Springer Series in Reliability Engineering Series Editor Hoang Pham For further volumes: http://www.com/series/6917 Gilberto Francisco Martha de Souza Editor Thermal Power Plant Performance Analysis 123 Gilberto Francisco Martha de Souza Department of Mechatronics and Mechanical Systems Polytechnic School University of São Paulo 05508-900 São Paulo Brazil e-mail: gfmsouza@usp.br ISSN 1614-7839 e-ISSN 2191-5377 ISBN 978-1-4471-2308-8 e-ISBN 978-1-4471-2309-5 DOI 10.1007/978-1-4471-2309-5 Springer London Dordrecht Heidelberg New York British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Control Number: 2011943798 Ó Springer-Verlag London Limited 2012 Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licenses issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers. The use of registered names, trademarks, etc., in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant laws and regulations and therefore free for general use. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made.
Printed on acid-free paper Springer is part of Springer Science+Business Media (www.com) To Leonardo, Livia, Cleusa and Maria da Conceição Contents Introduction. 1 Gilberto Francisco Martha de Souza Fundamentals of Thermodynamics Applied to Thermal Power Plants. Simões-Moreira Analysis of Thermal Plants Configuration. 41 Nisio de Carvalho L.
Brum Fuels: Analysis of Plant Performance and Environmental Impact. 61 Marilin Mariano dos Santos, Patricia Helena Lara dos Santos Matai and Laiete Soto Messias Fundamentals of Reliability. Guedes Soares Fundamentals of Maintenance. 123 Gilberto Francisco Martha de Souza and Fernando Jesus Guevara Carazas Fundamentals of Risk Analysis.
Ayyub Reliability Analysis of Gas Turbine. 189 Fernando Jesus Guevara Carazas and Gilberto Francisco Martha de Souza vii viii Contents Combined-Cycle Gas and Steam Turbine Power Plant Reliability Analysis. 221 Gilberto Francisco Martha de Souza, Fernando Jesus Guevara Carazas, Leonan dos Santos Guimarães and Carmen Elena Patino Rodriguez Risk-Based Inspection and Maintenance (RBIM) of Power Plants. 249 Faisal Khan, Mahmoud Haddara and Mohamed Khalifa Index.
281 Introduction Gilberto Francisco Martha de Souza Abstract This chapter presents the motivation for the development of the present book. Because the need for electricity is pervasive in our society, there is a continuing interest in the technology of electric power production and distribution. The chapter presents some forecasts of electric power production that indicate the massive use of thermal power plants, fired with coal or natural gas. In order to improve the efficiency of those power plants, the use of Overall Equipment Effectiveness (OEE) as a key performance indicator is discussed.
Finally the link between reliability and maintainability concepts and the OEE index is presented. 1 Introduction According to the report International Energy Outlook (IEO) 2010 [2] the world net electricity generation projection increases by 87%, from 18.8 trillion kilowatt hours in 2007 to 25.0 trillion kilowatt hours in 2020 and 35.2 trillion kilowatt hours in 2035. Although the recession slowed the rate of growth in electricity demand in 2008 and 2009, growth returns to pre-recession rates by 2015. In general, in OECD countries, where electricity markets are well established and consumption patterns are mature, the growth of electricity demand is slower than in non-OECD countries, where a large amount of potential demand remains unmet.
According to that report, the total net generation in non-OECD countries increases by 3.3% per year on average, as compared with 1.1% per year in OECD nations. de Souza (&) Department of Mechatronics and Mechanical Systems Engineering, Polytechnic School, University of São Paulo, Av. Mello Moraes, 2231, 05508-900 São Paulo, Brazil e-mail: gfmsouza@usp. de Souza (ed.), Thermal Power Plant Performance Analysis, 1 Springer Series in Reliability Engineering, DOI: 10.1007/978-1-4471-2309-5_1, Ó Springer-Verlag London Limited 2012 2 G.
de Souza 40 trillion kilowatthours 35 30 25 Nuclear 20 Renewables Natural gas 15 Coal 10 Liquids 5 0 2007 2015 2020 2025 2030 2035 year Fig. 1 Forecast of world net electricity generation by fuel, 2007–2030, DoE [2] The OECD (Organization for Economic Co-operation and Development) provides a forum in which governments can work together to share experiences and seek solutions to common problems. The following countries are consider as OCDE members for the statistics of International Energy Outlook: the United States, Canada, Mexico, Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, the Netherlands, Norway, Poland, Portugal, Slovakia, Spain, Sweden, Switzerland, Turkey, the United Kingdom, Japan, South Korea, Australia, and New Zealand. The rapid increase in world energy prices from 2003 to 2008, combined with concerns about the environmental consequences of greenhouse gas emissions, has led to renewed interest in alternatives to fossil fuels—particularly, nuclear power and renewable resources.
As a result, long-term prospects continue to improve for generation from both nuclear and renewable energy sources—supported by government incentives and by higher fossil fuel prices. According to DoE [2] from 2007 to 2035, world renewable energy use for electricity generation will grow by an average of 3.0% per year, as shown in Fig. 1, and the renewable share of world electricity generation will increase from 18% in 2007 to 23% in 2035. Coal-fired generation increase forecast is an annual average of 2.3%, making coal the second fastest-growing source for electricity generation in the projection.
