Analysis of Captive Cogeneration Power Plant

Upset Scenarios using Dynamic Simulation

Software
By :
Arvind Kaushik Chemical Engineer
C Nageswara Rao Mechanical Engineer
Soumya Majumdar Mechanical Engineer
Ramesh Kumar G Mechanical Engineer

Larsen & Toubro Limited Hydrocarbon - IC

Research & Development - Thermal
Powai Works, Mumbai 400076
India.

About Larsen & Toubro

Founded in 1938 by two Danish

Engineers.

Technology, engineering, construcNon

and manufacturing company

Ranks Among Top 5 Companies in

Indias Private Sector.

Professionally Managed since

IncepNon.

Successful Track Record in Oil & Gas,

Renery, Power, Petrochemicals,
Cement & Infrastructure.

-12)

Network of Oces Worldwide.

Employees: 50,000

Ownership: Majority with Public

State-of-the-art Manufacturing
FaciliNes in India and Oman .

Turnover : US $ 11.7 bn (FY 11

& Financial InsNtuNons

2

Research & Development, Hydrocarbon IC

CHEMICAL
ENGG.

WATER
TECHNOLOGIES

Reforming
& syngas
related
Processes

Water
Treatment

Hydrogen,
Ammonia &
Methanol

DesalinaUon
- RO
- Thermal

Gas
Processing
SeparaUon
Process

STP / ETP
Recycling

Well head &

Process plaVorms

THERMAL
ENGG.

Fired
Heaters
Modular
Systems
Super
CriUcal Boilers
Power plant
SimulaUon
CFD

OCEAN
ENGG.
MECHANICAL
ENGG.

Stress
Analysis
Structural
Analysis
Piping
Analysis
Experi-
mental
Techniques

ROTATING
MACHINERY

MATL. SCI. &

CORROSION

Machinery
& System
Design

Equip.
Metallurgy

Machinery /
Structural
DiagnosUcs

Cathodic
ProtecUon

Rotor
Dynamics &
Tribology

Residual Life
Assessment
Composites
Failure
Analysis
Corrosion
Control)

1. Study the eects of load disturbances on the system.

2. Study the eects of any one equipment trip or mulNple equipment trip .
The trips could be isolated events or cascade.
3. To dene, design and rene the operaNons / control philosophy, system
and mechanism of a given power plant / system.
4. To test the plant operaNon under various modes of operaNon.
5. Tuning and adjustment of controller parameters.
6. O-line training of plant operators.

Features of Modular Modeling System (MMS) Soiware

1. Modular approach to mathemaNcal modeling of power plants.
2. One or more modules represents one equipment (e.g. boiler, turbine,
valve, pipe, pump, duct , fan, motor, transformer, generator, etc., )
3. The plant/system model is created by interconnecNng modules through
ports.
4. An MMS model is processed through automated steps that produce a
simulaNon executable.
5. Programming languages ACSL, Fortran and Visual C++.
6. Library of various modules Electrical, Mechanical, BoP and Controls.

Features of MMS soiware Contd.

1. Choice of integraNon algorithms such as Euler, Rungekuja, Gear, Adam-
Smith etc.,
2. AutomaNc sorNng and sequencing of dierenNal equaNons for soluNon.
3. User needs to have understanding of ACSL, to build and execute models.
4. Knowledge of Visual C++ required if one needs to develop new modules.
5.In-built simplied property rouNnes for water, air, and fuels etc,
6. Vendor nHance Technologies , US.

Dynamic Model PreparaNon Data Required.

1. Steady state heat balance diagram.
2. P&I diagram.
3. G.A. drawings.
4. Equipment specicaNon sheets (Pumps, Control valves, HX, etc).
5. Control system logic diagrams and descripNon.
6. OperaNon and control philosophy.
7. Start-up sequence.
8. Shut down sequence.
7

Modeling Sequence
Define the
System
Boundaries
and gather
equipment
data

Controller
tunings

Generate
model of
each
equipment
and test

Generate
upset
conditions

Link the
equipment
modules

Get results
and analyze

Execution
and
achieving
the steady
state
operation

Tie to a
training
simulator,
if desired

Major Equipment Modeled

5 nos. Boilers Thermax.
4 nos. Steam turbines; Triveni 11.8 MWe base load; Condensing
4 nos. Generators 11 kVA .
5 nos. deaerators.
5 no. boiler feed water pumps along with drive turbines
3 nos. power uid pumps and 3 nos. injecNon water pumps
BOP (PRDS; De-aerators, Pipes, Pumps, Valves, condenser, FD fans, etc)
Transformers, Electrical network bus, Electrical motors, etc.

