ModelBasedOptimizationTechnologies

forPowerPlantEmissions,Efficiency&AvailabilityImprovements
AsiaPacificPartnership StevePiche,NeuCo
April30,2008 DougBartlett,NeuCo
Outline
CompanyIntroduction
ApplicationOverview
DefininganOptimizationProblem
ModelbasedOptimizationTechnologyOverview
ModelingTechnologies
ModelBasedOptimizationApproaches
CombustionOptimizationatAlliantEdgewater
Summary
Introduction:AboutNeuCo
PowerOptimizationMarketLeader
Onlycompany100%dedicatedtopoweroptimization
Morethan100optimizationsystemsworldwide
OfficesinMassachusetts,Ohio,Texas&Beijing
StrongExperienceBase
ComprisedofNeuCo&formerPegasusTechnologies
Morethan20yearscombinedA.I.&domainexperience
ConsistsofworldpioneersinA.I.field
CommittedtoTechnologyLeadership
100%technologyownership
TwoU.S.DeptofEnergyprojectstotaling$35Minvestment
Morethan150patentsinpoweroptimization
CommittedtoCustomerSuccess
Committedto100%customersatisfaction
Allbusinessprocessesdesignedtomaximizecustomervalue
DedicatedCustomerCenter
OurMission

Tomaximizetheimpactyourgeneratingassetshaveonyour
bottomlineusingRealtimeAssetOptimizationsolutionsto
improve:
Availability
Havingmaximumreliablecapacitywheneverneeded
Efficiency
Producingthiscapacityatthelowestpossiblecost
Emissions
Whileminimizingcostlybyproducts
ApplicationsOverview
NeuCoSolutions

Streamlines detection, diagnosis

and resolution of equipment MaintenanceOpt
and process anomalies

Pinpoints efficiency and capacity

PerformanceOpt
bottlenecks and their impacts

CombustionOpt

Optimizes fuel and air mixing

to reduce emissions and SootOpt
improve efficiency
Dynamically directs boiler cleaning actions
to achieve unit reliability, efficiency and emissions goals

ProcessLink Platform
TechnologiesUtilized

Neural network and heuristic models MaintenanceOpt

Rulebased optimization

First principle models

PerformanceOpt
and optimization

CombustionOpt

Neural network models

Direct (design of SootOpt
experiments), steady state
(neural) and dynamic (MPC) Neural network & heuristic models
optimization Steady state & rulebased optimization

ProcessLink Platform
ProcessLinkPlatform
Anintegratedcollectionofprocessmodelingandoptimizationtools
Containsallofthetechnologiesdiscussedinthispresentation
FormsthecoreofallNeuCoproductsandsolutions
Commonplatformenablesknowledgesharing&integrationbetweenproducts
Anindustrialstrengthenterprisesoftwareplatform
LeveragesMicrosoft.NETenterprisefeatures Commercial Products
Products Under Development

MaintenanceOpt

Diagnostic
ClearingHouse
CombustionOpt SootOpt PerformanceOpt ESPOpt FGDOpt FuelOpt

NeuralNetworks Rulebased FirstPrinciples NeuralNetworks NeuralNetworks NeuralNetworks RuleBased

ModelPredictive optimization RuleBased ModelPredictive Optimization
RuleBased
Control NeuralNetworks Optimization Optimization Control NeuralNetworks

ProcessLink
ProcessLinkComponents
ProcessLinksreusablesetofcomponentsarecommonacrossall
NeuCoproducts
GUI Layer Database Layer Action Layer

ProcessLink Object ClosedLoop DCS

Studio Repository Services

Process
Data
Server
End User OpenLoop
Applications Services

Trigger
Database

NeuCo Customer
Center
9
NeuCosCombustionOptApplication
WhyCombustionOpt:
Combustioncontrolsmanipulateafewvariables(suchasO2)asafunctionofload,
leaving35100fuelandairinjectionpointsthatsignificantlyimpactcombustion
performancetoinfrequentofflinetuningoroperatortweaking
WhatCombustionOptDoes:
Providesrealtimeclosedloopoptimizationoffuelandairmixingbymanipulatingall
relevantfuelandairinjectionpoints

Using:
Neuralnetworkandmodelpredictive
controltechnologies
ToAchieve:
NOx,heatrate,steamtemp,CO,MW,
andopacityimprovements

