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Lang J Hills.Pdf University of Southern Queensland Faculty of Health, Engineering & Sciences Energy Efficiency Improvement in Coal Fired Power Plant through Operational Optimisation A dissertation submitted by Jason Lang in fulfilment of the requirements of ENG4112 Research Project towards the degree of Bachelor of Electrical Electronic Engineering Submitted: October, 2015 Abstract Energy consumption is a significant cost to all business with the countries large industrial plants consuming 75 % of all energy produced in Australia. This cost is not only a finan- cial burden but it has an environmental cost. The energy consumption within coal-fired power stations that is directly associated with generation is called auxiliary power. Ap- proximately 10 % of all power produced is used to drive power stations internal auxiliary power needs. It is the auxiliary power consumption at Tarong Power Station that is the focus of this dissertation. This dissertation first seeks to understand the stations energy consumption through a comprehensive review of auxiliary power issues worldwide and the creation of control system tracking logic. The next stage of the dissertation then models that consumption in MATLAB and finally proposes ways in which to reduce that consumption without capital investment. The auxiliary power consumption within Tarong Power Station is recorded by two energy meters per unit on the main high voltage unit transformer feeds. The energy consumed is then reported each week as a percentage of unit generation. It is at this high level that the consumption is currently understood. This project has created energy tracking logic in the unit control system, a Siemens T3000 installation, to provide additional usage knowledge. A number of MATLAB models have been produced. The first of these reproduces the energy usage map of a running unit. The final Simulink model allows modification of the major component loading to trial energy reduction options. Using this model a reduction of 10 % at low loads has been achieved. The accuracy of the energy tracking logic and models created is proven to be within 2 % of the field energy metering. This dissertation has concluded that meaningful energy efficiency improvement can be obtained through operational improvement at Tarong Power Station. University of Southern Queensland Faculty of Health, Engineering & Sciences ENG4111/2 Research Project Limitations of Use The Council of the University of Southern Queensland, its Faculty of Health, Engineering & Sciences, and the staff of the University of Southern Queensland, do not accept any responsibility for the truth, accuracy or completeness of material contained within or associated with this dissertation. Persons using all or any part of this material do so at their own risk, and not at the risk of the Council of the University of Southern Queensland, its Faculty of Health, Engineering & Sciences or the staff of the University of Southern Queensland. This dissertation reports an educational exercise and has no purpose or validity beyond this exercise. The sole purpose of the course pair entitled \Research Project" is to con- tribute to the overall education within the student's chosen degree program. This doc- ument, the associated hardware, software, drawings, and other material set out in the associated appendices should not be used for any other purpose: if they are so used, it is entirely at the risk of the user. Dean Faculty of Health, Engineering & Sciences Certification of Dissertation I certify that the ideas, designs and experimental work, results, analyses and conclusions set out in this dissertation are entirely my own effort, except where otherwise indicated and acknowledged. I further certify that the work is original and has not been previously submitted for assessment in any other course or institution, except where specifically stated. Jason Lang 0061014535 Acknowledgments I would like to make the following acknowledgements; Stanwell Corporation and in particular David Janes, Jan Potgieter, Les Airs, and Malcolm Westaway. USQ and in particular Catherine Hills. My wife and daughter; Steph and Caitlin Lang. Without their support and assistance this project would not have became a reality. Jason Lang Contents Abstract i Acknowledgments iv List of Figures xi List of Tables xv Acronyms & Abbreviations xviii Chapter 1 Introduction1 1.1 Project Outline.................................2 1.1.1 Aims...................................3 1.1.2 Objectives................................3 1.1.3 Scope..................................4 1.2 Overview of the Dissertation.........................5 1.3 Conclusion...................................5 Chapter 2 Background - Tarong Power Station6 CONTENTS vii 2.1 History.....................................6 2.2 Production Costs................................7 2.3 Electricity Generation Process......................... 