Simulation and optimisation

of thermal power stations by use of Turabs

Axel Ohrt Johansen∗
Project manager, Elsam Engineering A/S, Kraftvaerksvej 53, DK-7000 Fredericia, Denmark

Abstract
Elsam is focusing on the complex task of ensuring optimum operation of power stations producing
both district heat and power by launching its Turabs optimisation project. The task is aimed at calculating
a PQ diagram for Elsam’s seven largest production units located on Funen and in Jutland, Denmark,
thereby enabling pricing of the heat and power production at the individual power stations. The system is
deeply rooted in a simulation programme by the name of Turabs developed by Elsam Engineering A/S
over the last ten years. The system consists of two application programmes, run online, and one off-line
module for “what-if” calculations. The system is implemented in a new internal priority network
connecting the seven power station units to each other. Turabs performs online calculations of the seven
power station units and returns data stamped with date and hour to a real-time database. Corresponding
simulated PQ diagrams provide Elsam with a continuous picture of fuel amount and Cv-value within the
operating areas of all seven power stations, which enable optimisation of the mutual operation of the
power station units.

Keywords: Turabs, plant optimisation, numerical simulation, Cv-value, PQ diagram

Nomenclature

ε Scalar - convergence criteria

F Residual vector

x Solution vector

b Right side vector

A Symmetric matrix
Pkondens Power production at condensing mode with the same boiler load
Pactual Power production at actual load.
Qdistrict heating District heat production at actual load.
Pkondens − Pactual A relation between loss in power production caused by district heat production and
Cv = the actual district heat production.
Qdistrict heating

∗
Tel.: +45 7923 3300; Fax: +45 7556 4477; E-mail address: aoj@elsam-eng.com
Abbreviations

SKVB3: Skaerbaekvaerket, unit 3. VHP: Very High-pressure turbine.

NJVB3: Nordjyllandsvaerket, unit 3. HP1: High Pressure turbine no. 1.
ESVB3: Esbjergvaerket, unit 3. HP2: High Pressure turbine no. 2.
SSVB3: Studstrupvaerket, unit 3. LP1: Low Pressure turbine no.1.
SSVB4: Studstrupvaerket, unit 4. LP2: Low Pressure turbine no. 2.
ENVB3: Enstedvaerket, unit 3. TOL: Turabs Online application.
FYVB7: Fynsvaerket, unit 7. TWI: Turabs What If application.
HPPH: High pressure pre-heater. LPPH: Low pressure pre-heater.
TPQ: Turabs PQ application.
PQ-diagram: A diagram showing a plant operation area with respect to district heat and power production.
SQL: An ANSI standard computer language for accessing and manipulating databases.
InSQL®: WonderWare® SQL database for online monitoring of data.

1. Introduction

Elsam has seven main production units, which are connected with each other and with the
European continent through a high voltage system. The power system is further connected with
both Norway and Sweden through AC sea cables. The production units are designed for fossil
fuels (natural gas, coal and oil), they produce both heat and power, and the power stations have
drawn up long-term contracts for supply of power and district heat through distribution
companies. Elsam’s portfolio also includes the world’s largest offshore wind farm with an output
of 160 MW at maximum production. It may thus be something of a jigsaw puzzle to organise the
heat and power production also taking into account the production of green energy and the power
reserves which may be supplied from the Norwegian market based on hydro power as well as
power reserves from the remaining European market.

2. Mathematical modelling

The system of mathematical modelling is implemented in a Web-based IT environment

under an internal priority network connecting the power station units mutually and with Elsam.

The modelling system comprises three different applications and applies Turabs as its
fundamental element. Each application handles various functions with various target groups in
the Elsam Group. An online application has been developed, Turabs Online (TOL), which
comprises calculation models of Elsam’s seven largest production units. For consequential
calculations an analysis tool has been developed with Turabs What If (TWI). For mutual
optimisation between the units, Turabs PQ application (TPQ) has been developed which is used
for identification of the operating ranges of the unit and mapping of the fuel consumption and Cv-
values for the total operating ranges of all units.

2.1 Background

By the end of the 1990’s Turabs was selected as Elsam’s simulation tool to optimise the
power plant process at the individual units. A prototype of the system was fully developed in year
2000 and was subsequently installed and tested at SKVB3. On basis of the satisfactory
experience it was decided to expand the system to comprise all units.
3. Units

The seven units are specified in table 1 below. The units are all backpressure plants - with
the exception of ENVB3. Two of the units are so-called convoy plants (SKVB3 and NJVB3),
which have identical thermodynamic cycles. SKVB3 is natural gas-fired whereas the other units
are coal-fired.

