Utility Improves Efficiency and Saves Money by Using Thermal System Monitoring Software
Overview
Salt River Project Coronado Station is an eastern Arizona 773 MWe coal-fired, steam electric generating station. Salt River Project monitors plant instruments like many other utilities to track efficiency. GSE Engineering, Programs and Performance (formerly True North Consulting) was able to support the Salt River Project by utilizing a Thermal System Monitor (TSM Enterprise) to aid in identifying a costly
maintenance issue.
Challenge
Salt River Project wanted to establish new thermal performance baselines by conducting a heat rate test for Unit 2. GSE was brought in to help with the performance of the heat rate tests.
While evaluating data for Unit 2, GSE engineers identified anomalies in the gas exit temperature, which can indicate a possible soot blower problem. Further evaluations were required to pinpoint the exact nature of the problem.
Solution
GSE selected TSM Enterprise to evaluate the Salt River Project Unit 2 heat rate test data. TSM Enterprise is a tool designed to perform thermal performance analysis and reporting functions while providing a platform for further analysis. TSM Enterprise is designed to display a top-down evaluation of a plant’s thermal performance.
GSE’s TSM Enterprise identified a 30°F differential in gas exit temperatures for Unit 2 air heaters A&B.
A physical inspection of the air heater soot-blowing equipment was performed. Although the control room indicators were not reporting a problem, the inspection revealed that one of the heaters had an inactive blower. The soot-blowing equipment was activated and a heavy air heater was cleaned.
Results
Using TSM Enterprise software, Salt River Project was able to identify and resolve an issue with their air heater performance, resulting in overall gas exit temperature improvement. Reducing the gas exit temperature increases boiler efficiency and lowers the unit heat rate, resulting in lower fuel consumption and fuel costs.
Evaluating data using the right tools identifies underlying issues and aids in disbursing maintenance dollars properly. TSM Enterprise provides an overall summary to quickly grasp the unit’s status while providing the ability to obtain detailed reporting of significant thermal performance behavior easily.
Knowledge, experience and the right tools are critical for quickly identifying costly maintenance issues in today’s power industry.
GSE is committed to providing the best tools and experience available to improve a plant’s bottom line, whether it is lower fuel costs or increased power output.
