UK TWG 24 The influence of operational parameters on power plant efficiency 1 Introduction

This information is provided to support the completion of the Combustion BREF questionnaire submissions on behalf of the UK power industry. Plant efficiency varies with a number of operational parameters, including ambient conditions and the mode of operation; in particular two-shifting operation, to meet typical grid demand patterns in a liberalised energy market, in which a coal fired utility boiler may be required to start-up and shut-down each day rather than running through at base-load in line with the original design intent. This note complements the proposed UK methodology for energy efficiency calculation that has been issued by the Environment Agency following consultation with the UK power industry (Appendix A). 2 Load profile and mode of operation

Figure 1 shows the variation in sent out (exported) load and the net plant efficiency for a large coal fired utility boiler (Plant A) with a nominal electricity output rating of 500 MWe (generated) at and an associated nominal thermal input rating of about 1350 MWth. The load and efficiency are plotted for a one day period that is typical of two-shifting operation. In this case, the efficiency is determined by dividing the load by the thermal input determined from fuel metering. The boiler unit starts up on heavy fuel oil and this is progressively replaced with coal as the individual mill blocks are brought into service. At the end of the start up period, flame stability has been established and the unit is operating on coal alone at the point of Minimum Stable Generation (MSG) which is 235 MWe in this example. The fuelling is then increased until the Maximum Continuous Rating (MCR) of 480 MWe is achieved.
Typical two-shifting day
600

Ignition

Synchronisation

De-Synchronisation 60
50

500

Baseload

Sent Out Load (MWe )

400

40

Efficiency (%)

300

30

200

20

100

10

0
Time

00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00

Sent Out Load

Efficiency

Figure 1 Load and efficiency variation during two-shifting It can be seen that the efficiency during most of the operating period, during periods of high load, is relatively stable at an average value of 36.9%. The efficiency during start-up is erratic for two reasons. Firstly, the fuel flow and thermal input change rapidly and unevenly during the change over from oil to coal. Secondly, the boiler has not reached thermal

equilibrium and a proportion of the thermal input is used for warming-up the boiler without having an immediate impact on generation. The converse is true during shut-down when, on a transient basis, the heat that is thermally retained by the boiler is released, giving an apparent increase in the instantaneous efficiency. For these reasons, the instantaneous efficiency values during start-up and shut-down are less physically meaningful than the steady-state values obtained during normal operation. However, the main point to note is that two-shifting operation contains periods in which the efficiency is lower than the base load value and this inevitably reduces the overall efficiency that can be achieved in this operating mode. For this boiler unit, an analysis of the heat accounts for a month in which about 50% of the operation is two-shifting indicates that the efficiency reduces from a nominal base load efficiency of 36.9% to 35.0% across the month. 3 Operational parameters

A number of operational parameters affect plant efficiency. Table 1 lists the relevant parameters, for Plant B, and gives associated value ranges for each of these. For example, the cooling water inlet temperature is 18C 7C in this example.

Table 1 Ranges of operational parameters considered (Plant B)

The uncertainty in the efficiency-load relationship can be evaluated, using performance modelling software, by imposing this maximum variation in each of the parameters that influences the efficiency. This has been done at four load points for a 500 MWe unit, as noted in Table 1. The resultant uncertainty band in efficiency (at 95% confidence) is plotted in Figure 2. This is given as a cumulative uncertainty with the parameters being ranked in order of importance, noting that the result is given for each of the load conditions considered in Table 1.

From Figure 2, it can be seen that the total uncertainty in the efficiency is of the order of 1.5 % points and the most important factors in this example are: the boiler feed water pump drive being in or out of service and the cooling water inlet temperature. This analysis has been repeated for two other stations with very similar results. That is, the efficiency varies from the base-line by about 1.5% points. For example, the base load efficiency of Plant A is about 36% 1.5%.

