Power Plant Air Pollutant Control “Mega” Symposium

Sootblowing Optimization for

Opacity Control:
Energy Research Center

Field Experience with Advisory

and Closed Loop Operation

Nenad Sarunac, Xiadong Bian, and Wei Zhang

Energy Research Center, Lehigh University
Michael E. Cilinski and Thomas Johnson
PSE&G Power, LLC

THE INFORMATION CONTAINED IN THIS DOCUMENT IS PROPRIETARY TO THE ENERGY RESEARCH CENTER (ERC).
THE ERC IS NOT CONVEYING ANY OWNERSHIP TO ANY PARTY BY DISCLOSING THIS INFORMATION.
 Introduction: Slagging and Fouling

◙ All coals contain mineral matter (inorganic components,

or coal ash).
Energy Research Center

◙ Slagging and fouling are strongly affected by coal

mineral content and boiler operating conditions.
◙ Furnace Slagging:
◘ Molten or sticky ash particles deposit on water walls.
◘ Develops first in reducing zones.
◙ High-Temperature Convective Pass Fouling:
◘ Similar to furnace slagging + evaporated ash materials begin to
condense on tube walls.
◙ Low-Temperature Convective Pass Fouling:
◘ Formed by accumulation of fly ash particles and condensed
vapor-phase species (sulfate-based deposits).
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Introduction: Slagging and Fouling

◙ Furnace Slagging:
◘ Reduces heat transfer to water-walls.
◘ Increases heat available to convective pass.
Energy Research Center

■ Higher furnace exit gas temperature (FEGT).

■ Lower main steam temperature.
■ Higher reheat steam temperature.
■ Higher desuperheating spray flows.
■ Reduced performance.
■ Higher NOx emissions.
◙ Convective Pass Slagging and Fouling:
◘ Reduces heat transfer in convective pass.
■ Lower reheat steam temperature.
■ Lower desuperheating spray flows.
■ Increased flue gas temperature at boiler exit.
■ Reduced performance.
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Introduction: Sootblowing Optimization

◙ Sootblowing used to control slagging and fouling.

◙ Over-cleaning of the furnace walls can result in:
Energy Research Center

◘ Lower reheat steam temperatures

◘ Increased moisture levels and erosion damage in last stages of
LP turbine.
◘ Lower turbine and unit power output (reduced TRHT).
◘ Heat rate penalty
◙ Convective pass cleaning increases heat transfer:
◘ Higher steam temperatures and desuperheating sprays.
◘ Lower boiler exit gas temperature.
◙ For best performance it is important to maintain optimal
balance between furnace and convective pass heat
transfer. ⇒ Sootblowing Optimization
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Sootblowing Optimization Challenges
◙ Which boiler heat transfer sections to clean and on what
schedule?
◘ Trade-offs:
Emissions
Energy Research Center

■
■ Main and Reheat Steam Temperatures
■ Heat Rate
■ Opacity
■ Other Factors:
● Tube life
● Sootblower steam or air consumption
● Maintenance costs

◘ For utilities affected by the Ozone Transport Season (OTS)

regulations, trade-offs will be different during the OTS and for
the rest of the year.
◙ Sootblowing optimization is not an easy problem.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 ERC Sootblowing Optimization
Approach
◙ Design Philosophy:
◘ Knowledge is stronger than data.
◘ Understanding of physical process is essential. Knowledge
Energy Research Center

◘ Use the existing power plant instrumentation. Facts

◘ Low computational and data requirements.
◘ Low data quality requirements. Data

◘ Adaptability is a must
◙ Practical and cost-effective approach based on
Artificial Intelligence (AI):
◘ Knowledge-Base Expert System (KBES)
◘ Unit-Specific Facts → Sootblower characterization tests
◘ Adaptive Fuzzy Logic
◘ User-Controllable Settings.
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 ERC Sootblowing Optimization
Methodology
◙ Six-step sootblowing optimization program:
◘ Step 0: Characterize ash and fuel, retune boiler.
Energy Research Center

◘ Step 1: Setup instrumentation and calculations.

