DC-CPOM-GA-HROA05-2010-001

OPTIMIZATION OF BOILERS START UP WITH SOFTWARE BOILERMAX AND USE STEAM COIL AIR HEATER

By: SISWO PAMBUDI Operator PT. D & C Engineering Company Email: siswo.budi@yahoo.co.id

Abstract Start UP process require thorough readiness to reduce losses due to excessive fuel consumption because the process of firing up to 50% met the full load requires a long time. But it can be minimized by optimizing the heat transfer in the primary air draft fan before entering the inlet hot air mill A using a steam coil air heater that utilizes a heat source from the auxiliary steam header, so the heating time for coal in mill A can be shortened. In Cilacap power plant design has been equipped with such equipment, but in practice its use has not been enabled. In addition, the ideal set point on the turbine bypass also can accelerate the start-up process because it will control the pressure, so that will be able to speed up the process of increasing the steam temperature within the permissible limits especially during warm and hot start.

I. INTRODUCTION 1.1 Background 1. The development of the power generation business process requires a high and Heat Rate as indicators of plant performance. 2. From the data start-up process visible use of components of the equipment available for start-up cost savings using the utilization of steam from the auxiliary to the steam coil which is expected to save time and cost of fuel consumption has not been utilized. 3. Problems - problems that often occur in the field due to bad weather conditions or the condition of the equipment is broken suddenly and cause unit trip, it requires operators to be able to quickly analyze and know the main causes interference and determine the repair time if needed and start up by considering the cost of the process. 4. Electrical energy needs in the community that higher fuel prices and the trend of increasingly expensive oil demand electricity generating unit to operate stably for to save the cost of using fuel oil for start-up process. 1.2 PURPOSE The purpose of this paper is: 1. Maximize heat transfer in turbine and boiler equipment as boiler start-up process with a focus on the Steam coil (when cold start-up) as a corporate asset that has not been used

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optimally. and setting the turbine bypass valve open (when warm and hot start-ups using boilerMax) Provide an overview of the scientific explanations about the benefits of Steam coil AH and turbine bypass fuel consumption both operationally and in financial Comparing the effectiveness of start-up using a steam coil and setting the value of a proportionate turbine bypass. Shortening the start-up (warm and hot) using the turbine bypass system. Ensure no degradation occurs in the reheater and super-heater material so that the optimal age of boiler tubes due to the use of turbine bypass when start-ups.

II. THEORY Steam coil air heater is generally operated at start up or low load, which get hot steam from the auxiliary steam header connected to each other between units 1 and 2, so as to mutually supply steam heat for the purpose of start-up when one unit of trip / shutdown, with The average temperature steam reaches 174 0 C and pressure 0.7 Mpa, a temperature sufficient to meet the mixture of air temperature before entering the mill to reduce the moisture content of coal in the mill. required temperature before the mill is a mixture of air inlet 150 0 C, this is a temperature sufficient for mill work like a normal running state of the unit, so it

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can accelerate combustion in the furnace which in turn will accelerate the start-up process. So at start up the boiler or on low load steam coil air heater can be an option for saving fuel, because all this when low loads below 160 MW always use a tiny oil, Apart from using steam coil to accelerate the start-up process can also be done by opening Turbine bypass valve set point with a calculation based on steam temperature increase in the average limit of 2 0 C / min and turbine pipe 1.5 0 C to avoid thermal shock on the main steam pipes in a way of controlling the pressure through the turbine bypass. Turbine bypass system is a system that connects the main steam line with the re-heater and condenser with the function to ensure the cooling of steam in the super-heater and reheater at the time of firing when the turbine is not rolling; another function is to load rejection. The starting of IP Cylinder start has good flexibility, which is favorable to the operation of double shift peak "load. By adopting IP Cylinder starting, bypass capacity should meet the capacity requirements (More Than or equal to 35% B-MCR), and the bypass system operated normally and should be Automatic status well be preferred. " Preparations for rotation impulsing: a. To provide power supply to DEH, dial and system should be in normal status; b. To start lubricating oil pump and head shaft pump, to ensure that lubricating oil system and head shaft oil system are in normal status; c. To start the fire-resistant oil pump; d. To re-check the lubricating oil system, fireresistant oil system, DEH and TSI system and vehicle jigger device; e. Operation requirements of low pressure bypass before rotation impulsing; The opening of low pressure bypass valve gradually increases along with the startup of boiler. When the reheat steam pressure rises to 0.686MPa, low pressure bypass should lunch pressure feedback automatic control. (Manual book of steam turbine) To make it easier to get max value of open bypass valve on the turbine can be installed boiler software max the primary purpose of BoilerMax is software to minimize startup costs while taking the given process-specific basic conditions into account.