Table 1.
Characteristics of Elsam’s seven largest units
Unit name Superheater Superheater Max. net power Max. district heat
temperature [°C] pressure [bara] production [MW] production [MJ/S]
SKVB3 582/580/580 290/77/19.5 391 435
NJVB3 582/580/580 290/77/19.5 391 435
ESVB3 560/560 251/56 378 460
SSVB3 540/540 220/49 350 455
SSVB4 540/540 220/49 350 455
ENVB3 540/540 200/45 660 80
FYVB7 538/540 240/60 371 480

In the following section the description of the individual units is limited to comprise only
the turbine cycle at the convoy plants, ie. a description of SKVB3.

4. Skærbækværket unit 3

Over time Denmark has been dependent on foreign fuel resources and this has been an
incentive to try to reach a continuously higher efficiency at power stations. It was therefore a
natural consequence to build a unit with double reheat and supercritical steam data. The
efficiency at SKVB3 is thus 48% in condensing mode with a fuel utilisation of up to 93% by
combined heat and power production. The overall efficiency of the unit was increased to 49% by
installation of an expansion turbine, which by reducing the pressure of the natural gas, supplies a
net output to the power production of 4 MW. The boiler is built as a 75 m high tower boiler with
a furnace volume of 59,000 m3. The boiler efficiency is 95.7% by gas firing.

The unit is equipped with an Alstom® extraction unit, designed with maximum capacity for
district heat production. The turbine plant comprises five turbine parts:
• A very high-pressure turbine with 14 steps.
• A compact module with a high pressure and intermediate pressure part (HP/IP0) with 6
and 9 steps, respectively.
• An asymmetric intermediate pressure part IP1 and IP2 with 5 and 7 steps respectively.
Steam extraction for two serial connected district heat exchangers from the first (IP1) and
the second (IP2) part, respectively.
• Two double-current low-pressure turbines (LP1 and LP2).

The steam is reheated to 580 °C both after the very high-pressure turbine (VHP) and after the
high-pressure turbine (HP). The double reheat results in the efficiency of the plant being
increased by approximately 1 percentage point compared to a plant with single reheat. The
turbine plant is throttle-regulated and is normally run in slide pressure mode, which results in the
best available efficiency. Due to the slide pressure mode, the up or down throttle of the plant
takes place based on the boiler pressure while the control valves of the turbine are wide open.
The live steam pressure varies from 285 bara at full load to 90 bar in circulation mode. The
regulation capacity of the plant is according to Elsam’s load gradient requirements. The outlet
pressure is 78 bara. In the high pressure turbine the steam is expanded from 76 bara to 20.5 bara
and in the first intermediate pressure turbine (IP0) it is expanded from 19 bara to 7 bara, after
which the steam is led to the asymmetrical IP1/IP2 turbine. Here the steam is expanded to a
pressure of 2.3 bara by outlet from IP1 and to approx. 1 bara by outlet from IP2. From here the
steam is led either to the district heat exchangers or to LP1 and LP2, respectively, and further on
to the condenser.

4.1 Main cooling-water system

The plant is cooled using seawater and the main cooling-water system is optimised for an
inlet temperature of 10 °C. The condenser at the cooling-water side is divided into two parts.
Operation can thus be maintained while one part is cut off. The condenser pipes and the tube
plates are made of titanium to avoid corrosion at the seawater side. Cooling water is taken in
from Kolding fiord and led through two 50% main cooling pumps to the cooling-water intake
structure with automatic cleaning grating and on through two mussel filters to the condenser. The
total amount of cooling water for supply of the main cooling system is 14,000 kg/s at 100% load.

4.2 District heating

District heating is supplied to the surrounding towns with a total population of approx.
250,000 inhabitants. At SKVB3, steam for the district heat production is extracted at two outlets
of the asymmetrical double-current intermediate-pressure turbine and led to the two heat
exchangers. These heat exchangers are serial connected by which is achieved the best possible
reduction of the power production combined with heat production. Outlet pressure and
temperature is 1.34 bar and 220 °C and 0.46 bara and 113 °C, respectively. The district heating
water is heated to a forward temperature of 105 to 120 °C. The return temperature is normally
48 °C. The maximum district heat production is 435 MJ/s in backpressure mode only. The local
area can at most take 330 MJ/s district heating. The remaining production capacity can be used
for storage in a district heat storage tank balancing economy and energy in relation to heat and
power production. The district heat production can be regulated from a minimum of 15 MJ/s to
the required output, being subject to, however, the usual interdependence between power and
heat production. The district heat storage tank holds 25,000 m3 and can instantaneously release a
power production capacity of approx. 60 MW.

