About us

STEAG encotec (India) Pvt. Ltd.(SeI) is wholly owned subsidiary of STEAG encotec GmbH, Germany. SeI offers services in the field of: Engineering Consulting Services Power Generation Operation and Maintenance Renovation & Modernization Information Technology for Power Plants New Technologies for Power Plants SeI has offered services in recent time to: IOCL, MSEB, GSEG, BHEL, HPGCL, NLC, etc.

SR Systematic Energy Management

_________________________________________________

Energy Management Systems

SR Intelligent IT-Solutions for Energy Suppliers

SR1 SRv
Data Validation

Lifetime Monitoring

SR2
Energy Management

SRp
Statistic Forecast

SRx
Energy Data Management

SR3
Energy

Controlling

SRk
Power Cycle Evaluation

SR4
SR5
Power Trade System Power Plant Optimization SR4 Compact Power Plant Optimization

SR1 Lifetime Monitoring in Power Plants

Current Demands
Components of power plants exposed to high temperatures and pressures suffer serious material degradation during their lifetime. This degradation indicates a need for component exchange or at least its repair. The accumulated material degradation is not proportional to operating time, for which reason a regular monitoring of the plant operation is recommended. Such a monitoring must be carried out by continuously operating a data logger together with a data evaluation system.

SR1 is the solution ...

for continuously recording operating temperatures and pressures around all the critical components of a power plant for calculating the creep and the fatigue for keeping the operator well-informed about the current status of his plant for reducing the cost for routine maintenance inspections as well as additional tests

SR1 Saving the measured values

SR1 Calculating the creep damage

Actual stress:

p di + 1) r= ( 2 s va

Fatigue in the time x:

C f p/T =

x 100[%] X

SR1 Saving the stress cycles

SR2 Energy Management System

You have a varying demand of electricity, steam, hot and chilled water, compressed air, etc. ? You have alternative means of generating and supplying these energies ? You have various buying and selling contracts for your moving energies ?

SR2 helps to cut your energy bill significantly!

And pays back shortly!

SR2 Engineering Logic

Energy Plants

Energy Contracts

Energy Demands

System Parameters

Energy Plant

Online Data

SR2

Forecasts

Closed Loop Control

Online Application

Offline Application

1/2 hour

Day

What / If?

Year

SR2 Optimization in Industrial Cogen Plant

Boiler 1 85 t/h Oil/Gas Boiler 2 75 t/h Coal/Gas Boiler 3 75 t/h Coal/Gas

Live Steam 60 bar/500 C

Flue Gas Desulfurization and DeNOx Plant

Boiler 7 85 t/h Oil

Boiler 8 85 t/h Oil/Gas

175 C
M M M M

138 C

ST 1 Deaerator

ST 3

ST 4

ST 5

G
15 MW

G
12,5 MW

G
12,5 MW

G
12,5 MW Air Compr. 1

Air Compr. 3

District Heat Steam 170C

Process Heat Steam 250 C

TDM / h

SR2 Verified Savings in Industrial Cogen Plant

13 11 9 7 5

General Motors Germany: Daily Energy Cost Profile at Beginning of SR2 Installation

Actual Cost without SR2

Optimized Cost Difference 7,500 US$/day

13 11 9

Daily Energy Cost Profile after 12 Months from SR2 Installation

TDM / h

Actual Cost with SR2

Optimized Cost

Difference 3,500 US$/day

7 5 3 0 3 6 9 12 15 18 Hour 21 24 further potential for optimization Verified Savings: 4,000 US$/day, equivalent to 4 % of variable cost

SR2 Optimization in Municipal Heat/Power Plant

SR2 Verified Savings from Optimization in Municipality

5,000 US$/day

Actual Variable Cost

Savings after one year: 2,500 US$/day

Difference Actual to Optimized Cost

April 98 March 99

equivalent to 8 % of variable cost

SR2 How the Online System works

every h Demand Forecasts

1st step 24 h operation plan

every h Load Distribution (24h Forecast)

every 15 min Online Plant Data

2nd step Fine Tuning

every 15 min Load Comparison (Is/Should be)

every 15 min

Balancing all the variable costs

Cost Comparison (Is/Should be)

