Development of More Accurate Correction Factors through Heat Balance Modeling
M. B. Caudill, Vice President, Performance Consulting Services, Inc.
R. D. Griebenow, President, Performance Consulting Services, Inc.
Download

Abstract

On-line controllable loss monitoring systems require a method to calculate the heat rate and generation impact of off-design operation. Most systems utilize the correction curves supplied by the turbine vendor for the four primary losses (initial pressure, initial temperature, reheat temperature, and exhaust pressure). However, these curves are typically very generic and do not include the effects of unique turbine cycle design characteristics. In addition, the response may vary as the unit ages and the performance of individual cycle components begins to degrade. Therefore, using the correction curves provided by the turbine manufacturer may not provide the desired accuracy in many performance monitoring system applications.

This paper outlines a method to develop heat rate and generation correction curves for the primary controllable parameters through heat balance modeling. It will include plant specific curves developed using this method for the original design cycle configuration and a comparison with the curves provided by the original turbine addition, it will include the results of studies performed to determine the impact of turbine cycle performance degradation on the plant specific correction curves.

Development of Controllable Parameter Heat Rate Effect Curves Using PEPSE®
Ronald D. Griebenow, President, Performance Consulting Services, Inc.
Download

Abstract

On-line controllable loss monitoring systems require a method to calculate the heat rate impact of off design operation. Most systems utilize the correction curves supplied by the turbine vendor for the four primary losses (initial pressure, initial temperature, reheat temperature, and exhaust pressure). Using the generic curves provided by the turbine manufacturer may not provide the desired accuracy in your performance monitoring system results.

This paper outlines a method to develop heat rate effect curves for the primary controllable parameters using the PEPSE® heat balance code. The results of this method will be compared to the curves supplied by General Electric for one of the 270 megawatt steam turbines owned and operated by Santee Cooper.

It's the Megawatts Stupid!
2005 Presented at the EPRI Heat Rate Improvement Conference
Bruce Kelly, Senior Engineer, Performance Consulting Services, Inc.
Ron Griebenow, President, Performance Consulting Services, Inc.
Download

Abstract

Most people would probably remember a sign in the early Clinton White house which read, "It's the Economy Stupid". That phrase successfully set the tone for the Clinton Presidency. The phrase which should set the tone for the next generation of performance engineering at fossil fueled power plants is, "It's the Megawatts, Stupid". For too long performance engineers have been trying to promote energy saving ideas to power plant owners and managers, however, these owners and managers are not going to pay too much attention to the bottom line until the top line is satisfied. The top line, which is the meeting of production goals, is usually the highest priority, with fuel savings falling further down the priority list. It is important to realize that power plants are factories and as such do have production quotas. As most performance engineers are well aware, the top line is directly connected to the bottom line in that the process of carefully monitoring and manipulating performance enhances the top line by increasing availability and capacity factor.

This paper will address the issues of heat rate improvement that directly affect the top line of fossil fueled power plants, offering a new focus for heat rate improvement activities.
________________________________________

Heat Rate Assessments and Training Improve Bottom Line for AES
2005 Presented at the EPRI Heat Rate Improvement Conference
Steve Williams, AES Corporation
Tony Coleman, AES Corporation
Ron Griebenow, Performance Engineer, Performance Consulting Services, Inc.
Marcus Caudill,Vice President, Performance Consulting Services, Inc.
Download

Abstract

AES Corporation is a global energy provider that is motivated to improve and optimize corporate heat rate. With more than 113 facilities worldwide, representing over 45,000 megawatts of capacity, a heat rate improvement of one percent would represent a large savings in fuel costs. With this in mind, AES has established a corporate plan to support the separate AES businesses in optimizing heat rate. Two key activities that have jumpstarted the heat rate improvement process are heat rate assessments and heat rate awareness training.

The purpose of the heat rate assessment is to help identify the key contributors to offdesign heat rate, and then to prioritize corrective actions based on cost effectiveness. Heat rate assessments and training have been conducted at a number of AES facilities over the past year, with key findings that can result in almost immediate payback for the assessment cost. This paper presents an outline of the assessment process, key findings from various assessments, and future plans to continue the heat rate improvement process at AES.
________________________________________

Performance Assessments: An Essential Tool for Heat Rate Improvement
1998 Presented at the EPRI Heat Rate Improvement Conference
Marcus Caudill, EPRI-CAC, Performance Consulting Services, Inc
Peter Ruestman, EPRI-CAC, Performance Consulting Services, Inc
Ken LaMont, Hoosier Energy
Bob Hill, Hoosier Energy
Download

Abstract

As the utility industry transitions from a regulated to a competitive market, many companies are facing a shift in business practices to meet this new challenge.

Many areas of plant and corporate operations are being studied, including marketing, staffing, maintenance, operation, and management practices. The ultimate goal of all of these studies is to reduce overall generating costs, while still providing a reliable supply of electric power. While there are significant economic reasons for considering all areas of plant cost containment, the area of heat rate improvement offers the opportunity to significantly reduce plant fuel consumption, which is usually the largest single operating cost in a plant.

While there are many tools available to help improve heat rate and reduce fuel consumption, a performance assessment is an essential tool that provides a comprehensive picture of current heat rate improvement activities, establishes or verifies current and potential performance levels and defines a plan for achieving and maintaining peak unit performance. This paper details the methodology developed for conducting a successful performance assessment and discusses the application of the method to a performance assessment of Hoosier Energy's Merom Generating Station.
________________________________________

An Overview of the Motivation and the Method for Heat Rate Awareness Training
1998 Presented at the EPRI Heat Rate Improvement Conference
Marcus Caudill, EPRI-CAC, Performance Consulting Services, Inc
Peter Ruestman, EPRI-CAC, Performance Consulting Services, Inc
Download

Abstract

Staff training is not a new concept in the electric power industry. In particular, unit operator training has been proven to offer significant savings in operations and maintenance costs. As the utility industry continues its transition from a regulated to a competitive market, the importance of a well-trained team of employees becomes more evident. Most of the training in the area of heat rate improvement has been developed for performance engineers and others with a technical background, with little heat rate training effort focused on maintenance, electrical, I&C, chemistry and operations personnel.

EPRI-CAC has developed two levels of heat rate awareness training, an introductory level that requires no previous exposure to heat rate concepts, and a secondary level that assumes some basic knowledge of power cycles. This paper discusses the motivation for the development of these heat rate awareness classes, an overview of the class methodology and materials, and feedback from initial class participants.