4.3. Control system

The control system performs all tasks of control, regulation, supervision and protection of
boiler, turbine, generator, condensate system including auxiliary systems and district heating and
own consumption. The operating situation and the development in the efficiency of the individual
plant components are continuously supervised by means of calculations in the control system.
Results of this supervision and measuring signals from several parts of the process make up
around 6,000 tags per plant, which are transferred to a central InSql® database where data can be
compared and analysed over time to obtain optimum operation both financially and technically. It
is also possible to compare operational results from Elsam’s other power stations as all control
systems send data to the central InSql® database.

5. The application Turabs

Turabs is a simulation programme developed by Elsam Engineering for calculation of

turbine and water/steam circuits in general. Turabs is the result of more than 10 years of
continuous development and is tuned through the experience gained from energy projects
worldwide. The system is a static calculation programme, which with a comprehensive
component library and advanced water/steam and gas library can be used for design and
consequence calculation of power station units. Turabs equips engineers to carry out accurate
pressure, temperature and flow analyses from a position of knowledge, and rapidly achieve an
optimised design. This cuts production costs and improves product quality. The system is run on
a Windows platform and comprises a pre-processor, which can run in a design and in an off-
design mode so that based on a design calculation, consequence calculations can quickly be
established in the form of off-design calculation. With Turabs online, an off-design simulation is
established based on online measuring data from the various power station units. Turabs includes
an individual equation solver, which empirically is very robust. Turabs solves (minimises a
functional F) a constrained nonlinear equation system by establishing a Jakobiant matrix which is
solved iteratively by means of a modified Newton Rapson algorithm.

F = Ax − b (1)

A Cholesky decomposition [1] is used in connection with the iterative solution of the
equation system (1) and at the same time a Cuthil McKey re-numeration of the equation system is
used. The solution vector is accepted during an iteration process when the Eucliedean norm is
less than ε :

1
⋅ ∑ Fi 2 ≤ ε (2)
2 i

where ε is the convergence criterion. The solution vector is supervised by a control routine,
which ensures that the solution will always be within a predefined definition interval.

The following solver algorithms (search directions) are available:

• The Line search Method, [2] page 116

• The Double Dog Leg Step Method, [2] page 139
• The Locally Constrained Optimal Hook Step Method, [2] page 134
• The method of Bisection, [2] page 25

The various solvers are extensively described in [2]. The Turabs system includes an
algorithm, which utilises a hierarchic priority of the above search directions dependent on the
convergence speed of the equation solver at the actual operating point.
 The hierarchy indicates how fast the line search and dogleg methods are compared to the
method of bisection. The method of bisection is not used until it is absolutely necessary.

Moreover Turabs includes a comprehensive component library of turbines, generators,

condensers, pre-heaters, pipes, valves and controllers which are all implemented in the Turabs
code. In general the involved components are very detailed and fulfil the above descriptions of
the actual plant. A comprehensive modified water/steam (IFC67) and gas library [3] is connected
covering the pressure and temperature range from 0 to 1000 °C and 0 to 800 bara.

6. Functionality

The design models for Elsam’s power station units are established based on guarantee heat
balances and measurements of heat consumption at the individual units. The models operate
within the normal load area, ie. from 15 % load to 100 % load varying from condensate mode
only to backpressure mode. The models may also operate in the heat and power overload by
bypassing the HP or LP pre-heaters. The design models are established based on no-loss line at
100 % load. Three applications each with Turabs as a common denominator have been developed
for each unit. A process calculation based on TWI is shown in Fig. 1.

6.1 Turabs online

By calculating the entire power station process a number of key figures showing the
operating situation, eg. unit efficiency and Cv-value, can be obtained for each unit. It is also
possible to get indications of suddenly arising problems at a unit if inconsistencies between the
measured data and the corresponding calculated data of the unit are registered. It is thus possible
to compare the entire data basis for the computer model and track down a defect component or
track down long-term deviations on vital components. The system is able to optimise the unit by
means of a number of operating parameters and thus increase the efficiency of the unit. One
example is that Turabs online (TOL) calculates an optimum amount of cooling water to the
condenser at the individual units, but many other parameters can be optimised. TOL receives data
from the control system each 60 seconds and subsequently makes an off-design calculation. The
calculation time varies from 0.5 to 2 seconds for a system with 1300 nonlinear equations. The
calculations take place at a 3 GHz Pentium PC.