Figure 2 Cumulative variation in efficiency (Plant B) due to operational parameters Further discussion of the parameters that affect coal fired power plant performance can be found in Power Generation from Coal. Measuring and Reporting Efficiency, Performance and CO2 Emissions, published under the auspices of the Coal Industry Advisory Board and the International Energy Agency in 2010. This report also discusses the importance of achieving a common understanding of the basis on which the plant efficiency is calculated so that meaningful cross-comparisons can be made between different countries, noting that the report was written is response to the Plan of Action on climate change that was released with the G8 Gleneagles Summit communiqu in July 2005. The G8 requested a review and assessment of information on the energy efficiency of coalfired power generation. The report therefore reviews the methods used to calculate and express coal-fired power plant efficiency and proposes a means to reconcile differences between these methods so that comparisons can be made on a common basis for the benefit of policy makers. 4 Concluding remarks

The efficiency of coal fired power plant is affected by both the operational mode of the plant and the operating parameters that influence boiler performance, as discussed above. For a 500 MWe boiler, typical of the UK fleet, the sent out efficiency is lowered by two-shifting operation by about 2 percentage points when two shifting for 50% of the time. Operational parameters, particularly cooling water inlet temperature, which depends on ambient conditions, give rise to a variation of about 1.5% percentage points. These factors need to be taken into account when determining Best Available Techniques for power generation.

Appendix A UK Energy efficiency calculation methodology Proposal for Efficiency Calculation 1. 1.1 Background Comparison of the efficiencies of similar plant enables best practice to be determined for this parameter taking the uncontrollable constraints, e.g., the cooling method, into consideration. It needs to be recognised that plant efficiency is affected by a number of parameters including load, frequency of start-up and shut-down and ambient conditions. Even the annual average plant efficiency can therefore vary from year to year depending on the load profile, e.g., base-load vs two-shifting. It is important that these aspects are captured in the BREF questionnaire returns. During the life of a plant calculation of efficiency is carried out by means of: 1. Spot testing for the purpose of new plant design guarantee tests 2. Spot evaluation testing, correcting back to new plant guarantee conditions for comparison against design. 3. Operational efficiency calculated over a particular mode of operation or period of time. 4. Annual calculation for regulatory etc purposes Each calculation is carried out slightly differently, making different assumptions and corrections and has different advantages and disadvantages. - The spot evaluation testing is the most accurate if carried out to recognised performance standards but there will still be some differences between methods and this data may not be available at a sufficient number of sites or in sufficient detail. - The operational efficiency data is likely to be more easily available but still limited if for, say, baseload operation only. - The annual average is the easiest to provide as part of the questionnaire but it will be difficult to compare plants due to the different operating modes even if the number of SUSDs, average load etc is provided. However, operational efficiency and annual averaging can be calculated from plan values that are based on a historic base-line performance assessment of the plant. That is, the plan efficiencies are derived from an actual or projected load profile with monthly average assumptions or measurements for the following key items, as an example for a CHP plant: ambient temperature and pressure profile, steam demands, condensate recovery (% and temperatures), planned outages on each main plant item, target forced outage rate for the main plant items, fuel type, expected performance of the plant based on assessment of historical performance and the future operating and maintenance regime.

1.2

1.3

This has the advantage of eliminating any unreliable plant measurements and also offers the possibility of cross-comparison based on an agreed load profile.

1.4

It is proposed that the operational efficiency at baseload (the period would be set by the available data) and the annual efficiency calculation is requested for the questionnaire but this can be based on plan values for a stated load profile. The operational/annual calculation across a unit or LCP is suitable for the majority of plant, namely power generators (fossil fuel and biomass fuel), CCGTs, CHP plant, engines (gas, diesel, biofuel). Efficiency calculation formula For annual average efficiency purposes, it is most meaningful to consider all of the energy transfers across the site boundary, including energy imports (Gross-Net-Net definition). If a plan approach is used, a number of scenarios can be considered, e.g., two-shifting, base-load and mixed profiles. Gross Net Net (GNN) for an explicitly defined boundary for an explicitly defined period is:

1.5

2.