10
CombustionOptNOxImpact
OptimizationImpactonUnitHeatRate
DefininganOptimizationProblem
Introduction:Optimization DataSources:
ERPs (e.g.SAP)
Optimizationistheprocessof CMMSs (e.g. Maximo)
turningdataintoactionable Monitors (e.g. GeneralPhysics)
knowledgethatdeliversbottom Analyzers (e.g. Zolo)
Detectors (e.g. SmartSignal)
linebenefit Historians (e.g.OSI)
DCSs (e.g.ABB)
Knowledge

Tohelpyouunderstand: Action
Whatshappening
Whyitshappening
Whattodoaboutit

15
ExamplePowerPlantOptimizationChallenge
E.g.Whatistheoptimumsettingformymanipulatedvariables:
Totalairsupply
Burnertiltpositions
Sleevedamperpositions
Overfiredairdamperpositions
inordertoreduceNOx?
ExampleSolution:CombustionOptimization

BoilerEfficiency

CO
NOx

Low High

ExcessAir
CVs=ControlledVariables

Theplantvariablesyouwanttocontrol
Youdecidewhatisimportant
ControlledVariables(CVs)
mp
a tTe em p
erhe e a tT
Su p Re h

xyg e n
es s O
Exc

L OI

, N Ox,
CO ity
c
Op a
MVs=ManipulatedVariables
Theprocessvariablesyoucanmovetocontroltheplant
ManipulatedVariables(MVs)

o ns
os it i
p e rP
Da m

u p ply
AirS bution to
ri x
Dis t db o
W in cedP
a
F u rn
lo w
A i rF
DVs=DisturbanceVariables
AffectstheCVs,buttypicallycannotbeadjusted
DisturbanceVariables(DVs)

d
D e ma n
Un it W )
(M

l
Coa ion
p o s it
Co m

t A i r
ie n
Amb itions
d
Co n
WhatareyourCVs,MVs&DVs???

DefinitionofengineeringproblemdictatestheCV/MV/DVselection
GoalsandConstraints
SampleGoals: Optimizerconfiguredforthefollowing:
ReduceNOx
MinimizeO2Average
MinimizeReheatandSuperheatSpray
MaintainReheatandSuperheatTemperaturenear1005
SampleConstraints:Tomaintaincriticaloperationalconstraints,
thefollowingadditionalobjectiveswereaddedtotheobjective
profile:
MaintainCObelow100ppm
MaintainAverageBoilerO2above2.3%
MaintainReheatandSuperheatTemperaturesbelow1010
DefininganOptimizationProblem
1. Listthegoalsoftheoptimizationsystem
2. Listtheconstraintsonthesystem
3. Usingthegoalsandconstraints,determinethelistofcontrolled
variables(CVs)
4. GiventheCVs,listthemanipulatedanddisturbancevariablesthat
affecttheCVs
ModelBasedOptimization
TechnologyOverview
Modeling&OptimizationTechnologies
ModelingTechnologies:
NeuralNetworkModeling
FirstPrincipleModeling
HeuristicModeling

ModelBasedOptimizationApproaches:
NumericOptimization
SteadyState(e.g.NeuralNetbasedandFirstPrinciplesbased)
Dynamic(e.g.ModelPredictiveControl)
RuleBasedOptimization
WhatisModeling?
Theprocessofidentifyingrelationshipsbetweeninputvariablesand
outputvariables
e.g.HowdoesO2 supplyeffectNOx?

Model
function(inputs) Output(s)
Inputs
InformationProcessor
SteadyState(SS)PredictionModel
PredictstheSteadyStateresponseoftheCVstoasetofMVsand
DVs
Doesnotattempttocaptureprocessdynamics(e.g.timeconstant)
Snapshotmodels
Easytooptimize
Goal:IfIweretomakechangesinthemanipulatedvariables,
whatwouldbethefinalsteadystatevaluesofthecontrolled
variables
SteadyState(SS)PredictionModel
Verysimplestructure

Verypowerfulmodel

Optimizerassumesallinputsareindependent

Model Outputs
Inputs Structure (CVs)
(MVs,DVs)
SteadyState

CV

CV

Time

MV

MV

Time
SteadyStateModeling

CV

CV

Time

MV

MV

Time
MIMOSteadyStateModeling

Inputs

Outputs
NeuralNetworkModeling
NeuralNetModelCharacteristics
Aneuralnetisauniversalapproximator
Canapproximatealmostanyrelationshipifsufficientdataisavailable
Canbebuilttodealwithlargenumbersofinputsandoutputs
Canhandlenonlinearities
Canbeincrementallyenhancedwithnewlyavailableinformation
(data)
Oncetrained,modelisverycomputationallyefficient
 NeuralNetModelTraining
1. TrainingoftheNNmodel
O2 willbeiterative.Each
2 iterationiscalledan
epoch