SCHEMATIC DIAGRAM: STEAM AND POWER GENERATION SYSTEM

ATM

LC

FC

LC

Deaerator
Deaerator
Deaerator
Deaerator

To BFW Pump
To BFW Pump
To BFW Pump
To BFW Pump

HP STEAM HEADER

ATM

ATM

Boiler 1

Deaerator

To
To
To
To

Boiler 2

STG 2

To Boiler 2
To Boiler 3
To Boiler 4
To Boiler 5

ATM

Boiler 3

ATM

STG 3

ACC

ATM

Boiler 5

Boiler 4

Power Fluid Pump Turbines

STG 4

100 psig & 338F

6.9 barg & 180C

Boiler Feed Water Pump Turbines

PC PC

ACC

ACC

ATM

ATM

ProducNon
Heaters

ATM

LC

LC

InjecNon
Heaters

Ospec Oil
/ Skim Oil
Heaters

MP STEAM HEADER

PC

Tank /
Vessel
Heaters

PC

PC

LC

N2 Blanket

LC

LC

PC

UNlity StaNons

LP STEAM
HEADER

7.2 psig & 234F

0.5 barg & 112C

PC
PC

LP CONDENSATE
FLASH DRUM

N2 Blanket

ACC
MP CONDENSATE
FLASH DRUM

LC

Deaerators

MP CONDENSATE HEADER

ATM

LC

ATM

Demineralised
Water Make-Up

BFW Makeup
Tank

Treated Condensate Storage

Tank

43 psig & 304F

3 barg & 173C

ATM

ACC
ACC

ATM

600 psig & 700F

41.4 barg & 371C

InjecUon Water Pump Turbines

STG 1

ATM

LP CONDENSATE

AcNvated
Carbon Filter
Package

LEGEND
STG Steam Turbine Generator
LP Low Pressure

Condensate
Polishing
Package

Thumbli
Water Wells

Filter
Package

DesalinaNon
Package

MP Medium Pressure
HP High Pressure
ACC Air Cooled Condenser
ATM Atmospheric
PC Pressure Control
LC Level Control
FC Flow Control

D
S

Desuperheater
Silencer

Plant Configuration (Electrical System)

G2

G1

11 kV Bus A

12 MW, 11 kV, 3, 50 Hz

GENERATORS; 15 MVA,

G3

G4

11 kV Bus B

TRANSFORMERS

11 /6.9 kV

11 /0.433 kV

11 kV Bus C

11 /6.9 kV

6.6 kV Bus

415 V Split Bus

SB1

SB2

SB3

SB4

SB5

SB6

M1

M2

M5

M3

M7

M6

M4

M8

6.6 kV Motors
11 /6.9 kV

EG1

33 kV Bus

EM2

EM5

EM3

M14

M12

EM4

EM6

EM8

EM12

EM10

EM13

EM11

EM9

EG3

11 /6.9 kV

EM7

6.6 kV Emergency Motors/Loads

SS

6.6 kV Emergency Bus

EM1

11 /35 kV

M10

M13

EG2

EMERGENCY DIESEL GENERATORS

11 /35 kV

M11

M9

SS

EM14

6.6 /0.433 kV

415 V Split Bus

Well Pads

Well Pads

OperaNons Base

SB7

SB8

SB9

SB10

SB11

SB12

SB13

SB14

EM15

11

Control Systems Implemented

UUlity Boilers
Three-element / single element drum level control based
on steam drum level, Steam ow rate and the Feed water
ow rate.
Firing rate control based on HP header pressure.
Air fuel raNo control by FD fans
Temperature control of steam by desuperheaNng

12

Control Systems implemented (Contd.)

