Methods and systems for enhancing control of power plant generating units

• US 9,945,264 B2
• Filed: 12/31/2014
• Issued: 04/17/2018
• Est. Priority Date: 12/31/2013
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (GE Vernova, Inc.)
• Original Assignee: General Electric Company
• Inventors: Wichmann, Lisa Anne, Pandey, Achalesh Kumar, Pool, Eric Thomas, Raczynski, Christopher Michael, Pamujula, Suresh
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Azad, Md
• Application Number:
  US14/587,682
• Publication Number:
  US 20150185716A1
• Time in Patent Office: 1,203 Days
• Field of Search: 700287, 60773, 701100, 703 7, 703 13, 703 18
• CPC Class Codes: F01K 13/02 Controlling, e.g. stopping or starting
• CPC Class Codes: F01K 23/101 Regulating means specially adapted therefor F01K23/105, F01K23/108 take precedence
• CPC Class Codes: F02C 6/00 Plural gas-turbine plants; Combinations of gas-turbine plants with other apparatus; Adaptations of gas-turbine plants for special use
• CPC Class Codes: F02C 9/28 Regulating systems responsive to plant or ambient parameters, e.g. temperature, pressure, rotor speed F02C9/30 - F02C9/38, F02C9/44 take precedence
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2220/72 a steam turbine
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: F05D 2270/053 Explicitly mentioned power
• CPC Class Codes: F05D 2270/709 with neural networks
• CPC Class Codes: G05B 13/04 involving the use of models or simulators
• CPC Class Codes: G05F 1/66 Regulating electric power
• CPC Class Codes: Y02E 20/16 Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]

Abstract

A control method for optimizing or enhancing an operation of a power plant that includes thermal generating units for generating electricity. The power plant may include multiple possible operating modes differentiated by characteristics of operating parameters. The method may include tuning a power plant model so to configure a tuned power plant model. The method may further include simulating proposed operating modes of the power plant with the tuned power plant model. The simulating may include a simulation procedure that includes: defining a second operating period; selecting the proposed operating modes from the possible operating modes; with the tuned power plant model, performing a simulation run for each of the proposed operating modes whereby the operation of the power plant during the second operating period is simulated; and obtaining simulation results from each of the simulation runs.

Claims

1. A control method for enhancing an operation of a power plant, wherein the power plant includes thermal generating units for generating electricity for a market, and wherein the power plant comprises possible operating modes differentiated by characteristics of operating parameters, each of which comprises a physical aspect of the operation of the power plant, and wherein the market includes an economic dispatch system for distributing an expected demand for the electricity in the market among a group of power plants that each submits an offer for generating a portion of the expected demand for electricity during a future market period defined by a dispatch system administrator, wherein the offer includes an incremental heat rate schedule for the power plant, the incremental heat rate comprising a heat rate for the power plant at selected output levels, the control method including:

tuning a power plant model so to configure a tuned power plant model, wherein the tuning comprises a tuning procedure inclusive of the following steps;

a) defining a first operating period and a plurality of the operating parameters, and then, using sensors, sensing measured values using for the plurality of operating parameters during the first operating period;

b) defining a performance indicator that comprises a performance criteria for the operation of the power plant, wherein the performance indicator is defined so to depend upon, at least in part, a selected operating parameter chosen from the plurality of the operating parameters;

c) from the measured values, calculating a measured value for the performance indicator;

d) with the power plant model and a subset of the measured values as input data, simulating the operation of the power plant over the first operating period and determining therefrom a simulated value for the selected operating parameter;

e) based on the simulated value for the selected operating parameter, calculating a predicted value for the performance indicator;

f) comparing the measured value against the predicted value of the performance indicator so to determine a differential there between; and

g) tuning the power plant model based on the differential so to configure the tuned power plant model; and

simulating proposed operating modes of the power plant with the tuned power plant model, wherein the simulating comprising a simulation procedure inclusive of the following steps;

receiving forecasted values for a plurality of disturbance variables, including at least ambient temperature and ambient pressure;

defining a second operating period that corresponds to the future market period of the economic dispatch system;

selecting the proposed operating modes from the possible operating modes, wherein the proposed operating modes comprise competing operating modes defined at each of the selected output levels and then, for each of the competing operating modes, multiple cases related thereto;

generating a proposed parameter set for each of the multiple cases defined for the competing operating modes, wherein the proposed parameter sets comprise input data for the tuned power plant model, the input data defining values for selected variables during the second operating period, wherein the proposed parameter sets are generated to include the forecasted values for the plurality of disturbance variables received;

with the tuned power plant model, performing a simulation run for each of the proposed operating modes whereby the operation of the power plant during the second operating period is simulated; and

obtaining simulation results from each of the simulation runs; and

using an optimization procedure to determine an optimized operating mode from the simulation results for the second operating period and, based on the optimized operating mode, generating the offer, wherein the optimization procedure comprising the steps of;

defining performance objectives, the performance objections including a heat rate for the power plant;

evaluating the simulation results for each of the simulation runs according to the performance objectives so to determine therefrom an optimized simulation run;

designating as the optimized operating mode whichever of the proposed operating modes corresponds with the optimized simulation run;

determining the optimized operating mode at each of the selected output levels from the competing operating modes and the cases corresponding to each so to determine an optimized heat rate at each of the selected output levels;

using the optimized heat rate at each of the selected output levels, calculating a true incremental heat rate schedule; and

generating the offer in which the incremental heat rate schedule is based on the true incremental heat rate schedule.