The outlook for coal could be altered substantially, however, by any future legislation that would reduce or limit the growth of greenhouse gas emissions. Generation from natural gas and nuclear power—which produce relatively low levels of greenhouse gas emissions (natural gas) or none (nuclear)—according to projections, will increase by 2.0% per year, respectively. Introduction 3 The category liquids include petroleum based fuels, such as Diesel oil or crude oil, and the category renewable includes hydroelectric, wind and other renewable electric power generation. Those projections are based on a business-as-usual trend estimate, given known technology and technological and demographic trends.
The IEO 2010 cases assume that current laws and regulations are maintained throughout the projections. Most of the world’s electricity is produced at thermal power plants (TPP), which use traditional fuels, coal, gas and fuel oil, and up to 20% of the world’s electricity is produced by hydroelectric power plants (HPP). In countries with well-to hydropower, the figure is much higher: Norway (99%), Brazil (92%), Austria, Canada, Peru, New Zealand—over 50%. According to the DoE [2] forecast, coal-fired generation accounted for 42% of the world electricity supply.
Sustained high prices for oil and natural gas make coal-fired generation more attractive economically. The natural gas as an energy source for electric power generation is attractive for combined-cycle power plants because of its fuel efficiency and relative low emissions. The coal-fired power plants are based on Rankine thermodynamic cycle. This facility generates electricity by producing steam in a steam generator and expanding the steam through a turbine coupled to an electrical generator.
The same Rankine cycle can be used with liquid fuels. The natural gas fired plants are based on Brayton thermodynamic cycle with combustion turbines, in either simple or combined-cycle applications. Those combustion turbines can also be adapted to operate as dual fuel machines, using Diesel oil or natural gas as fuel. The thermal power plants are very important for social development and must be designed and operated according to the most suitable available technologies.
The final product, the electrical generation, must reflect responsible application of economic and engineering principles based on social and environmental concerns. The purpose of this book is to discuss the operational aspects associated with thermal power plants aiming at not only achieve thermodynamic based perfor- mance standards but also performance index associated with environmental and operational aspects. 2 Performance Index Process companies are adopting a new consolidated approach to performance improvement based upon the use of a KPI (key performance indicator) known as Overall Equipment Effectiveness (OEE). OEE is a very simple metric to immediately indicate the current status of a industrial process and also a complex tool allowing you to understand the effect of 4 G.
de Souza the various issues in the process and how they affect the entire process. OEE can be calculated as: OEE = Availability Performance Quality ð1Þ Availability refers to the process equipment being available for production when scheduled. At the most basic level, when a process is running it is creating value for the end user. When a process is stopped, it’s creating a cost with no associated value.
Whether it’s due to mechanical failure, raw materials or operator issues, a piece of equipment is either producing or not producing. By comparing scheduled run time to actual run time, the availability component of OEE allows for a determination of lost production due to down time. Performance is determined by how much waste is created through running at less than optimal speed. Performance allows for a determination of how much production was lost by cycles that did not meet the ideal cycle time.
Quality focuses on identifying time that was wasted by producing a product that does not meet quality standards. By comparing the quantity of good to reject parts the percent of time actually adding value by producing good product is exposed. The definition used for general industrial process can be adapted for electricity generation. The performance of the thermal power plant can be represented by its effi- ciency.
The efficiency of a power plant is usually measured as a ratio of its electrical output to the amount of heat used, expressed as a percentage. Typical commercial plants range from about 30–65% efficiency. The more efficient plants cost more to build. Efficiency depends more on how the energy is used rather than how it is produced because ratings are based on conversion of heat to electrical power.
The quality of the power plant is associated with the parameters (voltage and frequency) of the generated electricity in comparison with the required standards. The availability of the power plant is associated with the reliability and maintenance planning of each piece of equipment installed in the plant. The availability depends also on the skills of operators and maintenance teams. The use of OEE index can help the electricity-generating power-stations managers to investigate theirs competence in maintaining reliable equipment at competitive costs.
Although that index can be used to evaluate changes in operational procedures or equipment update aiming at improving plant performance the plant managers use it to highlight the strengths and weakness of equipment maintenance practices. According to Eti, Ogaji and Probert [3] the availability and quality rate for the world’s best power- stations are higher than 98%. The OEE can also be used as index to demonstrate the relation between the plant performance and the issues recommended by PAS 55 [1]. PAS 55 is the British Standards Institution’s (BSI) Publicly Available Speci- fication for the optimized management of physical assets.
The specification states that organizations must establish, document, implement, maintain, and continually Introduction 5 improve their asset management system. In this context, asset management system refers collectively to the overall policy, strategies, governance, plans and actions of an organization regarding its asset infrastructure. Aiming at discussing the aspects associated with performance evaluation of thermal power plants, the book presents chapters associated with thermal and environmental performance of power plants and also presents the concepts of reliability, maintenance and risk analysis applied to power plant management. Each chapter is written by an expert in the subject.
3 Chapter Contents After a brief introduction to the book, in Chap. 2 it is reviewed the fundamental principles of Thermodynamics aiming at its application to power plants cycle analysis.