SR2 What the Offline System offers

Optimizing the annual budget (incl. maintenance dates) "What happens if?" simulations (incl. unexpected outage) Cost efficient "In House" studies (incl. plant additions)

Identification of future bottlenecks

Optimizing energy contracts

SR2 Predesigned Components

Hot Water Generator Sat. Steam Generator Boiler with Superheater Boiler with Reheater WHSG GT GT Generator Motor (Heat and Power) Motor Generator Steam Turbine (3 stages) Steam Turbogenerator (3 stages) Motor

Generator Pump Compressor Water Turbine E-Pump

Spray Atemperator

Injection Condenser
Valve Water Storage Steam Storage

Steam Driven Pump Fuel Storage Heat Exchanger Heater Deaerator Cross Flow HE Condenser Cross Flow Condenser Energy Line Throtthing Valve (with Spray) Condensate Tank Energy Source Energy Sink Black Box (general)

SR2 System Architecture

Client
SR2-Edit Plant Configuration Module

Server

Applications
Problem (MPS generator) transformer
MIP-Solver

SR2-Conf Data Configuration Module

Data Server
SR2-Vis Presentation Module

(Optimizer)

SRp

(Forecast Module)

Online Data Interface Module Optional for further SR applications External Programs (via API) Archive external Archive internal

SR2 Integration in Clients Information System

SR2 Application Server incl. Data

Server (Windows NT)

Exteral Data / File Server (e.g. Netware)

Measurements

Results LAN

Plant Bus, Terminal Bus, Interface, etc. SRx Client Online Data (variable)

Parameters

SR2 Client Offline Office (Windows 95/NT)

SR2 Client Online Control Room (Windows 95/NT)

SR4 Optimization of Power Plant Operation

Current Demands
More strict environmental regulations ask for better plant control and make it even more important and more difficult to find the best point for economic operation of the plant Competition, especially from a deregulated market and from a growing number of Independent Power Producers, also requires knowledge of best price for power output The more and more urgently needed economic production of electricity and heat asks for maximized efficiency Maximum efficiency needs intelligent software tools implemented in the PMS Using online measurements and system parameters these systems should - reduce the costs of energy production ! - simulate current plant behavior for various boundary conditions !

SR4 is the solution ...

for highlighting the entire process for maximizing economic and environmental efficiency for comparing todays operation with its possible best for simulating the power plant behavior of tomorrow

SR4 Results

Online Balancing Current behavior of all components and the entire plant efficiency, performance, power output, fouling

Online Comparison Reference-to-Current / Best-toCurrent Reference : all components at guarantee point based on current operation and ambient conditions Best : optimized operation based on current component and ambient conditions Close follow-up of all relevant component characteristics, calculation of cost reduction potential Online/Offline Simulation & Forecast Results for various power plant parameter variations and the related fuel consumption figures

SR4 The Triangle of Simulations

Ambient Parameters (not controllable) ambient temp,pressure, humidity Cooling water temp, (load level, heating value,combustible), etc. Forecast

Operational Parameters (controllable during operation)

Simulations

Component Efficiencies (controllable during downtime) efficiency, spec. heat rate, gain factor,effectivity, approach temp, etc. Comparison

Load factor GT/ST, Soot Blowing, Steam Parameters, Cold end, Feed water split, etc. Optimization

SR4 Optimization Potential

Balancing Higher quality of relevant measured and calculated values Compact summary of process information allows more detailed evaluation Reference-to-Current evaluation Continuous evaluation of components and the entire unit Identification of faults and slowly increasing deviations Savings of up to some 100 $/h per unit Optimization Optimization of components, the unit or even the entire site Savings of up to 1 Mio $ per year Forecast Configurable parameter variation for different load conditions Forecast of plant efficiency deviations up to 2-3% supports the plant operation strategy