Calculation data are returned to the central InSql database so that a time serial analysis can be
performed of the measured and calculated data.

6.2 Turabs PQ application

The TPQ system is able to map the fuel consumption and the Cv-value within the entire
load area of the power station unit under varying heat and power production and is thus able to
supply data to Elsam's new operation optimisation programme, Octopus [4], which can optimise
the production at the seven power station units. The diagram is based on 144 TWI calculations.
For each calculation point in the PQ diagram is attached a Cv-value and a gross boiler input so
that the fuel consumption can be estimated quickly. A PQ diagram for SKVB3 with all possible
overload situations is illustrated in Fig. 2. The corresponding area with the Cv-values as a
functional value is shown in Fig. 3. The entire PQ diagram with overload situations can be seen at
the Web portal for the seven units. The PQ diagram gives the plant operators a precise overview
of the actual mobility of plant operation.

Re f: Alhstom varmeb alan ce 754V2 63--85 TEC H-WISE A/S.

10 0 % l ast.. 125 MJ/s
Skfrbfkvfrket blo k 3,
KRAFTVAERKSVEJ 53.
7000 FRED ERIC IA DENMAR K. TURABS
Total Heat rate Q MJ/ S
Q-nett o = 776.452
M Q-gross = 808.804
Q-condenser = 259. 445
0 .0 000m 0 1 .01 57 p 1 0 0.07 t 0 .5 4 06p 8 3.301t M 0 .0 000m 2 Q-district = 125.000
4 19 .35 h 1 6 .0 38 m 1 4 .8 53p 1 00 .00t 1 4.9 26 p 83 .0 22 t 1 5.000p 48 .0 00 t 3 4 8.78h 3 5.258m R-dist ri ct = 0. 67254
4 2 0.10h 5 73 .60m H2 3 48 .74 h 57 3 .60 m H1 2 02 .18h 57 3.60 m
PH2B PH2A PH1A PH1B
Total P ower Pe Pm MW
Q-g ross Q-g ro ss
-0 .000 0 1.00 00 p 2 5 .0 00t -0.000 0 1 .00 00 p 25 .0 00 t 2 .3 2 11 p 8 3.322t 2 .32 11 p 83 .3 22 t Pe-gross = 397.684
10 4.86 h 0 .0 0 00m 1 04 .86 h 0.00 00 m DT=0.0 67 0 .00 00 m 0 DT=0.2 78 3 4 9.01 h 1 7.629m 3 49 .01 h 17 .6 29 m
HJ 1 HJ 2 Pe-nett o/2 = 386.143
P Q Pe-nett o = 383.340
1 .0 4 75 p 2 49 .33t 0.55 73 p 12 5.30 t
2.32 11 p 10 0.08 t 2 .3 211p 1 00 .08 t 0.00 00 m .
M M 41 9 .52 h 8.0 1 91 m 4 19 .52h 8 .0 191 m
2 9 73.0 h 1 6.038m 27 3 1.4 h 35 .2 58 m Pe-int ern = 0. 00000
4 1 .563p 4 86 .50t
Pe-fw.pum p = 11.5414
3 4 12.5h 1 6.170m K S R 0.00 55 m .
Pm-f w.pump = 11. 3061
1 .82 86 p 2 5 0.62 t
-0 .0 0 0m . Pe-con.pum p = 1.45120
2 97 3.0 h 7 1 .3 86 m Pe-cool.pump= 1. 35142
VAL P1

7 8 .042p 3 70 .08t
Q-gross
1 34.040
Sp.Heat rat e HR KJ /K WH
3 0 59.1h 2 7.735m
RH1 VAHP
1 .85 69 p 2 5 0.67t HR-gross = 7028. 76
2 97 3.0 h 9 7 .5 69m
HR-net to/2 = 7238.85
7 2 .9 53p 1 .8 286p 25 0 .62 t
3 5 96.9h 2 97 3.0h 71 .3 86 m HR-net to = 7595. 59
0 .5 490p 12 5 .26 t
87 .7 38 p 3 86 .76t 0 .5 5 73p 1 25 .30 t 2 73 1.4h 54 .1 08 m Total E ffi ciency
30 86.7 h 1 .0 192m 2 7 31.4h 9 3.2 01 m
D ETA -gros s = 0. 51218
ETA -netto/ 2 = 0.49732
0.54 90 p 12 5.26 t ETA -netto = 0. 47396
27 3 1.4 h 54 .1 13 m