Especially fuel costs and thermal stress in the critical thick-Walled components are taken into account when computing the optimal set points for the fuel supply and the HP bypass station. Fig. 1 shows the functional principle of the BoilerMax

During a startup procedure, the actual values, which are cyclically scanned for temperatures, pressures and steam mass flow rates, are used for adjusting a physical unit of the model. Based on this nonlinear model, BoilerMax applies its predictive optimization routines to the rest of the startup procedure. The resulting online startup computed curves are then integrated into the existing control unit concept, serving as correction sets of points. The prediction horizon is 60 to 90 minutes, thus covering the entire length of a boiler startup up to the point nowhere is rolled on the steam turbine. This way the most cost-efficient operating mode overalls cans be computed. The predicted data is updated every one to two minutes, thus enabling an adequate response to disturbance conditions. Because of the high computing power required, BoilerMax is run on a PC That Is configured as an application server. The startup costs to be minimized refer to fuel, auxiliary power and auxiliary steam boiler costs incurred during a startup, from 'Fire ON to' Generator On-Line 'or' HP Bypass Closed '. Independent of the cost savings are realized, the model based multi-variable controller enables a predictive Also integration of thermal stress data into the closed control loop. The level of flexibility - e.g. covering different downtimes is improved as the physical model is continually adjusted to match the current state of the plant. Moreover, the startup cans be adapted to changing basic conditions, Such as different fuel costs or the maximum permissible

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loads, by modifying the target function and optimization constraints, respectively 2.1 Reducing Fuel Consumption With the predictive startup optimization, it is often possible to run a startup using less fuel, while maintaining the usual startup time and stress loading on critical thick-walled components. Figure 2 shows a comparison of two startup procedures in the Ingolstadt power plant, unit 4. The diagrams clearly show that it was possible to run a similar boiler startup while realizing an approximate 20% reduction of fuel consumption. Such fuel savings are possible, since the steam flow used for starting-up can be decreased by simultaneous and coordinated reduction of the opening of the HP bypass station. In addition, the startup time is slightly reduced. With a higher level of automation, achieved by the optimized startup procedures, startup procedures generally become more consistent. Figure 2 Comparison 2 starts up with boilermax (bold line) and without boilermax (thin line).

(P_GEN), the diagram in the bottom show the temperature differentials (DT_SH4AH and DT_SH5AH) occurring in HP header of two last of superheater levels Figure 3 represents the startup costs as a function of the duration of the preceding standstill. In particular, in the case of frequent brief standstills, when numerous startups are run under similar conditions, the spread of startup costs is obviously reduced. The optimized startup costs achieved with BoilerMax are at the lower end of the cost range that is characteristic of operations without BoilerMax. On average, the startup optimization resulted in a significant reduction of the startup costs. In the case of brief standstills, startup costs are high, as a high live-steam temperature has to be built up, since the temperatures in the turbine are still high. On the other hand, startup costs also rise in the case of long standstills because then the boiler cools down to lower temperatures. On account of a reduction of fuel consumption, steam production and, in some cases, a slower pressure build-up, the operator might get the impression that the entire startup procedure is somehow dragging on. However, it is important to consider that, during boiler startup, the target set points needed for steam flow and pressure must be available only when the turbine is about to be rolled on steam and that the predictive optimization concept makes full use of this fact. Figure 3 Start up cost as a function of the duration of the standstill in the Ingolstadt oil fired power plant unit 4 with and without Boiler max

In the ingolstade oil fired power plant upper diagram show the fuel quantity (F_F) and the HP bypass (Y_HBP), the diagram in the middle shows the live steam flow (F_LS) and the generator output

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2.2 Integration into the Unit Control System Predicting and optimizing the startup procedures of a boiler on the basis of a physical model involves elaborate numerical processing. Boiler-Max is therefore implemented on a high performance PC that is linked to the unit control system via a signal interface In the Staudinger und Heyden Power Plant, the BoilerMax PC was implemented independently and be connected directly to a control cabinet. Viewing and operating are done from regular operating and monitoring stations. In the Ingolstadt and Zolling power plants, the BoilerMax PC has been integrated with the 800xA operating system which was installed during a turbine retrofit project. With System 800xA, the BoilerMax PC can be integrated as an application server. This provides a special advantage: all parameter settings and calculation results, including the predicted process values, can be made visible and be integrated into the display without additional effort. Furthermore, this facilitates the staffs familiarization with the BoilerMax solution and the PC can be included in the regular maintenance routines for the Sys-tem 800xA. The unit model used for startup optimization is adjusted on-line by incorporating 100 to 200 measured values. In general, these signals are connected to the process control system as analog signals. The optimization results are fed back into the control system using approx. 10 signals. They are integrated into the existing control concept in the form of set point corrections for fuel and HP bypass control Depending on the given circumstances, this integration may affect different system levels. At present, however, BoilerMax needs to be activated before each startup. The more automated the integration of BoilerMax is the higher are the savings potentials, as a sustained improvement of cost-efficiency will ultimately be achieved only by repeated use of the optimization function. A higher degree of automation though poses higher demands on the robustness of the startup optimization, e.g. in view of automatic detection and handling of disturbances.