Steam Turbines
Turbine Governor Model (vendors Controller Block
Diagram and Transfer FuncNon Diagram)
Mechanical Power output, MW.
Generators
AutomaNc Voltage Regulator (AVR) vendors Transfer
FuncNon Diagram

13

Control System implemented (contd..)

De-aerator

Pressure & Level

Steam turbine drives for pumps
BFW pump rpm is controlled based on steam ow
Discharge pressure of power uid pump is maintained @
203.91 bar) by controlling steam ow to the PF pump drive
turbine.
InjecNon water pump discharge pressure is maintained at
121.02 barg
Soh starter for start-up of the power uid pump motor
14

Work Procedure
Step 1 - Data Gathering

Process ow diagrams, Heat Balance diagram and P&I diagram.

Equipment specicaNons, physical and Geometric Details data
OperaNng parameters data, allowable metal temperatures.
Control Valves, controllers specicaNons, and
Control system logic descripNon.

Step 2 - Data Input to Modules and Individual Module TesUng

Fuel System
Boilers complete with the Boiler feed pumps, economizer,
superheater FD fans etc.,
Steam Turbines with Condensers
Generators
Heavy Duty Pumps with motors,
Heat Exchangers, InterconnecNng Pipes Valves etc.,
15

Work Procedure (Contd.)

Step 3 InterconnecUng the Modules and System TesUng
Preliminary runs of the model to test the operaNon performance.
Achieving trouble-free steady state operaNon of the plant matching
with heat balance diagram.

Step 4 Modeling disturbances, study and analyze their eects.

One Boiler trips.

One steam turbine trips.
One steam turbine driven power uid pump trips.
One electric motor power uid pump trips.
One boiler feed water pump trips.
Fuel change-over from Fuel gas to Diesel.
Plant Start-Up.

Step 5 Suggest remedial acUon, if any.

16

Different Modes of Operation of Steam Turbines

Modeled in the Project.
MODE - A : 1 ST in Isochronous Mode and 3 STs in Droop Mode

with Remote AutomaNc Set Point Change.
MODE - B : 1 ST in Isochronous Mode and 3 STs in Droop Mode.
MODE - C : All four STs in Droop Mode.

Note: This presentaUon gives results for all STs operaUng in MODE C

17

Features Considered for Modeling All Upset

Conditions
All ve boilers operaNng with HP Steam Header Pressure
control on fuel ring in steady state.
All four steam turbines operaNng in DROOP Mode.
Steam Turbine Governor Model implemented as given by
the Vendor (Triveni).
AutomaNc Voltage Regulator (AVR) implemented as given
by Vendor (ABB).
Soi Starter modeled for start-up of Power Fluid Pump
Motor.
18

Operating Parameter Trends

When One Out Of Five Boilers Trips
Case of Steam Load Shedding To Maintain Plant
Frequency

1 Boiler Trip Case Results

19

Upset Condition One Boiler Trip

Steam supply lost due to the boiler trip = 110 TPH.
Steam deciency will be met by remaining four Boilers

ramping up @ ~30 tph/min.

Steam supply to one InjecNon Water Pump Turbine is

stopped .
MP steam header pressure drops.
Flow through the HP to MP steam PRDS will increase to

maintain MP steam header pressure.

1 Boiler Trip Case Results

20

List of Control Actions One Boiler Trip

IsolaNng Boiler steam line from HP steam Header.
Switching o Fuel supply to the tripped Boiler.
Closing the Boiler Feed water valve.
ConNnue 1 BFW Pump of tripped boiler in a minimum recycle mode.
FD Fan of the tripped boiler conNnues to operate at a reduced load.
IsolaNng boiler blow-down valve.
IsolaNng Boiler from BFW distribuNon Header.
To maintain plant frequency, steam load shedding is done by stopping one
InjecNon water pump turbine drive and corresponding pump within a duraNon
of 2 seconds of trip of the boiler.
Closing the XSVs on sucNon line to the turbine driven InjecNon Water pump .
No Electrical load shedding is required to be considered in this case
1 Boiler Trip Case Results

21

Effect on other operating boilers parameters-

Flow (-------) kg/s, Pressure (-------) Pa, Temperature (-------) oC.