SR4 The System Benefits

Continuous monitoring of plant efficiency

Balancing, optimization and simulation tool

Cost analysis of component deficiencies Complete thermodynamic boiler model Suitable to answer market needs by parameter variations the power plant behavior of tomorrow Graphical configuration leads to a transparent online and offline application with proven data management Extendable from SR4 Compact to a detailed, large SR4 system

SR4 The Basic System

Basic version: SR4 Compact Scope of Calculation: Online Balancing Online Best-to-Current Comparison and Simulation Main Steam Boiler: efficiency, fouling, oxygen content flue gas Air heater: pressure and oxygen content before/after heater, fouling Steam turbine: spec. heat consumption (net/gross), evaluation of water/steam-cycle Condenser / cold end: temperature, pressure, efficiency Entire unit simulations: reference point, best point, maximum power output, other boundary conditions Data Preparation: Data Management: Interfaces / Hardware: Options SR4 Standard objects : Special objects : a.s.o. Cooling tower, blower/fans, pumps, exhaust gas cleaning, a.s.o. Boiler with detailed heat exchange model, optimization Cold End, Plausibility check Data base SRx PC as SR4/SRx-Server and integration in Customer-LAN

Optional Data Preparation Plausibility check of input values with neural networks Data reconciliation of relevant values

SR4 Examples for Optional Results

Main Steam Boiler + Air Heater + Flue Gas Cleaning Net/gross boiler efficiency (current/reference), effective thermal power, heat balance, indirect coal flow calculation, pulverizer performance, gas temperatures and interstage velocities along the boiler, Superheater and reheater sprays, (T/p) of live steam and hot reheat, reheater steamside pressure drop, fouling of furnace chamber and boiler convection zones controlled by soot blowers, fouling and leakage of rotary air preheaters, flue gas composition, pressure drop flue gas, efficiency flue gas blower, emission monitoring evaluation ( NOx, SO2, CO ), delta of flue gas oxygen content over air heater (current/reference), delta of flue gas pressure air heater (current/reference), boiler simulation taking into account: fuel characteristics, combustion conditions, water-steam cycle parameters, flue gas conditions, Gas Turbine Net/gross efficiency GT (current/reference), back pressure at turbine outlet, efficiency air compressor (current/reference), flue gas mass flow / temperature / oxygen content / composition, gas turbine simulation taking all relevant influencing parameters into account

SR4 Examples for Optional Results

Heat Recovery Boiler Net/gross boiler efficiency (current/reference), pressure drop flue gas, effective thermal power, boiler simulation Water-Steam-Cycle Net/gross specific heat consumption (current/reference), delta costs (current/reference), feed heater performance/optimization, water-steam-cycle simulation taking all relevant influencing parameters into account Condenser Pressure / temperature / degree of recovery / media temperature difference, cold end performance/optimization, condenser simulation District heating system District heat output, el. power output equivalent Entire unit Net/gross unit efficiency, gross unit efficiency + current el. power output equivalent, entire unit parameter variation by activating the simulations of all relevant sub-units, several optimization scenarios

SR4 The Program Structure

Plant Management System (PMS)

System Parameters
Heating values, fixed costs, soot blowing parameters, ...

Plausibility / Reconciliation Online Mode

Graphical interface
Gas Turbine / Boiler / Steam Turbine / Condenser / Plant

Data Base
Measurement s, Formulas

Balancing : Current plant behavior, efficiency,

fouling, ...

( Configuration mode, offline presentation )

Ref.-to-Current Comparison : Boiler, heat

cycle, ...

Optimization : Plant optimum regarding

efficiency, costs,..

Offline Mode
Gas Turbine / Boiler / Steam Turbine / Condenser / Plant

Simulation : Various scenarios, forecasts, ...

Object Configuration
Characteristic values, TAG numbers, characteristic curves, ...

Visualization Online Mode

process figures, color switch, diagrams, ...