III. ANALYSIS START UP USING STEAM COIL AND BOILERMAX The data start-up unit # 1 at 27 October 2010 Table 1. Firing until stop tiny oil

Figure 4. Pipe Line steam coil in Mill

Hot Air can be supplied from Steam coil

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From the warm start-up process the data obtained data on average temperature rise per minute when the process of firing up to stop tiny oil = (481.6 - 62 730): 360 min = 1:16 0 C is achieved within 6 hours. Ideal start-up process based on the manual book is 3-4 hours. When the steam coil and boiler AH max use temperature mixture enters the mill average to reach 99 0 C with the assumption that the temperature of the steam coil is 170 0 C and is mixed with PAF- cold side temperature is 28 0 C) to shorten the time of start-up process, because the working temperature is reached more quickly. (See figure 4) Here is the data specifications oil gun Table 2. Specification oil gun

Data usage for guns and tiny oil for start-up process for 3 hours according to calculations: Fuel oil consumption during start up if use oil gun = 1600 x 3 hours x 12 pieces = 57 600 L Fuel oil consumption during start up if use tiny oil = 120 x 3 hours x 4 pieces = 1440 L It means company can do economization HSD if start up steam coil and Boilermax estimate HSD consumption for tiny oil is 1440 L or if use Oil gun is 57.600 L. The use of oil gun in Cilacap Power plant rarely used, so calculations focus on the use of tiny oil, then saving oil consumption reached an average of 1440 L IV. CLOSING 4.1 Conclusion 1. Based on the calculation when start-up time on optimizing it will automatically reduce the use of HSD for help burning for 3 hours, then the savings that can be done is 1440 L 2. While for the saving of time until it reaches the synchronous to the network can more quickly 3 hours. If calculated based on the calculation of the currency is as follows: RJTD request minimum power: 200 MW (200,000 KW) Loss Time : 3 Hours The price of electricity: 700/Kwh (for example) So the loss is: 200,000 KW x 3 hours x 700/KWH = IDR 420 million, when can a synchronous to the network 3 hours faster then it can save IDR 420 million, The use of turbine bypass to supply the cooling steam (for Protection) in the superheater and Reheater at start up the boiler while there is no incoming steam turbine so as not to over heat the superheater and Reheater tube, ensuring no degradation occurs in the reheater and superheater material so that the optimal age of boiler tube , shortening the start-up (warm and hot), maintaining continuities boiler operation in case of turbine trip (load shedding), and relieve labor and

Table 3. Specification oil gun Equipment Fuel Consumption Name Tiny Oil 120 (Kg/H) Data consumption HSD for oil guns and tiny oil for start-up in 6 hours according to calculations: HSD consumption during start up if use oil gun = 1600 x 6 hours x 12 pieces = 115 200 L HSD consumption during start up if use tiny oil = 120 x 6 hours x 4 pieces = 2880 L

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maintenance costs safety boiler valve boiler pressure is controlled by the bypass system 4.2 SUGGESTION Condition at start-up time for all equipment ready to operate without failure and the use of corporate assets in this case the steam coil which was installed but It not used. References http://hasimpci.wordpress.com/2009/08/15/steamcoil/http://05.abb.com/.../operational%20experience s%20with%20startup% Manual book of Steam Turbine

Biographies The author ever get an education at Diponegoro University, majoring Instrumentation and Electro (2004-2007) and get title diploma 3, Senior High School at SMU N 3 Cilacap (2001-2004), Junior High School at SLTP N 5 Cilacap (1998-2001) and Elementary School at SDN Karang Talun 06 (19921998). Ever worked for PT. Japanese Solderless Teminals (2008-2009) as staff quality control and help built and arranged the system in new department, PT Sari Asih Tangerang, Banten as staff Electronic Device Peripheral (EDP) in 2009-201