BL % E
HE AT
RA DI AT (0. ION 04 LO %) SS
(1. 4
PE
AIR
LO SS
IN LE T
(0 .
08 % )
D U CT
LO SS
(0
5% )
PI