The Tuoketuo Power Plant and Emerson Process Management have received the China Electric Power Technology Award. Emerson and the plant, operated by Inner Mongolia Datang International Tuoketuo Power Generation Co. Ltd., received the award for significant performance improvements at Tuoketuo Unit 7 (600 MW) following implementation of Emerson’s Unit Response Optimization (URO) technology.
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Implementation of Emerson Process Management’s Unit Response Optimization technology at Tuoketuo Unit 7 results in economic benefits and dramatic improvements in ramp rate and AGC performance
PITTSBURGH (April 16, 2013) — The Tuoketuo Power Plant – the largest coal-fired plant in China – and Emerson Process Management have received the China Electric Power Technology Award. The Chinese Society for Electrical Engineering (CSEE) presents the award annually to companies, institutes or individuals that have played an important role advancing China’s electric power industry.
Emerson and the 10-unit, 5,400-MW plant, operated by Inner Mongolia Datang International Tuoketuo Power Generation Co. Ltd., received the award for significant performance improvements at Tuoketuo Unit 7 (600 MW) following implementation of Emerson’s Unit Response Optimization (URO) technology. These improvements, achieved during the first year of operation, included a 1.0 percent per minute average ramp rate improvement, 85 percent improvement in Automatic Generation Control (AGC) performance, 30-40 percent reduction in steam pressure overshoot and a 73 percent increase (¥547,000 RMB or $82,000 USD) in average monthly revenue.
“We are honored to receive this prestigious award along with the Tuoketuo power plant,” said Bob Yeager, president of Emerson Process Management’s Power & Water Solutions. “The results achieved have been outstanding and are a testament to our proven URO technology, the expertise of our people and tremendous customer cooperation and support.”
The improvements are particularly important due to the circumstances in which the plant operates.
Electricity generated by the coal-fired plant is sold to North China Electric Power Group Company through a long-term purchase agreement to supply the generation demands of Beijing. Each month, all power plants connected to the North China power grid contribute funds to a common pool, which is distributed back to the utilities based on AGC performance. All Tuoketuo units must be able to quickly ramp up or down to meet the grid regulator’s request for power. Because Unit 7 had demonstrated less-than-optimal performance, URO technology was installed to improve its maneuverability and increase monthly revenue.
By modeling process response and unit characteristics, Emerson’s URO solution calculates a variable derivative ramp rate to optimize plant maneuverability and AGC capabilities eliminates overshoots and provides a high level of unit control precision. It combines feed-forward control with dynamic setpoint control for turbine valve position, main steam pressure, and fuel variables to track expected responses and correct the feed-forward reactions. The overall goal is to optimize final output of the boiler by providing predictive control of changes in the boiler due to load, fuel BTU quality and spray valve performance. By considering current plant operating constraints and varying economic factors, the model provides optimal results over a full range of process characteristics and allows for quicker and more stable unit reaction to load changes.
For the first year following implementation, Unit 7 had the quickest ramp rate and best AGC performance of all Tuoketuo units. Average ramp rate went from 1.5-2.0 percent maximum continuous rating (MCR) per minute to 2.5-3.0 percent MCR per minute, resulting in an 85 percent improvement in the unit’s AGC Kp Performance Index (1.4 to 2.6) and a 73 percent increase in average monthly compensation.
Due to Unit 7’s success, the plant implemented URO technology at Unit 2 the following year – with even more positive results – and is currently installing the URO solution at Unit 1. Completion is expected in spring 2013.