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Dr. Hans-Peter Wolf

AGH Letniej Szkoły Energetyki 2018

TrainingEBSILON®Professional

AGH Letniej Szkoły Energetyki 2018 EBSILON Professional Training 2

● EBSILON®Professional: generalpresentation

● Power plant modeling: part I○ Topology design○ Simulation and viewing results○ Design and Off-Design

calculations○ Power plant efficiency○ controllers○ parameter studies○ air and fluegas path

● Component library

● Power plant modeling: part II○ Advanced water/steam cycle○ Identification methods and tools○ Excel import/export

● Combined cycle powerplant modelling:○ gas turbine○ heat recovery steam generator

● EbsScript

Agenda


1991 HEW (now Vattenfall)

1992 Preussenelektra (now Vattenfall)

1993 STEAG

1994 Bayernwerk

1996 VEAG (now Vattenfall)

1997 RWE

2000 BEWAG (now Vattenfall)

2003 China, India, …

2004 Spain, Sweden, …

more than 1000 licenses

more than 60 universities / researchinstitutes

more than 60 Online-Systems in morethan 40 power plants

<1991 Calculation kernel (Prof.Janicka)

Graphical User Interface (DOS)

1996 Data validation

1997 1. Windows-Implementation

2000 Re-Design of User Interface

EbsScript, Interfaces

2001 EPOS-Modules

2003 Boiler components

2005 Interface to SRx (online modules)

153 components

350 EbsScript-functions

EBSILON Success Story


EBSILON Features

● User friendliness by intuitive handling (100 % Windows compliant)

● No programming skills required

● Graphical objects for components and pipes (component library)

● Complete observance of physical laws

● No restrictions regarding variety and size of the model

● Easy expandability of existing models

● Design calculation possible

● Complete and partial part load calculation possible

● Extension by self-defined components (Macros) possible

● Large number of fluids considered (water/steam, air, fluegas, coals, oils, gases,

refrigerants, seawater, mixtures, self-defined fluids)

● Fast diagnosis of topology- and specification errors

● Multilingual User Interface (German, English, French, Spanish, Turkish, Chinese)

● different Unit Systems (SI, BTU + other units)

EBSILON®Professional is a tool for the creation of simulation models of almost all kinds ofstationary thermal power processes (fossile, nuclear, solarthermal, CCPP, CHP, ORC, Kalinaand refrigeration processes) in full and part load


EBSILON Features

Licenses:

● EBSILON®Professional consists of a CD (not licensed)

● and a license (time-limited or unlimited), in form of :

- single workstation dongle (USB or Parallel),

- network dongle

- Keycode

● Additional to the base license extra options can be obtained, e.g.

- EbsScript (programming language similar to Pascal)

- EbsValidate (data validation/reconciliation)

- EbsHTML (Export of model and its results to HTML)

- EbsOptimize („genetic“ optimzation algorithm)

- EbsBoiler (detailed boiler components)

- EbsGTLib (gasturbine library)

- EPOS (additional modules for Online-Systems)


Overview of training objectives

● Global aim: learn about power plant modeling using EBSILON● Single steps: learn how to

- Build the geometry / topology of the power plant by drag and dropo Windows „look and feel“o Tools to put the necessary information into a nice formo Understand what happens „behind the screen“ when you build the

model

- Make the model run free of errors/warningso Learn about the error messageso Learn about typical pitfalls in modelingo Learn how to influence the model by the numerous parameters

(specification values or spec. values)o Learn about design and part load calculation

- Make the results fit operational data, water / steam cycle schemes or any other data set as good as necessary.

- Learn about methods and tools for component identification, that is intented to automatically determine the spec. values

- Let EBSILON do a routine work for you by using EbsScript


Training methods

● Learning by Doing

● For the next sessions this will be

- Installation of software if not already done or if difficulties encountered

- Build simple power plant, guided by an online demo

- Experience the model behavior by some simple parameter studies:

○ Error analysis

○ Design and part load calculation

○ Try fixed pressure and sliding pressure operation

- Experience the behavior of important components in case studies

○ Turbine

○ Condenser

○ Preheater

○ Heatexchanger

- Experience the power of control components

○ Calculate steam flow required for given power output

○ Add combustion and simple flue gas path


Furnace

Steam generator

Turbine

Condenser

Generator

Cooling tower

Feed water tank

Compressor

Heat exchanger

Motor + Pump

Valve

Splitter

Pipe loss

Mixer

The most important components


Air

Flue gas

Oil

Gas

Coal / Ash

Electrical

Shaft

Logical

Ref.Val.

Act.Val.