With drop in HP Steam Header pressure the remaining 4

Boilers Ramp by approx. 30 TPH/min
1 Boiler Trip Case Results

22

Effect on MP steam header pressure &

steam Plow through the PRDS.

Flow through HP to MP PRDS increases to maintain the MP

Steam Header Pressure. 1 Boiler Trip Case Results

23

Effect on steam Plow (---) kg/s and Power (----) MW of one

boiler trip.

1 Boiler Trip Case Results

24

Effect on Plant Frequency, Hz

Plant frequency
is maintained
within acceptable
limits (> 49).
The drop is due
to the fall in HP
Steam Pressure

1 Boiler Trip Case Results

25

Observations One Boiler Trip

Due to a sudden shorvall of 110 tph steam the HP header
pressure falls sharply from 43 barg to 33-34 barg.
It takes around 10 minutes for the HP header pressure to
stabilize at a new value of 34 barg.
To stabilize the HP steam header pressure:
Remaining 4 boilers are ramped-up to their maximum capacity
InjecNon Water Turbine driven Pump is tripped aier 2 seconds.

HP Steam header pressure stabilizes at 34 bar.

Plant Frequency is maintained within acceptable limits so that
there is no need for the load shedding.
1 Boiler Trip Case Results

26

Operating Parameter Trends

When One Out Of Four Steam Turbines Trips
Case of Electrical Load Shedding To Maintain
Plant Frequency

1 Steam Turbine Trip Results

27

Upset Condition One ST Trip

Power Lost from Steam Turbine = 8.67 MW

The remaining 3 operaNng STGs ramp up to compensate for the

power loss due to 1 Steam turbine trip.

To maintain plant frequency, electrical load shedding is done.

1 Steam Turbine Trip Results

28

List of Control Actions One ST Trip

- IsolaNng the tripped Steam Turbine from the HP steam
Header.
- IsolaNng the Generator connected to the tripped Turbine
from the connected 11 kV Bus.
- Total electrical load shedding of 5.171 MW is considered to
keep frequency within a range of 48.5 to 51.5 Hz by tripping
one motor driven IW pump and one export oil pump.

1 Steam Turbine Trip Results

29

Effect on 11 kV Bus Voltage, kV

11 kV Bus voltage
dips to a minimum
8.98 kV.
DuraNon of
voltage dip below
9.9 kV is 0.8 s.
Thereaier the 11
kV Bus Voltage
stabilizes within 40
seconds.

1 Steam Turbine Trip Results

30

Effect on Plant Frequency, Hz

The plant stability is
achieved by ramping
remaining STs to 11.22
MW & shedding 5.17
MW load aier a Nme
interval of 0.5 s.
Fig.1 Total Plant Power MW

Min. Frequency is
48.54 Hz.

1 Steam Turbine Trip Results

If the electrical load

shedding of 3.8 MW is
done by tripping only one
Motor Driven IW Pump
then the frequency drops
to 48 Hz.

31

Effect on operating boilers parameters-

Steam Flow (-------) kg/s, Pressure (-------) Pa, Temperature (-------)
oC.

1 Steam Turbine Trip Results

32

Boiler 1 Drum level (----) m, Feedwater Plow (----) kg/s &

Steam generation (-----) kg/s

1 Steam Turbine Trip Results

33

Observations One ST Trip

Tripping of ST results in short-fall of 8.67 MW of power. The plant stability
is achieved by ramping remaining STs to 11.22 MW & shedding 5.17 MW
of electrical load within a Nme interval of 0.5 s.
The maximum drop in frequency is up to 48.54 Hz.
If Electrical Load Shedding of 3.8 MW is done by tripping only one Motor
Driven InjecNon Water Pump then the maximum drop in frequency is upto
48 Hz.
Immediately aier the trip due to sudden loss of power generaNon the 11
kV Bus voltage dips to a minimum value of 8.98 kV and the voltage dip is
for a total duraNon of 0.8 s.
Thereaier the 11 kV Bus Voltage recovers back to 11 kV and stabilizes
within 40 seconds.
1 Steam Turbine Trip Results

34

Operating Parameter Trends

When Steam Driven PF Pump Trips
Case of Additional of Electrical Load

1 Boiler Trip Case Results

35

Upset Conditions - Steam Driven PF Pump Trips

Auto start of 1 Motor driven PF Pump aier the turbine driven pump

trips.

