1Power Plant Performance Monitoring Indonesia Customer Seminar June 13 & 14 2012 Jakarta Indonesia Why monitor Condenser Performance? It is where the money is made or lost Optimize cooling water program Identify mechanical issues such as with air-removal systems What is a Condenser and how does it work? Nothing more than a heat exchanger Condenses steam by transferring heat to cooling medium The better the heat transfer rate, the better the vacuum, the more efficient the Steam Turbine/Plant What is Nalco’s Condenser Performance Offering? Condenser Performance Monitoring Tool (CPMT) Captures plant data, as well as Trasar data Compiles information, performs calculations, generates Dashboard for reviewing with customer So how does the Condenser Performance Monitoring Tool work? Gathers the plant’s raw data for the key parameters Uses these to make necessary calculations Calculations provide quantitative information to trend condenser performance . So how does the Condenser Performance Monitoring Tool work? Graphs provide big picture view of condenser performance and allow for comparison of the key parameters Most important is that it allows for filtering of data to compare like-for-like conditions In the end the tool provides an accurate method of troubleshooting and identifying areas of improvement . What is required by the plant? Provide the proper design documentation Inform the Nalco Representative of any changes that have been or will be made to the Cooing or Condenser Systems Help with set up of the Historian Download sheet . What is required by the rep? Modification of the tool to fit plant’s needs Periodic download of data from customer computer Migration of that data to the tool Analysis of that data with customer . DESIGN DATA ENTRY . particularly number of pumps for each season Thermal Kit Extremely valuable in comparing actual to design under all conditions Contains information regarding Back Pressure vs Inlet Water Temperatures. as well as flow and heat load on the condenser . a thorough understanding of the pump operation is needed.What design data is needed? Condenser Design thermal and flow balance Typically found in the Condenser Spec Sheet Cooling Cooling Tower spec sheet if applicable For Once-Through’s. 11 Design Data Entry Condenser Spec Sheet Cooling Tower Spec Sheet . 12 Design Data Entry . 13 Design Data Entry . Data Capture HISTORIAN DOWNLOAD . both net and gross Cogen Steam if applicable Ambient Temperature Hotwell Temperature .What operational data points are needed? Basic points Plant load Steam Load Condenser Back Pressure Cooling Water In and Out Temps Heat Rate. if cooling tower and no Wet Bulb Each GT MW output. but not typically brought back to historian .or at least a % expected Wet Bulb. which is captured by the unit.if HRSG Fuel usage for all applicable systems Important to note that we can pull anything into the tool This allows us to trend other plant operations with the Condenser and Cooling Tower Performance An example would be the 3D Trasar or NCSM data.What operational data points are needed? “Would like to have” points Cooling Water In and Out Pressures Extraction Steam.if cooling tower Humidity %. 17 Historian Download Setup . 18 Historian Data Download . Data Import UPLOADING HISTORIAN DATA . 20 Accessing the CPMT and Importing Data . Data Review GRAPHING TOOLS AND DASHBOARD . 22 Graphing Options . 23 Dashboard . A Discussion about Condenser Performance WE HAVE THE DATA NOW WHAT? . What parameters do we care about and why? Air Steam CW Out CW In Condensate . What are some key indicators of Condenser Performance? Back Pressure (BP) Heat Rate (HR) Air-In-leakage Cleanliness Factor (CF%) Initial Temperature Difference (ITD) Terminal Temperature Difference (TTD) Temperature Rise (TR) Log Mean Temperature Differential (LMTD) . Performance Definitions and Calculations ITD – temperature difference between the Steam Temp and the Inlet Water Temp Stm – CWin Can be key in identifying inlet water/cooling tower issues TTD – temperature difference between the Steam Temp and the Outlet Water Temp Stm – CWout Indication of overall heat transfer and performance . Performance Definitions and Calculations TR – temperature difference between CWout and CWin Indication of how much heat was picked up by cooling water Can be a good indication of fouling LMTD .logarithmic average temperature difference TR / ln(ITD/TTD) (for counter current) In essence is the average temperature change across the tube bundle . Performance Definitions and Calculations LMTD Temperature Steam Temperature Constant TTD ITD TR Distance Down Tube . Performance Definitions and Calculations Industry standard but very much misunderstood CF% = Ua / Ud Ua = Q / A * LMTD Ud = Ui * FL * F1 * F2 FL = Steam Load Factor F1 = Inlet Water Correction Factor F2 = Tube Gauge Correction Factor Ui = Ideal Heat Transfer Coefficient . What are some key aspects of Condenser Operation? . Performance Consequences.Turbine Efficiency Efficiency of Turbine determined by BTUin and BTUout Lower BTUout value = more btu’s transferred to Turbine Therefore.5 psia = 1304 btu/lb 2. lower BP in condenser.0 inHg = 1111 btu/lb Additional 6 btu/lb to Turbine and MW generation at lower BP .5 psia = 1304 btu/lb 101.0 inHg = 1105 btu/lb 3. more BTU’s transferred to Turbine 101. Performance Consequences – Inlet Water Temp Many don’t consider this when discussing current operating BP Inlet Water Temp dictates condenser performance Assuming constant TR.2 inHg increase in BP . every 2°F can mean as much as a 0. 34 Effect of Cooling Water Inlet Temperature Cooling Water In Temp vs.50 1.00 3.00 1.00 50 60 70 80 90 Cooling Water Inlet Temp f *Assumes 20°F TR and 6°F TTD 100 110 .00 2. BP* Back Pressure inHg 4.50 4.50 2.50 3. Performance Consequences – Air In-Leakage Air In-leakage a significant contributor to degradation in condenser performance Typically not monitored on-line Typically not well understood Blankets tubes preventing heat transfer Air Resistance = Rair Scale/Foulant Resistance = Rfoul Condensate Resistance = Rcond Tube Resistance = Rtube Water Resistance = Rwater U = 1/(Σ Resistances) . Important Considerations PITFALLS OF CONDENSER MONITORING . can be accomplished The data is only as good as the tools used to collect it Bad probes Bad location Not sent back to the historian All play a role in poor data collection Seeing what you want to see Analyze the data.Common Obstacles Cycling plants difficult to monitor. but with a properly set up Thermal Kit and filtering. not what you would like to happen Check multiple parameters to make sure they correlate Make sure you understand plant operation/dispatch . start by filtering the data to the condition desired Remember. and date all at the same time to really drill down to what you are looking for . inlet water temp.Analyzing Data Be patient Look at all parameters before starting to form a conclusion Because it is important to compare like conditions. you can filter on many parameters at once For instance. you can filter plant load. CASE STUDIES . Case #1.Vacuum Pump Seal Water . Case #2.Bio-Surfactant Addition Mechanical Cleaning Surfactant Addition . Case #3.Air In-leakage . DISCUSSION .