10 2.4 Unit Energy Requirements - Auxiliary Consumption............ 14 2.5 Energy Monitoring............................... 16 2.6 Control System................................. 19 2.7 Conclusion................................... 20 Chapter 3 Literature Review 21 3.1 Auxiliary Power Usage and Reduction.................... 21 3.2 Power Calculations............................... 32 3.2.1 Average or Real Power......................... 33 3.2.2 Power Factor.............................. 34 3.2.3 Apparent Power............................ 35 3.2.4 Reactive Power............................. 35 3.2.5 Power Triangle............................. 36 3.2.6 Wattmeters/Watthour Meters..................... 37 3.3 Practical Industrial Power Measurement................... 37 3.4 Standards.................................... 40 3.5 Control Optimisation.............................. 40 3.6 Power Station Modelling............................ 41 3.7 Conclusion................................... 44 CONTENTS viii Chapter 4 Methodology 46 4.1 Selection..................................... 46 4.2 Initial Data Gathering............................. 49 4.2.1 Drawings................................ 50 4.2.2 Operation and Maintenance Manuals................. 52 4.2.3 Energy Metering Data......................... 52 4.2.4 T3000.................................. 53 4.2.5 Plant Performance Reports...................... 54 4.3 T3000 Energy Tracking Logic Creation.................... 55 4.4 MATLAB Models Creation.......................... 59 4.4.1 Conceptional MATLAB Script Creation............... 61 4.4.2 SIMULINK Auxiliary Power Model Creation............ 63 4.4.3 SIMULINK Auxiliary Position Model Creation........... 70 4.4.4 SIMULINK Auxiliary Process Model Creation........... 71 4.4.5 Model Comparison Data........................ 74 4.5 Conclusion................................... 74 Chapter 5 Results and Data Analysis 77 5.1 Performance Reports Data........................... 77 5.2 T3000 Daily Auxiliary Total Data...................... 79 5.3 MATLAB Model Output Data........................ 83 5.3.1 SIMULINK Auxiliary Power Model................. 83 CONTENTS ix 5.3.2 SIMULINK Auxiliary Position Model................ 86 5.3.3 SIMULINK Auxiliary Process Model................. 89 5.4 Overall Auxiliary Energy Usage........................ 92 5.5 Other Data................................... 94 5.6 Data Shortcomings............................... 97 5.7 Conclusion................................... 98 Chapter 6 Proposed Options of Energy Reduction 99 6.1 Induced Draft Fans............................... 100 6.2 Forced Draft Fans............................... 104 6.3 Primary Air Fans................................ 106 6.4 Circulating Water Pumps........................... 108 6.5 Condensate Extraction Pumps........................ 111 6.6 Boiler Feed Pumps............................... 112 6.7 Reduction Options Summary......................... 115 6.8 Entire Unit - Optimum Solution....................... 117 6.8.1 Low Risk................................ 117 6.8.2 Medium Risk.............................. 119 6.8.3 High Risk................................ 120 6.8.4 Reduction Summary.......................... 121 6.9 Conclusion................................... 124 CONTENTS x Chapter 7 Conclusion and Further Work 125 7.1 Project Conclusions.............................. 125 7.2 Future Work.................................. 128 7.3 Conclusion................................... 130 Bibliography 131 Appendix A Project Specification 134 Appendix B Conceptual MATLAB Auxiliary Calculation Script 136 Appendix C Unit Auxiliary Power Consumption Simulink Model - Power Model 143 Appendix D Unit Auxiliary Power Consumption Simulink Model - Posi- tion Model 151 Appendix E Unit Auxiliary Power Consumption Simulink Model - Process Model 159 Appendix F Process Information Management System (PIMS) Extracted Data 167 Appendix G Located Drawing Data 169 Appendix H Energy Metering Manual Data 170 Appendix I Stanwell Corporation Energy Reductions Recommendations Report 174 List of Figures 2.1 Monthly Report is a Snapshot of the Data Produced to Track Unit Perfor- mance (Sands & Blake 2015)..........................9 2.2 Unit 4 T3000 Overview - Screen Capture from Tarong Power Station DCS (Siemens 2015).................................. 12 2.3 Unit 1 Distribution Overview (Hitachi 2003)................. 17 2.4 Station Ancillary Distribution Overview (Hitachi 2003)........... 18 3.1 Typical Auxiliary Loads in Coal Fired Power Plant (EPRI 2011)...... 23 3.2 Typical Auxiliary Loads and their Breakdown of Usage in Coal Fired Power Plant (EPRI 2011)...............................
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