Plant Performance Optimizer

Maximizing Power Generation, Minimizing Steam Consumption

Advanced Energy Solutions is an integrated set of software
applications to aid the industrial power and co-generation plants
for better management of their plant needs and also meet the
demands of their customers and regulatory commissions.
Advanced Energy Solutions has a common platform which
supports a suite of applications. Process optimization functions
cover the combustion process, both heat and power load
allocation, and electric power delivery. Typical achievable
benefits include heat and power production costs savings,
increased effective boiler operation range, optimized flue gas
emissions, optimized production capacity utilization, optimized
transient states control, extended production assets life, and
reduced maintenance.
Advanced Energy Solutions is comprised of multiple components
and Plant Performance Optimizer is one of them.
Plant Performance Optimizer
Plant Performance Optimizer (PPO) dynamically allocates
resources for steam and power to meet the load demand in a
closed loop. This closed-loop functions in a cascade to co-
ordinate the set points for the optimizer/control systems of the
individual plant units. It considers various constraints for
optimization.
Figure 1: Plant Performance Optimizer Functionality
Plant Performance Optimizer 2

PPO accepts overall load demands in multiple forms like electric
or steam load at various temperature and pressure levels. The
energy savings achievable makes dynamic, economic load
allocation an attractive choice to meet the generation demand
with minimum fuel cost.
Plant Performance Optimizer minimizes electric and thermal
power generation heat losses by distributing the load onto all
operating boilers and turbines. It consists of the following two
components:
Economic Load Allocation for Boilers (ELA-B)
Economic Load Allocation for Turbines (ELA-T)

Economic Load Allocation for Boilers (ELA-B)
Boiler Load Allocation together with the master pressure control
allocate load efficiently to different boilers while considering the
boiler dynamics. The main objective of the ELA-B is to allocate
the steam demand optimally to different boilers by considering all
operational and business constraints. The important features are:
Distributes total heat input amongst boilers
o Maintains widest effective steam production
range
o Minimizes steam production costs
Allocation based on:
o Boiler cost curves
o Individual boiler limits
o Operational restrictions

Economic Load Allocation for Turbines - (ELA-T)
Turbine Load Allocation provides optimal set points for individual
turbines. ELA-T can operate in several optimization scenarios.
The objective may vary depending on the power plant topology
and operational preferences.
For example, in pressure control mode, the objective is to
maximize the power generation while maintaining output steam
flow and parameters given by steam consumers. For example,
profit is achieved by increased generation. In the generation-
control mode, the objective is to minimize the steam consumption
while maintaining total generated power and maintaining output
steam flow and parameters, so with ELA-T profit is achieved in
terms of lower steam demand.
Figure 2: ELA-B dynamic load allocation for 3 boilers
Plant Performance Optimizer 3

The important features are:
Pressure Control Mode:
Only back-pressure turbines
o Total steam flow given by process steam
demand maintained by MPC
o Space for optimization in turbine loading
Value:
o Maximize power generation while maintaining
output steam flows and parameters given by
steam consumers
Generation Control Mode:
At least one condensing turbine
o Total generation set point can be set
Dispatch center, RTU
TLC component
o Output steam demand given
Value:
o Minimize steam consumption while maintaining
total generated power and maintaining output
steam flows and parameters

Basic Functionality of PPO

Figure 3: Basic PPO functionality
Figure 3 represents the basic functionality of PPO. The PPO
solves an optimization formulation with a set of objective
functions and constraints. The objective function and constraints
are different for load allocation of boilers and turbines. However
both can be solved under the common framework of load
allocation and configuration tools are given to specify the
necessary objective function and constraints for boiler and
turbines.
PPO Functions
Optimal allocation of boiler load is based on the
individual boiler cost curves, limits and maximum ramp
rates as well as operational constraints
Mode of load allocation between boilers is dynamic and
continuous
Integrated with Master Pressure Controller to get total
steam demand
Minimization of slippage
Load demand forecast and management
Generation monitoring
Unit performance monitoring
Maintenance management
Unit and auxiliary devices availability management
What-if analysis
Optimal allocation in closed loop mode

PPO Benefits to its Customers
Optimal utilization of boiler reduces maintenance and
operation costs
Minimizes steam production costs by optimally
allocating total steam demand to the available boilers
Improves safety/life of boilers as operational constraints
are considered in load allocation
Better plant responsiveness to load changes
Immediate response to varying economic conditions
(real-time pricing)
Flexible reaction to customer requirements provides an
advantage in the highly competitive marketplace
Reduction in emissions
Cost saving evaluation
Plant Performance Optimizer provides a state-of-the-art solution
for simultaneous pressure control in the common steam header
together with optimized individual unit (boilers/turbines) load
allocation. It also helps to control boiler/turbine load more
effectively, fully respecting boiler load dynamics, unsteady
common steam header demand, and boiler operational
economics.
Plant Performance Optimizer 4

More Information
For more information on Honeywells Plant
Performance Optimizer, visit our website
www.honeywell.com/ps, or contact your
Honeywell account manager.

Automation & Control Solutions
Process Solutions
Honeywell
2500 W. Union Hills Dr.
Phoenix, AZ 85027
Tel: +1-602-313-6665 or 877-466-3993
www.honeywell.com/ps


PN-08-46-ENG
November 2008
2008 Honeywell International Inc.