2. The control method according to claim 1, wherein the second operating period comprises a subsequent, non-overlapping operating period in relation to the first operating period.

3. The control method according to claim 2, wherein algorithms of the power plant model comprise logic statements in which performance multipliers correlate process inputs to process outputs for the operation of the power plant;

wherein the step of tuning the power plant model based on the differential includes making an adjustment to one of the performance multipliers and then recalculating the predicted value for the performance indicator so to determine if the adjustment made to the one of the performance multipliers results in reducing the differential;

wherein, if the adjustment to the one of the performance multipliers is determined to reduce the differential, the control method includes the step of incorporating the adjustment to the one of the performance multipliers into the power plant model so to configure the tuned power plant model;

wherein, if the adjustment to the one of the performance multipliers is determined to increase the differential, the method includes repeating the step of tuning using a different adjustment to one of the performance multipliers for each repetition; and

wherein the repetition of the step of tuning continues until the recalculation of the predicted value for the performance indicator results in reducing the differential.

4. The control method according to claim 2, wherein the differential is designated an original differential;

wherein the step of tuning the power plant model based on the original differential so to configure the tuned power plant model comprises a tuning simulation that includes the following steps;

making an adjustment to one or more algorithms in the power plant model so to configure an adjusted power plant model;

with the adjusted power plant model and the subset of the measured values of the plurality of operating parameters as input data, simulating the operation of the power plant over the first operating period and recalculating therefrom the simulated value for the selected operating parameter;

using the simulated value for the selected operating parameter as recalculated to recalculate the predicted value for the performance indicator;

comparing the measured value for the performance indicator and the predicted value for the performance indicator as recalculated to determine a recalculated differential; and

comparing the original differential to the recalculated differential so to determine which of the power plant model and the adjusted power plant model calculated the predicted value for the performance indicator more accurately relative to the measured value for the performance indicator.

5. The control method according to claim 2, wherein the enhancing of the operation of the power plant comprise an economic optimization made pursuant to a cost function defined within the performance objectives;

wherein the performance indicator is designated a first performance indicator;

further comprising the step of defining a second performance indicator;

wherein the simulation results for each of the simulation runs include a predicted value for the second performance indicator; and

wherein the cost function comprises a correlation between the predicted value for the second performance indicator and a predicted operating cost for each of the simulation runs.

6. The control method according to claim 5, further comprising the step of defining a third performance indicator;

wherein the simulation results for each of the simulation runs include a predicted value for the third performance indicator;

wherein the cost function further comprises a correlation between the predicted value for the third performance indicator to a predicted operating revenue for each of the simulation runs.

7. The control method according to claim 5, wherein the performance objectives further comprise operability constraints;

and

wherein the step of evaluating each of the simulation runs according to the performance objectives so to determine the optimized simulation run includes determining whether the simulation runs violates the operability constraints, and then disqualifying any of the simulation runs determined to violate the operability constraints from consideration as the optimized simulation run.

8. The control method according to claim 2, wherein the tuning procedure comprise a tuning cycle;

further comprising the steps of regularly repeating the tuning cycle such that each repetition comprises a retuning of the tuned power plant model resulting from a just previous repetition of the tuning cycle;

wherein the steps of the simulation procedure and the optimization procedure comprise an optimization cycle;

further comprising the steps of regularly repeating the optimization cycle;

wherein the optimization cycle comprises the tuned power plant model from a latest tuning cycle.

9. The control method according to claim 2, further comprising at least one of:

communicating the optimized operating mode to a power plant operator for approval for operating the power plant in a manner based upon the optimized operating mode during the second operating period; and

electronically communicating the optimized operating mode to a computerized plant controller so to automatically implement control of the power plant pursuant to the optimized operating mode during the second operating period.

10. The control method according to claim 2, wherein the thermal generating units are controlled by actuators having variable setpoints controllably linked to a control system;

and

wherein the operating parameters of the power plant include variables in which;

manipulated variables regard controllable process inputs that are manipulated via the actuators so to control the controlled variables;

the disturbance variables regard uncontrollable process inputs that affect the controlled variables; and

controlled variables regard process outputs that are controlled relative to defined target levels;

wherein the proposed parameter sets each comprises input data for the power plant model, the input data defining values for selected variables during the second operating period.