1 3 8 2. Thetrainingwillbestopped
manuallyorbyan
automaticcriteria
4
*
7 9 11
10
1 hr 2 hr 3 hr 4 hr
SOFA 12

13 15
*
6

5 14

1 hr 2 hr 3 hr 4 hr
NeuralNetModeling:inspiredbyBrainCells

BiologicalNeuron

ArtificialNeuron
x1
W11 sum= W11x1+ W12x2 +...+W1NxN
x2
W12
f()

x3 W13
W1jxj
O1

W1N

N

xN
Oi =f(Wij xj +bi )
i=1
NeuralNetModel:AlternateView

Nodes

1. Nodescanbeadjustedtosuit
needsforthedegreesof
freedomoftheproblem

2. Trainingalgorithmwilluse
processdatatofindthe
weights,K11,K12,K21,and
K22togivethebest
approximation
TrainingANeuralNetwork
x1
x2
x3 y

x N

+

Backpropagation
Adjustweightstominimizemodelerror
ModelsLearnfromData
ModelNOxPredictions(blue)
vs.actualMeasuredNOx(red)
atthebeginningofdata
collection,andafterSootOpt
systemhasbeenrunning
OnlinePrediction
Goalistopredicttheeffectsofmovesinthemanipulatedvariables
atcurrenttime,t,onthefuturesteadystatevaluesofthecontrolled
variablesattimet+1
Tomakethisprediction,wecanuse:
Theneuralnetworkmodel
Thecurrentvaluesofthecontrolledvariablesattimet
Feedback(CorrectedValue)
MV(t) CV(t+1)
NN + CV(t+1)
DV(t) Model

MV(t1) CV(t)
NN
+
DV(t1) Model
+

CV(t)

CV(t+1)=Modelprediction
CV(t)=Actualvalue
CV(t+1)=Correctedpredictionusedforoptimization
ModelBasedOptimization
SimplifiedOptimizationSystem

Models Optimizer

PlantInfrastructure

Actuator
DCS Plant
Sensor
ModelBasedOptimization
x1
x1 x 2
Process
x2
y y
. . x 3
x
. 3
.
.
.
.
.
. . .
x 4
.
xN

+ x1
.
y
Process +
x2
+
. .

. x3
y
.
.

+
.
.

. + x4

Usesystemobservationsandmodelpredictionstoadaptmodelto
representsystem
Usemodelofsystemtoexploreanddirectsystemresponse
Repeat(retuning/onlinelearning)
 NeuralOptimization
Determinegoalsandconstraints(profile)fortheoptimizer
UseoptimizationtechnologytodetermineoptimalsetpointsforMVs

Goal
Neural CVs
and
Model Constraint
Calculator

Optimized MVs Cost

Optimizer
ModelPredictiveControl
ModelPredictiveControl

ModelPredictiveController

Manipulated DCS/Plant
SP Dynamic Variables
Optimizer
Model (MVs)

Setpoints&
Constraints
OutputandGradient

Controlled&Disturbance
Variables
(CVs&DVs)

Controllerfrequencyistypically15seconds
Dynamics

CV
Time Response
Delay

Time

MV

Time
FutureModelPredictions
Past Half Hour Current Time Future Hour

O2 FutureSetPoints
O2 HistoricalSetPoint

Firststepoffuturetimehorizon

NOxModelPredictions

COModelPredictions
OptimizerGoals
Past Half Hour Current Time Future Hour

O2 FutureSetPoints
O2 HistoricalSetPoint

Firststepoffuturetimehorizon

NOxModelPredictions

Desired NOx

CO Limit

COModelPredictions
CVHistory
Past Half Hour Current Time Future Hour

O2 FutureSetPoints
O2 HistoricalSetPoint

Firststepoffuturetimehorizon

NOxOpenLoopModelPredictions
NOxHistoricalValues
NOxCurrentValue

Desired NOx

CO Limit
COCurrentValue

COOpenLoopModelPredictions
COModelPredictions
FeedbackAdjustedPredictions
Past Half Hour Current Time Future Hour