◘ Step 2: Characterize sootblower groups.
◘ Step 3: Create data and knowledge bases.
◘ Step 4: Develop a site-specific version of the
sootblowing optimization code (IntelliCLEAN)
◘ Step 5: Field implementation of IntelliCLEAN and
evaluation of plant benefits.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Bridgeport Harbor
Energy Research Center

Unit 3 (BP3)
 Unit Description
◙ Subcritical, tangentially-fired
◙ Rated at 400 MW net.
◙ TFS 2000R low-NOx firing system
Energy Research Center

◙ Low-Sulfur Indonesian coal

◘ High moisture content, low HHV
◘ Low N, low ash content (less than 1 percent).
◘ Ash softening temperature lower than design.
◘ Highly reflective slag
◙ Small ESP + Large temperature stratification at APH exit
→ unit sensitive to opacity spikes → automatic load run-
back.
◘ SO3 injection to control fly ash resistivity.
◙ 48 wall blowers on fixed sootblowing schedule
◙ 18 retractable sootblowers on fixed sootblowing schedule.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Sootblower Locations
Economizer Outlet Link T, P

Final SHT T, P
SHT Desup. Final RHT T, P Radiant RHT
Spray
Outlet T, P
Energy Research Center

Vertical Primary SHT (SHT

Pendant RHT Drum Drum P, T

Final SHT (SHT Rear

Rear Pendant)

Pendant)

SHT Division Wall

SHT Division Wall

55,56 53,54

Platen SHT

Radiant RHT (Front Wall)

49,50
Downcomers
57,58
65,66
51,52
59,60
61,62

Horizontal
Primary SHT

RHT Desuperheating Spray

63,64 FEGT
Rear
WW Radiant RHT
Tubes (Side Wall) RHT Desuperheater
Economizer Inlet T, P

RHT
Desuperheater Cold RHT Flow
Feedwater 1,16
Outlet T, P
Inlet T, P
(Radiant RHT Inlet)

17,32

Even No - North
Odd No - South Burner
Belt Side WW Tubes
Side WW Tubes

33,48 Boiler Circulating Pump

Front
WW
Pump Discharge Lines
Tubes

WW Crossover Lines Front Lower

Rear Lower WW Drum
WW Drum

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Variation in Main Steam Temperature:
Regular Sootblowing Sequence at BP3
1000 100

Tmst
Operating SB
Percent Pg
80
Energy Research Center

990
Main Steam Temperature [ F]
o

Sootblower ID, Percent Pg

60

980 40

20

970

960 -20
8:00 9:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00
Time

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Project Goals

◙ Prevent opacity spikes and automatic load run-

backs by controlling amount of ash that is
Energy Research Center

allowed to accumulate on boiler heat transfer

surfaces.
◙ Reduce sootblower activation frequency.
◙ Maintain FEGT below a critical value to control
furnace and pendant slagging.
◙ Maintain steam temperature set-points.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Implementation of Intelligent
Sootblowing at BP3
◙ Characterized the sootblowers.
◙ Created the data and knowledge bases.
Energy Research Center

◙ Created the plant-specific version of the KBES.

◙ Incorporated KBES into the IntelliCLEAN code.
◙ Field Deployment: On-Line Advisory
◘ Implemented IntelliCLEAN in an on-line advisory
mode.
◘ Verified IntelliCLEAN operation.
◘ Determined the effect on unit operation, performance
and emissions.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Main IntelliCLEAN Advisory
Screen at BP 3
Modules:
◘ Sootblowing –
Blower groups
Energy Research Center

and section
status

◘ Advisor –
Sootblowing
advice and
sequences

◘ Furnace
Cleanliness –
Section
cleanliness
status and
history
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Results: On-Line Advisory
◙ Cleaner furnace → Lower FEGT
◙ Smaller, more frequent opacity spikes.
Energy Research Center

◘ IntelliCLEAN is controlling ash deposition.

◘ No load run-backs.
◙ Higher main and reheat steam temperatures.
◙ Lower RHT spray flow rate (32% reduction).
◙ Lower opacity (25% reduction).
◙ Cleaner boiler:
◘ Lower boiler gas exit temperature.
◘ Lower SO3 injection rate.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Daily Load and Opacity Profiles at
BP3: On-Line Advisory
120

Opacity-Induced Load Derate [MW]

Regular Sootblowing Sequence IntelliCLEAN in Operation

100

80

Opacity-Induced
Energy Research Center

60

Load Derate 40

No Derates with IntelliCLEAN

20

0
8/22/05 0:00 8/22/05 8/23/05 0:00 8/23/05 8/24/05 0:00 8/24/05 8/25/05 0:00 8/25/05 8/26/05 0:00
12:00 12:00 12:00 12:00
100

80
Opacity [%]

60

Opacity Spikes
40

20

0
8/22/05 0:00 8/22/05 8/23/05 0:00 8/23/05 8/24/05 0:00 8/24/05 8/25/05 0:00 8/25/05 8/26/05 0:00
0 12:00 12:00 48 12:00 12:00 96
Time (hrs)
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Results BP 3: On-Line Advisory
Energy Research Center