(Electrical energy + Useful heat exported) / Heat energy input

Plant efficiency is normally calculated and reported on a net (lower heating value) basis for performance calculations. All annual quantities refer to the energy flows to and from the plant, excluding periods of auxiliary firing. The plant efficiency can be determined as follows: Efficiency, Where Eo Ei And Eo Where Le Li He Hi Ei Where Fi NCV = (Le Li) + (He Hi) = E o / Ei

= annual net energy output, GJ = annual net energy input, GJ

= annual electricity exported to the public grid and industrial customers, GJ = annual electricity imported from the public grid and other suppliers, GJ = annual heat exported to industrial customers (as steam or hot water), GJ = annual heat imported, e.g., condensate return from customer site, GJ = Fi * NCV / 1000

= annual fuel consumption, Sm3 or tonnes = annual average net calorific value, MJ/Sm3 or MJ/tonne

Any consistent set of units can be used for the fuel consumption and NCV. For example, it is normal practice to report natural gas consumption in standard m3, where the metric standard metering conditions are 15.0C and 101.325kPa. Alternatively, the annual fuel heat input can be taken directly from an installations EU ETS report when using actual performance values.

3. 3.1

Calculation boundary Where possible the efficiency should be calculated over an individual unit, recognising that partitioning of works power may not be straightforward and is dependent on plant design. Where this is not possible or it is more meaningful (due to elements of works power being aggregated for example) the efficiency can be calculated over the LCP. Alternatively, common losses or energy imports can be partitioned between units so that a consistent efficiency definition is employed (Gross-Net-Net). Drawing to be inserted to reflect the above formula with the imported power, gross power generated, power used on site, power exported, heat exported, heat returned, useful heat. (Replacing the existing Sankey type diagram in the BREF in section 2.7.3) Data required when calculating annual efficiency over the Unit or LCP Fuel Mass of fuel(s) consumed (tonnes) Average lower calorific value of fuel(s) (MJ/t)

3.2

4. 4.1 4.2

Power imported (MWh) if there is only a single meter on the power station then the power per unit or per LCP will have to be proportioned accordingly, e.g., if the meter is across four units then divide by four for a single unit. Power exported from site annual (MWh) Useful heat exported from site (MJ) Returned heat (as steam/condensate) (MJ) Supporting information: Cooling water system (Air cooled condenser, direct cooling or hybrid) Annual average ambient air temperature Annual average river water temperature Maintenance cycle duration and how far is the unit through the cycle. Operating mode Number of SUSDs during the year and the average running load (when operating), fuels and level of co-firing. Abatement Data required for calculating spot test efficiency Test method used and identification of excluded plant (e.g., boiler blow-down) Boiler combustion and heat transfer losses Steam mass flows and enthalpies across the turbine

4.3 4.4 4.5 4.6

5. 5.1 5.2 5.3

5.4 Power output at generator terminals. Etc

Specific comments The following additional comments could be helpful regarding the energy efficiency section of the questionnaire: A description of the required efficiency could be added at the top of the sheet, e.g., Annual average plant efficiency for 2010 (based on the lower heating value of the fuel and taking account of all energy imports and exports across the site boundary)*. *Footnote: If operation in 2010 was atypical due, to example, a major breakdown, then pick the closest year of typical operation and state the reason. An information box could be added with the following text: Plant efficiency is affected by a number of parameters including: load, frequency of start-up and shutdowns and ambient conditions. Please indicate potential deviations from the design (base-load) value due to changes in operation. Consider adding an extra row with Year: and Plant efficiency: (since the current layout is not very clear). ISO (Net) Base Load efficiency for the specific gas turbine emissions reference should be a one-off declaration rather than a demonstration since there is no reason why this cant be either the design or guarantee value without a proving exercise.