SR4 The system requirements

For the connection of SR4 to the data acquisition system a suitable interface will be used. Approximately 200-500 measurements per unit will be selected for transfer at 1 min intervals. All the results are stored in an integrated data base, they can be visualized in actual (on-line) mode and historically for any period of registered time. The SR4 Compact software should run exclusively on a PC application server so that sufficient capacity is available to generate results of diagnosis and optimization every 5 minutes. The PC can be linked to the clients PC LAN (TCP/IP) so that any authorized client (Windows NT) has access to the online visualization of current and past operation. For this purpose the SR4 client software, available on the SR4 server is downloaded automatically when an authorized client of the LAN requires any information. The graphic and numeric presentation of SR4 Compact results includes presentation with automatic visual changes to indicate individual component deficiencies and trend curves as well as x/y-presentations of any combination of variables (original data and results). Testing and tuning of the system during on-line operation is to the major part done by remote control of system operation. For this purpose an ISDN or telephone socket shall be supplied by the client and the server PC will be connected to the suppliers offices. The general hardware requirements for SR4 Compact for the two units are specified as follows:

Trademark PC Pentium IV, 800 MHz, 128 MB RAM; Raid 5 Array, 3x18,2 GByte HD; CD ROM drive for Windows NT; MOD 5,2 Gbyte, with 2 storage media; ISDN router ZyXel Prestige 100 including connection (for system tuning, trial run and for service); Operating system Windows NT 4.0 Terminal Server (alt. Windows 2000 server); Color monitor 19''; Color printer; Interfaces to clients and the DCS for measuring data;

SR4 The data requirements

Approximately 200-500 measurements of operational data we need from your plant for balancing and optimization Relevant units: Gas Turbine;Boiler;Steam Turbine;Condenser;; Entire Plant All technical specifications on boiler geometry, boiler efficiency definition, cycle calculations (design), soot blower characteristics, fuels, air preheaters, gas turbines, steam turbines, etc. have to be supplied by the customer and will be used exclusively to determine the parameters for the system configuration. Some documents in detail : - Supply of the documents and information required for process modeling, according to our requirements; - Lists of available measuring points including TAG numbers; - P&I diagrams and flow schematics; - Functional descriptions; - Design data and acceptance test data; - Fuel analysis; - Burner arrangement, firing sequence; - Boiler drawing, including summary of boiler heating surface data (surface area, pitch, etc.); - Number and arrangement of soot blowers, along with their steam or compressed air consumption characteristics; - Heat flow diagrams of the water/steam cycle and reheater mass flow data as a function of load. - Information about operational cost factors as a basis for the determination of current operating costs; - Information about plant-specific boundary conditions ( e.g. maximum allowable interval between two soot blowing cycles ) - Check and approval of results. Services to be Provided by the Purchaser The Purchaser shall assign a project manager who shall be responsible for: - Supply of the documents and information required for process modeling, according to our requirements. - Information about operational cost factors as a basis for the determination of current operating costs; - Information about plant-specific boundary conditions, e.g. maximum allowable interval between two soot blowing cycles; - Check and approval of results

SR4 Integration in Clients Information System

SR4 Application Server

incl. Data Server (WinNT / Win2000)

External Data / File Server (e.g. Netware)

Measurements

Results LAN

Parameter s

SRx Client Online Data (WinNT / Win2000)

SR4 Client Engineering Office Studies & Parameters (WinNT / Win2000)

SR4 Client Online Control Room Plant Load Schedules (WinNT / Win2000)

SR4 Realized Data Communication for Interfaces

Siemens : Teleperm XP, Teleperm XP-XU, WinTM (Teleperm ME) ABB : XTC (ProControl Interface to PBS30), PIMS, GLINK Hartmann&Braun (now ABB) : CONVISA, CONLINK IDS : HIGH LEIT OS9, HIGH LEIT NT

B&R : DCS2000 OSI Software (Oil Systems) : PI System (via PI-API) Aspen Tech : Info Plus X SEG : VLS2000 Others : OPC-Data-Interface, DDE-Server, Profibus, M-BUS, ODBC, SQL, OLE, FTP, MS-Excel, Yokogawa