O2 FutureSetPoints
O2 HistoricalSetPoint

Firststepoffuturetimehorizon

NOxClosedLoopModelPredictions
NOxHistoricalValues
NOxCurrentValue

Desired NOx

CO Limit
COCurrentValue
COClosedLoopModelPredictions

COModelPredictions
OptimizerComputesMVs
Past Half Hour Current Time Future Hour

O2 FutureSetPoints
O2 HistoricalSetPoint

OutputtotheDCS

NOxClosedLoopModelPredictions
NOxHistoricalValues
NOxCurrentValue

Desired NOx

CO Limit
COCurrentValue

COClosedLoopModelPredictions
COModelPredictions
ValueofNonlinearDynamicModels
Dynamicmodelsarerequiredforfastchangingvariablessuchas
reheatandsuperheattempcontrol.
DynamicmodelsallowfasterresponsetoCOexcursions.
Becausefeedbackisusedtoupdatethemodelsateachtimestep,
modelsdonotneedtobequiteasaccurate.
CombustionOptatAlliantEdgewater
EdgewaterUnit5

BoilerDesign:
Originallydesignedforsubbituminous,now100%PRB
B&W,drybottom,drum,compartmentalizedwindbox
2400psi,1000SH,1000RH
5RollerMills(4originallyforfullload,now5forNOx)
30LNBburners(2006) 15south,15North
OFA21ports7South,14North
2FDFans
2IDFans
2PAFans
RH&SHspraysonlyfortemperaturecontrol
ManipulatedVariables(Preliminary)
AIR FUEL
O2Trim(1) MillMasterBias(5)
FDFanbias(1) PrimaryAirFlowBias(5)
SecAirDuctPressure(1)
PrimaryAirDuctPress(1)
StoichiometrySP(5)
OverfireAir(21ports)
Flowbias
Yaw(grouped,w/independentdownloads)
Tilt(grouped,)
OptimizerImplementation
Duetothelargenumberofvariablesandhighlydynamicnatureof
theplantoperation,theprojectteamimplementedahybridsystem:
MPCrespondstoplantdynamicsandminimizesexcessairtoreduce
NOxwhileavoidingCOspikes
Theneuraloptimizerimprovesoverallair/fuelbalancewithintheboiler,
creatingtheconditionsrequiredtominimizeNOx
Bothmodelingtechniquescombineprocessmodelingtomaximize
unitperformancewithfeedbackfromplantmeasurementsto
respondtoactualunitconditions
Theoptimizersworktogethertotakeadvantageofthecapabilitiesof
eachsystem.
HybridNeural/MPCImplementation
Etc FanBias
AuxAirBias
Neural
OFATiltsandBias
Optimization
PrimaryAirBias
NOx MillMasterBias
CO
O2Dist.
Profile

O2Bias
MPC StoichiometrySP
OFAMasterBias
ProjectStatus

Theimplementationiscompleteandtheoptimizerisnowin
continuousservice
Initialresultslookgood:
COisundercontrol
TheO2distributionacrosstheboilerhasbeenreducedsignificantly
themaximumdifferencebetweenthehighandlowO2sensorshas
beenreducedfromanaverageof1.7%to1.2%
TheoptimizerisabletokeeptheO2trimclosetoitsminimumunder
normaloperatingconditions,whilerespondingtoloadchangesand
otherdisturbancestomaintainCObelowitslimit
NOxlookslower,butwehavenotyetdonefinalteststomeasurethe
reduction.
ExcessOxygenDistribution
NextSteps
Finalplantteststoquantifyresults
ProjectcloseoutandhandovertoCustomerSupport
CustomerSupportthenmaintainsclosecontactwiththesite,using
remotemonitoringtoverifyperformanceandreportresults.
OtherProjectsatAlliant

CombustionOptatColumbia2(completedSpring07)
15%NOxreductionreportedatendofproject.
MaintenanceOptatColumbia2(completedWinter07)
CombustionOptatOttumwa(startingSpring08)
Conclusions
ModelbasedOptimizationTechnology
NeuralNetworkModeling
NeuralOptimization
ModelPredictiveControl
CombustionOptApplication
Appliedat100+powerplants
NOxreductiontypicallyinrangeof1020%
Abilitytoswitchbetweenobjectives
AlliantEdgewaterProject