Performance
Testing - Monitoring and Improvement
Power + Energy Associates are consultants providing expert
advisory, site and support services in the field of power plant and engine performance
testing, performance analysis and performance improvement. The scope of this work includes
desktop analysis, site investigation and site testing. Our work as independent performance
engineer covers new and existing facilities. P+EA has an extensive experience in this area
and advises on the implementation of new facilities and is involved in routine and annual
performance reviews on existing plants. We both act as the witness to official tests and
also undertake, organise, supervise and arrange tests.
The Need
Thermal efficiency of an engine or power plant is the comparison
of the energy content of the input fuel turned into electrical energy by the engine or
generating station. With ever increasing fuel costs, efficiency and performance are
clearly key drivers for the profitability of any power generating station. Today the
drivers also include limiting emissions and improving thermal efficiency is directly
linked to reduction of emissions.
Thermal power plants, gas turbines, engines and combined cycle power generating facilities
may be designed to operate in one operational mode but more likely for flexible operation
under different configurations and part load conditions. Each operating configuration is
therefore likely to present different performance issues. Each Operator is obliged to
deliver efficient plant performance, seek the most efficient utilisation of fuel and
utilise appropriate maintenance to achieve these targets.
Performance
Engineer Role
Performance testing and performance monitoring are seen as
essential for the achievement and maintenance of engine and power plant performance
targets and improving performance.
The independent performance engineer works alongside the project and power plant personnel
to advise on how best to achieve the expected performance with optimum operating costs.
These considerations will include not only plant overall output and thermal efficiency but
also component performance and emissions. Each plant will be fitted with certain
facilities enabling performance recovery with a minimum of down time, such as on-load
cleaning and other features. Right up front in the development programme agreement is
needed on the facilities for recovering performance. Project agreements all require
careful study in relation to the operating parameters and performance guarantees.
About Testing
There is no better way to establish how a plant is performing
than to carry out a properly arranged and supervised performance test. These tests are
best carried out when the plant is new (before start of commercial operation) then both
annually and after major outages. When performance upgrades are implemented it will be
required that the plant is tested before and after the upgrade implementation.
Thermal performance tests are essential to verify overall power plant outputs and heat
rates. All thermal Power Plants need to undergo rigorous acceptance testing in order
to comply with Contracts and Project Agreements. Expert supervision of performance tests
is needed to confirm performance and environmental guarantee compliance. Verification of
the correction curves will be needed. Independent fuel analysis will be important together
with the services of reliable independent laboratory. Plant component performance
evaluation such as boiler, turbine and condenser performance will prove valuable
benchmarks. Tests will be required to be carried at several loads and/or different
configurations.
Test Codes and Test
Procedures
The appropriate performance test codes need to be agreed and
these used as the basis of testing procedures. Choices will be made between various
international codes. Preparations for the tests will be important with test procedures and
analytical performance test models being developed prior to the start of
testing. Contractor documentation will need to be reviewed. The tests will
require the installation of special test instruments and calibration of a selected number
of permanent plant instruments. The successful completion of these tests will signal that
the plant is ready for commercial operation and is of course a major event the life of any
plant. The test procedures will also form the basis of future plant testing.
Performance
Assessment and Modelling
Assessment of performance on an existing plant will involve
extensive discussions, document reviews and checks on available performance records. Fuel
analysis and measurement will prove to be of high importance including employment of
on-line fuel chromatography feeding data directly to fuel flow computers. Following on the
periodic testing will be of great value in verifying plant performance, achieving optimum
performance, acquiring data and looking for performance shortfalls. So called annual
or “anniversary” tests are called for in many project agreements and off-take
agreements.
Performance modelling may well assist in predicting and enhancing plant performance.
Advances in technology are continuously appearing and these need to be justified as every
upgrade represents capital investment needing economically justified. A performance model
will be the tool to enable the assessment of these cases. Operations teams need a good
understanding of performance to successfully monitor plant performance and training
courses will cover performance analysis, heat rate improvement and the concepts behind
thermal and combined cycle performance.
Performance
Degradation
Performance degradation is always an important consideration.
Degradation is a fact of life and every plant is subject, to a greater or less degree, to
degradation in output and heat rate. Accurate performance data is essential for day-to-day
operation and billing purposes and avoid significant financial loss to the Owner.
Recovering performance will require action with performance and maintenance being linked.
Good performance analysis will detect changes in the plant, which will be used to
determine when maintenance is to be scheduled.
Anyone requiring more information about these matters or wishing to discuss performance
issues is cordially invited to contact Power + Energy Associates. |