SOF BID

Software for the Power Industry

Performance Monitoring online with

Plant optimization offline with

EbsilonProfessional

EPOS

Our clients: more than 100 utilities and manufacturers

Essen

Frankf urt
Zwingenberg

Frankfurt

ABB, ALSTOM, BABCOCK, BEWAG, Blohm + Voss, BMW, CEE, Colenco, DSD, ECH, Envi Con, E.ON, Electrowatt Hamburg und Zrich, enertech, ENERGOPROJEKT, EVH, EVT, GKWeser, GEW Rheinenergie, gtz China, gtz India, HEW, IBT, LAUBAG, Lurgi, Mannesmann Seiffert, Mitsubishi HI, Ramboll, MVV, NEM, Schering, PCE ENERTEC, PEF, RAB, Rheinbraun, RWE, Saarberg, Siemens, SIK, Stadtwerke Chemnitz, Stadtwerke Hannover, Standardkessel LentjesFasel, STEAG, TEAG, Technip, TV Nord, VA TECH, VEAG, Weig GmbH, ZBP INWAT

EbsilonProfessional EPOS
References and experiences of over 40 online installations from 0,04 MW to 1460 MW for industrial plants and utilities since 1996 Coal,oil,gas fired CCP plants Nuclear pp

Repowering

Mixed plants

total flexible from offline to online operation actual by high calculation velocity Optimal use of all potentials by realistic detailling

Exact What-If-calculations by identical models for simulation and validation

High availability by reliable convergence behaviour

Offline process simulation Modellierung

Mills

EbsilonProfessional

Graphical modelling with tool box Standard libraries for

fuels (coal, oil, gas) oxygen carrier gas turbines water-steam user defined and extensible

Fluegas path

Error analyzer English, French, German, Spanish, multilingual

Interactive offline process calculation

EbsilonProfessional

Input air temperature

Demo example CCP Total power 10.382 MW Efficiency 38.09%

Start of the calculation

Input of process parameters

Offline process simulation with actual, historical or manipulated data

EbsilonProfessional EPOS

Choice coal mixture

Determination overheads of a power plant

water-steam-circuit air path mills fluegas path fluegas desulphurization unit

In Ebsilon integrated optimizer

Optimization objectives design operation modes

EbsOptimize

Input of optimization measures

Input of variation measures

Input constraints

In the model available measures

SR4 Unit Overview

SR4 Boiler Sections

SR4 BPOS Calculations

SR4 Boiler Mapping

SR4 Turbine Cycle

SR4 Turbine Section

SR4 Condenser Section

SR4 HP Heater Section

SR4 LP Heater Section

SR4 Air and Flue Gas Section

SR4 AH- A Section

SR4 AH- B Section

SR4 Mill C

SR4 Auxiliary Power Consumers

SR4 Set Point Optimization

SR4 RH Metal Temperature Calculation

SR4 SH Platen Metal Temperature Calculation

SR4 Parameter Editor

SR4 What If Module

SRx Raw Data

SRx Plausible Data

SRx Reconcillated Data

SRx Substituted Data

SR4 Trending

SR4 Optimal Time for Waterwall Sootblowing

Generator Power Waterwall effectivity (fouling)

Economic Loss from soon or late sootblowing

Optimum

Waterwall Sootbl. Signal

SR References

No. Client
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 BMW Condea Jebel Ali K Endesa Endesa Endesa EVN EVN Henkel HEW HEW Hidroelectrica Iberdrola Infracor Kali & Salz LG-Power LVR LVR Mainfranken-Park MiRO Opel Petronas Petronas Rethmann Roche Diagnostics RWE RWE