Water (fluid)

Cooling water

Heating water

Steam

High press.Steam

Med. press.Steam

Low press.Steam

Types of Pipelines (Fluids)

Types of Pipelines


Exercise

● Create the topology of a simple power cycle (Clausius Rankine cycle)→ Step1.ebs

Components to be used:

- Steam generator

- Steam turbine

- Generator

- Condenser

- Cooling water pump

- Feed water pump


Exercise

● Specify the values given in the data below

● Data for the main steam: - T = 540 °C, - P = 200 bar, - M = 150 kg/s,

● Data for the condenser:- P[cond] = 0.1 bar- T[coolingwater] = 20 °C

●Close the circuit by providing on pin 2 of the turbine- M = 0 kg/s

→ Step2.ebs


● Try to perform a simulation

● Analyze and eliminate errors → Step3.ebs

● Analyze and eliminate warnings → Step4.ebs

Exercise


Exercise

● Introduce value crosses

● Learn how the layout can be controlled and refined

→ Step5.ebs


Full load (Design case, Nominal case)Components operate at design/nominal conditions● A Design calculation determines the nominal values of the

components.

Part load (Off-Design)Components calculate using● Nominal values from design calculation● And characteristic lines or physical relations for part-load conditions

(Stodola, heat transfer)

Identification (only „local“ to a component)● A component in identification mode calculates a nominal value from

a value which is specified from outside (e.g. outlet temperature of heat-exchanger, outlet enthalpy of turbine)

Full load / part load


● Add value cross to turbine to visualize turbine efficiency

● Perform design calculation with 100% load

● Part load calculation with 100 % (→ profile “offdesign_100”)(before doing that please activate massflow-dependant charline of

turbine in Design-profile)

● Part load calculation with 50% (→ profile “offdesign_50”)

● Design with 50% (→ profile “design_50”)

● Compare the electrical output for the last two cases.

→ Step6.ebs

Exercise


● Make the turbine to determine the life steam pressure (using the “law of Stodola”, a.k.a. “law of the ellipses”)

● Which modifications are necessary?

→ Step7.ebs

Exercise


The Design case normally is

● Global, i.e. for all components (but can be dependant on the profile)„light bulb“-button, Model option

But● Individual components can be „Local off-design“, (can also be dependant

on the profile)Specification value FMODE (calculation mode)• GLOBAL• Local part load (overwrites global setting)

Usually :root-Profile: full load (design case)Sub-profiles: part load

Full load / part load


● Introduce the efficiency meter

● Visualize the process efficiency (gross)

● Add value cross to visualize power produced by the boiler

→ Step8.ebs

Exercise


● Determine the net process efficiency by taking into account the power plant´s internal consumption

● Add value cross to visualize net power produced

→ Step9.ebs

Exercise


● Perform parameter study with three profiles under part load conditions

● See how the efficiency changes

● Data:- Cooling water temperature variation in the three profiles :

• T = 10, 20, 25 °C

● Create a x-y-Diagram, which shows how the cycle efficiencies(gross + net) depend on the cooling water temperature(hint: Extras -> Diagrams -> XY-Diagrams)

→ Step10.ebs

Exercise


● Introduce text fields

● Include the gross / net efficiency values and the cooling water temperature into the text fields

● Display the efficiencies as percent-values using 2 decimal digits (hint: use Online-help of text field to find out about syntax)

→ Step11.ebs

Exercise


● Introduce a controller with internal set value (comp. 39). The controller should correct the feedwater mass flow to achieve a given generator power.

● Create 3 subprofiles for the scheduled generator powers 150 MW, 120 MW and 90 MW

● Change some specification values of the controller (damping, controller start, etc.)

● Observe the convergence diagram

→ Step12.ebs

Exercise


● Hide the elements that are not necessary to observe or that you don’t want to be seen (i.e. controllers, summarizers, logical lines)

→ Step13.ebs

Exercise


● Insert a simple flue gas part (furnace + fuel inlet + air inlet + hot flue gas outlet)

● Compute the coal mass flow for the given boiler power output introducing a controller with external set value (comp.12). The controller should compare the power requested by the boiler with the power generated by the furnace.

● Calculate the block net efficiency and the boiler efficiency

→ Step14.ebs

Exercise


● Learning by Doing

● Learned how to choose components, connect lines, topology creation

● Learned about the definition of the physical behavior of components: nominal values by design calculation, part load definition by characteristic curves, structure of characteristic curves

● Made first experience with error analysis

● Understood the difference between part load and design calculation, learned about Profiles as a tool to manage calculation datasets.

● Learned the usage of value crosses and text boxes and how to include formula in text boxes

● Learned about control components: efficiency meter, power summarizer, difference meter, controller with internal and external set point

● Learned how to improve the model layout

Summary of Basic Training


Hotline :

0049 6251 105911

[email protected]


Advanced Exercise


● Create the topology of easy_pp (easy power plant) using demo example

● Perform calculation in design mode

remark: for succeeding off-design calculations please activate the mass-dependant efficiency charline in all turbines.