Power GeneraNon from the steam turbines ramp-up to make up for

the addiNonal electrical load of 4.583 MW to the Plant.

Soi Starter is modeled for the start up of motor driven PF Pumps

having an iniNal voltage of 0.3 Nmes of the full voltage and a voltage
ramp rate to achieve the full voltage within 20 seconds.
1 Steam Turbine Trip Results

36

List of Control Actions - Steam Driven PF Pump Trips

- Tripping one Power Fluid Pump Turbine Drive.
- IsolaNng PF Pump Turbine Drive from HP Steam Header.
- Closing XSV on sucNon line of PFP.
- Opening XSV on sucNon line to motor driven PFP.
- Switching on the motor for the PFP by closing the Breaker
connecNng it to the 6.6 kV Bus.
- No Electrical Load Shedding is considered in this case.
1 Steam Turbine Trip Results

37

 The minimum Plant frequency is 48.38 Hz.

The dip in plant frequency below 48.5 Hz is
for 4 s.
Plant Frequency stabilizes at a lower value
of 49.79 Hz.
Fig.1 Plant Frequency, Hz

11 kV Bus Voltage drops to a minimum

of 10.24 kV, 11.7 s aier the changeover.
At the instant the motor achieves its full
speed, 11 kV Bus Voltage goes up to 15.7
kV.
Voltage stabilizes within 90 s.
Fig.2 11 kV Bus Voltage, kV
Results for 1 PFP Changeover from Turbine Drive to Motor Drive

Due to a sudden reducNon in HP steam

consumpNon HP steam header pressure
rises to 43.6 bar.

Fig.3 HP Steam Header Pressure, Pa

Sudden Loss of 61 TPH of HP Steam results

in MP Steam Header pressure drop.
57.6 TPH of HP Steam is diverted through
the HP to MP Header PRDS to maintain MP
Steam Header Pressure.
Fig.4 MP Steam Header Pressure & PRDS Flow
Results for 1 PFP Changeover from Turbine Drive to Motor Drive

The motor achieves full speed within 28

seconds.
At the same instant the motor torque
and the motor current drops rapidly,
hence, the voltage goes up to a maximum
of 15.7 kV.

Fig.5 PFP Motor Parameters

Corresponding to 11 kV bus voltage

reaching a peak of 15.7 kV the total
electrical load also reaches a peak of 55 MW
resulNng in the plant frequency dipping to a
minimum of 48.38 Hz.

Fig.6 Total Electrical Load, MW

Increase in Electrical Load corresponding

to the addiNon of PF Pump Motor of 4.583
MW.

Results for 1 PFP Changeover from Turbine Drive to Motor Drive

Observations - Steam Driven PF Pump Trips

11 kV Bus Voltage drops to and reaches a minimum of 10.24 kV 11.7 s aier the changeover.
At the instant the motor achieves its full speed, 11 kV Bus Voltage going up to a maximum of
15.7 kV.
The 11 kV bus voltage exceeds 12.1 kV in a single peak for a total duraNon of 3.5 s. Thereaier
the 11 kV bus voltage is stable.
Total electrical load also reaches a peak of 55 MW resulNng in the plant frequency dipping to
a minimum of 48.38 Hz.
The dip in plant frequency below 48.5 Hz is for 4 seconds.
HP steam header pressure peaks to a maximum of 43.6 bar and this results in immediate
reducNon in steam output from the boilers to bring the HP header pressure back to 42.5 bar.
Aier the PFP changeover is complete the plant frequency stabilizes at a lower value of 49.79.
This phenomenon is as per reducNon in turbine speed with increase in load as per Droop
curve.

Results for 1 PFP Changeover from Turbine Drive to Motor Drive

Conclusions
It is signicant to note that steam load shedding is required during one
boiler trip, whereas electrical load shedding is necessitated by the Steam
Turbine trip.
MMS soiware from nHance Technologies Inc., is a robust, convenient and
powerful tool available to the Power Plant equipment and control systems
designers and analysts to predict performance of a given power plant to
meet a given duty.
The power plant thermal and electrical systems and the associated
downstream plants can be designed for all conNngencies with the
performance predicNons available by using the MMS Soiware.