11. The control method according to claim 10, wherein the proposed operating modes include a first proposed operating mode and a second proposed operating mode that are differentiated by the power plant comprising a proposed plant upgrade in the first proposed operating mode but not the second proposed operating mode;

and

wherein the selected variables of the proposed parameter set of the first proposed operating mode are generated so to reflect an expected performance boost that relates to the proposed plant upgrade.

12. The control method according to claim 2, wherein the thermal generating units are controlled by actuators having variable setpoints controllably linked to a control system;

and

wherein the operating parameters of the power plant include variables in which;

manipulated variables regard controllable process inputs that are manipulated via the actuators so to control the controlled variables;

disturbance variables regard uncontrollable process inputs that affect the controlled variables; and

controlled variables regard process outputs that are controlled relative to preferred target levels.

13. The control method according to claim 1, wherein the selected variables defined for the proposed parameter sets comprise one of the preferred target levels of the controlled variables;

wherein the one of the preferred target levels defined in the proposed parameter sets includes an output level; and

wherein the output level comprising a level of electricity generated by the power plant for commercial distribution within the market during the second operating period.

14. The control method according to claim 13, wherein the competing operating modes are defined via a differentiation of the output level;

and

wherein the multiple cases defined for each of the competing operating modes are defined via a differentiation of a manner by which the outputs level is satisfied by the power plant.

15. The control method according to claim 14, wherein the competing operating modes are defined via a differentiation of the output levels;

and

wherein the multiple cases at each of the different output levels are defined via a differentiation of a percentage of the output level provided by each of the thermal generating units.

16. The control method according to claim 15, wherein the power plant comprises a combined-cycle power plant the includes a gas turbine, a steam turbine, an inlet conditioning system, and a duct firing system, in which:

the inlet conditioning system is configured for cooling inlet air of the gas turbine so to boost a generating capacity of the gas turbine;

the steam turbine is configured to receive an exhaust from the gas turbine for use as a primary heat source within a boiler; and

the duct firing system is configured as a secondary heat source for the boiler to boost a generating capacity of the steam turbine; and

wherein the thermal generating units include;

the gas turbine or, alternatively, the gas turbine boosted by the inlet conditioning system; and

the steam turbine or, alternatively, the steam turbine boosted by the duct firing system.

17. The control method according to claim 1, wherein one of the controlled variables of the power plant includes an output level, the output level comprising a level of electricity generated by the power plant for commercial distribution within the market;

wherein the step of generating the proposed parameter sets includes;

holding the output level at a constant level;

holding a plurality of the disturbance variables at a constant level, wherein the constant level for the plurality of the disturbance variables corresponds to the forecasted values received for the disturbance variables; and

varying each of a plurality of the manipulated variables over a prospective range so to define the competing operating modes.

18. The control method according to claim 17, wherein the performance objective comprises a plant efficiency;

wherein the output level comprises a contracted load established through an economic dispatch bidding process; and

wherein the optimized operating mode comprises a control solution for most efficiently satisfying the contracted load given the forecasted values for the plurality of the disturbance variables.

19. The control method according to claim 18, wherein the market includes a fuel market for a purchase of fuel for use by the thermal generating units for a future market period, and wherein the control method includes the step of defining the second operating period to correspond to the future market period;

further comprising the steps of;

calculating a necessary fuel supply for the second operating period given the control solution determined for most efficiently satisfying the contracted load given the forecasted values of the plurality of the disturbance variables; and

communicating the necessary fuel supply for the second operating period to a system operator for advising a fuel purchase in the fuel market.

20. The control method according to claim 1, wherein the offer includes an indication of a generating capacity for the power plant;

further comprising the steps of;

defining the performance objectives so to include a true generating capacity for the power plant;

determining the true generating capacity for the power plant based upon the optimized operating mode determined for the future market period of the economic dispatch system; and

generating the offer in which the indication of the generating capacity is based on the true generating capacity of the power plant.

21. The control method according to claim 1, further comprising the step of defining a prediction horizon that is a future period of operation for the power plant, the prediction horizon comprising time intervals that repeat regularly between an initial and a final time interval, wherein the control method includes the step of defining the second operating period to correspond to the initial time interval of the prediction horizon;

wherein the step of determining the optimized operating mode comprises the steps of;

generating multiple proposed horizon parameter sets for the prediction horizon, wherein each of the proposed horizon parameter sets includes a generated one of the proposed parameter sets for each of the time intervals defined therein;

with the tuned power plant model, performing a horizon simulation run for each of the proposed horizon parameter sets over the prediction horizon whereby the operation of the power plant during the prediction horizon is simulated;

evaluating each of the horizon simulation runs according to the performance objectives so to determine therefrom an optimized horizon simulation run; and

determining the operating mode associated with the proposed parameter set of the initial time interval of the proposed horizon parameter set that corresponds to the optimized horizon simulation run and, so determined, designating that operating mode as the optimized operating mode.