→ Easy_PP_Step1.ebs

● Remove warnings


Exercise


● Create a hs- and Ts-Diagram of the turbine expansion.

● Change the nominal isentropic efficiency of the last stage of the LP-turbine. Check the h-s-Diagram

● Create a QT-Diagram of the HP-heaters

● Change the upper terminal temperature difference of the HP-heater to -10 K and create a QT-Diagram.

● Reset the values of the LP-turbine and the HP-heater back to the original values.

Exercise


● Identify the high pressure turbine using T[ext] = 330 °C● Identify the low pressure feed water preheater using T2 = 130 °C● Identify the low pressure after cooler using T4 = 44 °C● Identify the desuperheater using T4 = 195 °C

● Identification means: determine nominal values (i.e. design values) and also the part load characteristic by specifying “boundary conditions”

● Control the identification in “100% part load” profile switching to the simulation mode


Exercise


● Create subprofiles using EbsScript

● EbsScript is used to automate routine actions. The Pascal programming language is being used

● Manually create a 100% off-Design profile “Master_partload”.

● In EbsScript vary the feed water mass flow from 200 kg/s to 120 kg/s with step 20 kg/s and create subprofiles of Master_partload

● Check the results by comparing the subprofiles


Exercise


● Introduce a power output controller. The controller should control the feedwater massflow to achieve the requested power

● Automate the input of requested power using EbsScript and inserting a button


Exercise


Excel data export/import:

● Standard Excel Export : predefined layout. Used to document spec.values of components (select components by flag list or by setting inside component) to the “Workbook” .Also possible to import values into the profile from “Workbook”

● User Excel Import : user defined layout . It is mainly used to read profile specific values into different profiles.

Exercise: Import the temperature values at the turbine extraction E1 for different profiles (use EbsIdentInputData.xls)

● hint: give meaningful names to components which you use in EbsScript

or which you import from Excel)


Exercise


● Identify the turbine_E1 in design mode and at part load conditions (using the values which were imported into the subprofiles by User Excel).

● Fit its mass dependent characteristic line by manually entering the relative efficiencies (ETAETAN) and the relative massflows (M1M1N) of the subprofiles into the characteristic line of the design profile.

● Control the fitting results (check the temperature in the extraction of turbine_E1) switching to the char. lines mode

● View the hs-diagram of the turbine stages


Exercise


To automate fitting :

● Fit the mass dependent characteristic lines of turbine_E1 using EbsScript

● Control the results of fitting switching to the char. lines mode (in sub-profiles)


Exercise


● Protect the nominal values of all the components obtained in design mode by switching the affected components to “Local off design” This will protect the nominal values, when you do design calculations for additional components


Exercise


Polynomial adaption of the turbine efficiency :

● Export the characteristic line for the isentropic efficiency of Turbine_E1 to Excel.

● Fit a square function to the discrete values of the characteristic line and create the equation of the polynomial.

● Enter the equation which you have found into Turbine_E1. Hint: the relative massflow has to be used in the equation.

● Compare the results of the adaption polynomial with the resultsof the characteristic line.


Exercise


● Identification of main steam/water cycle components: how to match simulation to given data sets

● First EbsScript program utilized. Introduction to EbsScript as Pascal language

● Use of buttons

● EbsScript usage: working with multiple profiles

● Excel Import/Export. Difference between Standard and User Excel

● GLOBAL/Local off design: how to protect the nominal values in design mode

● EbsIdent usage: improving char. lines by polynomial fitting

Summary of 2nd day


Diagrams (Convergence Diagram)

no convergence

convergence

Possible reasons:

- Large pressure drops

- Contradicting specifications

- overdeterminations

- controllers not damped

Possible remedies:

- smaller pressure drops

- remove overdeterminations

- increase controller damping and/ormodel relaxation


Diagrams (Controller Convergence)

Improvement of controller and model convergence by „very high damping“ instead of „no damping“ of controller

150 iteration steps instead of 450 steps


Diagrams (QT-diagram)


Diagrams (hs-diagram)

hs-diagram of steam turbine


Diagrams (Ts-diagram)

Ts-diagram of complete

water-steam cycle


Tools (Fluid Properties)

Water-steam table properties

or air-fluegas properties can

be calculated


Variables: pl, hl, ml on all pipes

Equations: components define relations

fk (pl, hl, ml) between the pipes

Nonlinear System of equations

Circuit

Iterative solution of Matrix

Result pl, hl, ml

Specification values

Calculated values

Solution method

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