42

Conclusions
A complete thermal and electrical systems modeling was done using MMS
Soiware from nHance Technologies Inc. for the 48 MWe thermal power
plant.
Signicant insights were gained about the power plant operaNon in island
mode and the eect of various disturbances (i.e. equipment trips)
Although the study was carried out for a large number of cases such
dierent operaNng loads during years 2, 4 and 6 of operaNon, start-up of
the plant and the fuel change over etc. and with various turbine governor
operaNng modes, this presentaNon is for two trips cases for year 6 (full
load) operaNon.

Contd.
43

Author ProPiles

Mr. Arvind Kaushik is a post graduate (M.Tech) Chemical Engineer from Indian
InsNtute of Technology (IIT) Kanpur, India, since 1990. He has wide experience
of over 23 years in the design of thermal equipment, process opNmizaNon,
energy conservaNon in process plants, dynamic simulaNon of process and
power plants, commissioning and trouble-shooNng in India and overseas. At
present, as Sr. Dy. General Manager (R&D) at Larsen & Toubro Limited,
Mumbai, India, he is leading a team of Mechanical and Chemical Engineers in
the Thermal Engineering Group of Research & Development for innovaNons in
design of waste heat recovery equipment. His areas of interest include solar
thermal energy, low temperature thermal desalinaNon, thermal energy storage
systems, dynamic simulaNon of power plants, energy opNmizaNon of industrial
processes and commissioning and trouble-shooNng of process equipment.
E-mail: arvind_kaushik@LNTENC.com
44

Author ProPiles (Contd.)

Mr. C. Nageswara Rao completed his Masters in Design & ProducNon of

Thermal Power Equipment from NaNonal InsNtute of Technology, Trichy in
2004 and has since been working with R&D-Hydrocarbon IC of Larsen &
Toubro. His work experience is in the areas of thermal design of Fired Heaters,
Shell & Tube, Air-Cooled exchangers, Waste Heat Recovery Coils. He has also
used CFD tools for criNcal troubleshooNng acNviNes and has carried out
Dynamic SimulaNon studies of two capNve power plants. His other interests
include design of specialized heat recovery equipment and energy eciency
of power plants.
E-mail: Nageswara_Rao@LNTENC.com

45

Author ProPiles (Contd.)

Mr. Soumya Majumdar is Master of Technology in Mechanical Engineering

(specializaNon in Fluid Mechanics & Thermal Science) from IIT Kanpur in 2004.
At present he is working as a Manager in Thermal Engineering group of
Research & Development - Hydrocarbon Division at Larsen & Toubro Limited,
Mumbai, India. Mr. Majumdar has worked in the areas related to the thermal
design, analysis and troubleshooNng of heat transfer equipment such as Shell
& Tube Heat Exchangers, Air Cooled Heat Exchangers, Waste Heat Recovery
Coils and Waste Heat Recovery Boilers for various Hydrocarbon projects. He
has also worked in the area of thermo-hydraulic design of regeneraNve type
pebble-bed and cored-brick bed heaters. His varied work experience and eld
of interest also includes Dynamic SimulaNon of Power Plants and Process Gas
Compression modules.
E-mail: Soumya_Majumdar@LNTENC.com
46

Author ProPiles (Contd.)

Mr. Gajam Ramesh kumar earned his Masters in Thermal Engineering from
NaNonal InsNtute of Technology, Warangal. He did his thesis work on
ReacNve Flow Field Analysis using CFD at Defense Research & Development
Laboratory (DRDL), Hyderabad. At present he is working at the Research and
Development Department (PRDH) of Larsen & Toubro Limited, Mumbai
(India). The areas of his experNse are dynamic simulaNon of power plants,
thermal design / analysis / trouble shooNng of heat transfer equipment such
as S&T, ACHE, PFHE, WHR coils etc and other special heat transfer and uid
ow studies.
E-mail: Rameshkumar_G@LNTENC.com

47