Date ISA Tmst Trht Mrht,spray FEGT Opacity Teco,go Tesp,gi SO3

Status °F °F klbs/hr °F % °F °F %

8-22 OFF 1,000 1,002 64 2,454 10.5 727 309 73

8-23 OFF 1,002 1,004 62 2,458 9.2 725.5 304 72
8-24 ON 1,002 1,004 49 2,449 7.9 720.5 303 70
8-25 ON 1,003 1,005 46 2,432 7.9 716 300 65
Difference +1.5 +1.5 -15.5 -15.5 -1.95 -8 -5 -5
% Diff -32 -24.7

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 RHT Spray Profiles: On-Line
Advisory
Bridgeport Harbor Unit 3: August 2005

100
ISA OFF: 22-Aug-05
Feeder ISA OFF: 23-Aug-05
Energy Research Center

Trip ISA ON: 24-Aug-05

Reheat Desuperheating Spray [klbs/hr]

ISA ON: 25-Aug-05

80

60

40

20

ISA Testing Window

0
0:00 4:00 8:00 12:00 16:00 20:00 0:00
Time

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Intelligent Closed Loop
Sootblower Control
◙ Intelligent sootblower control loop closed in
March 2006.
Energy Research Center

◘ IntelliCLEAN is controlling plant sootblowers on a

24/7 basis.
◘ Control performed over entire load range, including
transient operation.
◘ 100% knowledge-based control.
■ No cleanliness or other first-principle calculations needed.
◘ The effect of a closed-loop sootblower control on unit
operation, performance and emissions was
determined by plant personnel.
■ Benefits to the plant were quantified.

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Intelligent Closed Loop
Sootblower Control
Energy Research Center

Plant Information
FOXBORO Network
(Data Acquisition and
Plant Historian)
DDE Interface
with Foxboro

IntelliCLEAN

CONTROL
NETWORK
DDE Interface
with Bailey

Bailey Infi 90
(Process Control)

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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Regular Sootblowing Operation
Energy Research Center

Load run-
run-back

Temp. Daily
Cal. OS OS
Drop OS
OS

Sootblower
in Service

No Sootblowing 1-48 Furnace

48-
48-66 Convection Pass
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Regular Sootblowing Operation
Energy Research Center

Load run-
run-back

Temp.
Drop

OS OS
OS OS
Daily
Cal.

Sootblower
in Service

No Sootblowing 1-48 Furnace

48-
48-66 Convection Pass
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Regular Sootblowing Operation
Energy Research Center

Load run-
run-back

Daily
Cal.
OS
Temp. OS OS
Drop OS

Sootblower
in Service

No Sootblowing 1-48 Furnace

48-
48-66 Convection Pass
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Closed Loop Intelligent
Sootblowing Control
Energy Research Center

Steam temperature set-

set-points maintained

Daily
Cal.

Sootblower
in Service

1-48 Furnace
48-
48-66 Convection Pass
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Closed Loop Intelligent
Sootblowing Control
AR
Energy Research Center

Better steam temperature control

Daily
Cal.

Sootblower
in Service

Convection pass cleaned 1-48 Furnace

to maintain steam temps. 48-
48-66 Convection Pass
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Closed Loop Intelligent
Sootblowing Control
Energy Research Center

Better steam temperature control

Daily
Cal.

Sootblower
in Service

1-48 Furnace
48-
48-66 Convection Pass
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Intelligent Closed Loop Sootblower
Control: Benefits to the Plant*
◙ Better management of slag and ash accumulation.
◘ Cleaner boiler
◘ Lower opacity
◘ No load run-backs.
Energy Research Center

◘ Increase in maximum unit power output from 388 to 400 MW (3 %).

◘ Cleaner Furnace:
■ Lower FEGT
◘ Lower boiler gas exit temperature
◘ Better ESP performance
◘ Lower SO3 injection rate
◙ Higher main and reheat steam temperatures.
◙ Lower RHT spray flow rate.
◙ Better unit heat rate.
◙ Note:
◘ Combustion tuning and optimization, performed ahead of
sootblowing optimization, contributed to performance improvements.
*Determined by plant operations
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD
 Contact Information
Dr. Nenad Sarunac
([email protected])
Lehigh University
Energy Research Center
Energy Research Center

117 ATLSS Drive

Bethlehem, PA 18015-4729

Phone: 610-758-5780
Fax: 610-758-5959
Mobile: 610-653-9119
www.lehigh.edu/energy

Mr. Michael E. Cilinski

([email protected])
Production Manager
Bridgeport Harbor Station
1 Atlantic Street
Bridgeport, CT 06604

Phone: 203-551-6009
Fax: 203-551-6053
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EPA, DOE, EPRI, and AWMA Power Plant Air Pollutant Control “Mega” Symposium, August 28-31, 2006 Baltimore, MD