Place
Dingolfing (D) Moers (D), Studie Dubai (VAE) Teruel 1,2,3 (E), As Pontes 1,2,3,4 (E) Compostilla 3,4,5 (E) Duernrohr 2 (A) Theiss (A) Dsseldorf (D) Wedel (D) Moorburg (D) Abono (E) Guardo (E) Marl (D) Werra (D), Studie Seoul (Korea) Bedburg Hau (D) Dsseldorf (D) Wrzburg (D) Karlsruhe (D) Rsselsheim (D) Kertih (MY) Gebeng (MY) Lnen (D), Studie Mannheim (D) Meppen (D) Ibbenbren (D)

SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx

1999 1998 2001 1993 1993 1992 1990 1998 1999 2001 1992 1995 1995 1994 2000 1999 2001 1992 1993 1999 1999 1990 1999 1999 1997 1998 1994 1997 1997 1999 1991 1999 1999 1999 1999 1999 1999 1999 1999 1999 1999 2001 2000 1996 1996 1999 2001 1998 1999 2001 1999 2001 2001 2001 1998 1998 1998

SR References

No. Client
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 RWE RWE RWE RWE Salzburg AG SAP Schering SESA Stadtwerke Stadtwerke Stadtwerke Stadtwerke Stadtwerke Stadtwerke Stadtwerke Stadtwerke Stadtwerke Stadtwerke Steag Steag Steag Steag Unin Fenosa Unin Fenosa Unin Fenosa Unin Fenosa Verbundkraft Wienstrom

Place
Neurath (D), Bl. D u. E Neurath (D), Bl. A, B, C Gowerk (D) KEO (D) Salzburg (A) St.Leon Roth (D) Berlin (D) Leuna (D) Chemnitz (D), Studie Schwbisch Hall (D) Hamm (D) Kempen (D) TW Ludwigshafen (D) Dsseldorf (D) Neustrelitz (D), Studie Rosenheim (D) Salzburg (A) EW Wels (A) Lnen (D) Herne (D), Bl. 4 Herne (D), Bl. 3 Walsum (D) La Robla (E) Narcea (E) Meirama (E) Sabn (E) Duernrohr 1 (A) Wien (A)

SR1 SR2 SR3 SR4 SR5 SRv SRp SRk SRx

1999 2000 1998 2001 2001 1999 2001 1997 2000 1996 1994 1993 2000 1999 1996 1998 1999 1999 1997 1998 2000 1998 1989 1990 1993 1992 1998 1999 1999 1999 1998 1999 2000 1999 2000 1999 1999 1999 1999 1999 1999 1997 1998 2000 1998 2001 2000 2000 1999 1999 1997 1997 1999 2001 2001 2001 1999 2001 1999 2001 2001 1999 2001 1999 2000

SR References
KW Lnen, Unit 6 (Steag AG, Essen, Germany); 1996 150 MW, high ash coal / oil, 2 Turbines KW Drnrohr, Unit 2 (EVN, Maria Enzersdorf, Austria); 1996/97 350 MW, Imported coal/gas KW Drnrohr, Unit 1 (Verbundkraft, Vienna, Austria); 1996/97 410 MW, Imported coal/gas KW Ibbenbren, Unit B (RWE, Essen, Germany); 1996/97 750 MW, Anthracite, wet bottom furnace HKW Herne, Unit 4 (Steag AG, Essen, Germany); 1997 500 MW, high ash coal, 400 MW district heating KW Neurath, Unit E (RWE, Essen, Germany); 1998/1999 600 MW

SR References
KW Simmering Unit 3 (Wiener Stadtwerke AG, Austria); 1999 Combined cycle, 487,3 MWel, District heating 350 MW, KW Thei 2000 (EVN AG, Austria); 1999 Combined cycle, 454 MWel KW Neurath, Unit D (RWE, Essen, Germany); 1999 600 MW HKW Herne, Unit 3 (Steag AG, Essen, Germany); 2000 300 MW, high ash coal, 150 MW district heating KW Neurath, Units A/B/C (RWE, Essen, Germany); 2000 300 MW each KW1, Unit 4 und 5 (Infracor, Hls, Marl, Germany); 2000 150 MW each, coal/ chemical residues