VHP HP IP0 IP1 IP2 LP2 L P1 GEN -1

HGE DC B A A E GH HGF B C G H HG G G G G G

27 9 .31 p 57 8.15 t
18 .6 13 p ~
Pe-gen = 3 97 .6 84 1.00 00 p 4 .0 0 00 t
33 9 4.4 h 26 5.00 m 36 4 5.3 h Pm -lo ss = 0 .9 44 00 16 .9 02 h 7 0 00.0 m
97 .6 56 m .
ETA-g en = 0 .9 86 8 4
Q-gross
S
101.460
0.00 00 m .
H K RH2
0 .01 34 p 0.90 79 x 0.00 00 m 5
G
7 .1 751 p 42 7 .44 t R 0.01 34 p 0 .9 0 06 x 2 29 4.4 h 66 .1 21 m 1.00 00 p 4 .0 0 00 t
0 .0 000m . G 2 0 .631p 38 0 .06 t 18 .9 95 p 5 80 .00t 3 32 6.6 h 6.85 47 m
22 76.3 h 4 9 .4 30 m
16 .9 02 h 7 0 00.0 m
3 2 03.9h 21 0 .78 m 36 4 5.3 h 2 12 .38m

28 5.01 p 5 80 .00t
13 .7 17 p 5 30 .38t N
0 .0 000m . 35 40.5 h 7 .5 983m 0 .01 34 p 11 .2 93 t PKVB
33 94.4 h 2 65 .00m
Q 2 28 6.7 h 11 5 .55 m
2 0.6 31 p 38 0 .06 t F 0 .06 67 p 0.94 70 x 1 .00 00 p 8.43 38 t
3 20 3.9 h 6.41 22 m 2 44 3.3 h 4.90 42 m 3 5.5 22 h 14 0 00.m

KED1 32 48.7 h E 1.77 96 p 4.00 24 t

16 2.22 p 2 1 5.00 t 1.6 7 69 m
E 0.2 3 83 p 0 .99 66 x 16 .9 91 h 14 000.m
Q-ne tto 30 59.1 h P 26 08.6 h 5 .48 58 m KON 1
550.372 92 5.47 h 1 .7 0 00 m 10 .2 42 p 8 2 .341t
1.06 13 m
Q-gross 28 .9 45 p 1 9 4.38t 34 5 .51 h 1 3 0.94m DT=2.85 9
573.304 82 7 .79 h 2 1 7.98m
ETA-b oil
1 .7 7 96 p
0.96 000 M 1 6 .9 91 h
VK3
0.9 6 50 p 9 8 .638t 0 .0 1 34 p 1 1 .293t

32 7.18 p 2 98 .00t 41 3.32 h 0 .4 335m 4 7 .4 15 h 1 2 0.89m

13 2 .50 m . FV4 PKVA
13 17.6 h 2 65 .00m
FVT
10 .2 42 p
2 8.945p 35 0.03 h 1.00 00 p 4 .0 0 00 t
8 21 .70h
16 .9 02 h 7 0 00.0 m
13 44.7 h
2 96 7.3h
13 2.50 m PK7 PK3
0 .0 000m 95 .7 62 p 21 3.56 t
M 91 6 .55 h 1.60 00 m PK0 B PK0 A

1 .8 005p 1 16 .94t
1 3.0 00 p 11 .3 95 t 13 .0 00 p 11 .3 95 t
4 9 0.73h 1 92 .38m
4 9.1 03 h 60 .4 44 m 49 .1 03 h 60 .4 44 m 1.00 00 p 4 .0 0 00 t
G 16 .9 02 h 7 0 00.0 m
34 8.78 h
0.00 00 m

0 .0 000m 3
M
10 .6 45 p 6 1 .2 65t
M 30 .2 69 p 16 4.77 t 25 7.26 h 1 2 6.16m
69 7 .57 h 20 7.65 m
VK2
33 2 .72 p 29 2.56 t
12 9 0.4 h 26 5.00 m
10 .6 45 p 10 .6 45 p 6 1 .1 70t
25 6.86 h 1 2 0.67m 1 2.0 00 p 11 .4 18 t
26 6.01 h 49 .1 03 h
4 9.1 03 h 12 0 .89 m
PK2 0.00 00 m
PFVB

N
0 .0 000m .
26 4.68 h
26 .7 70 p 2 1 2.04t
77 .2 62 p 25 4.40 t PK4A PK4B 0.00 00 m
90 7.29 h 0 .0 0 00m
11 0 7.1 h 27 .7 35 m H
M M 11 .0 46 p 3 5 .7 00t
15 0.47 h 1 2 0.67m
31 .5 92 p 14 3.76 t
60 7 .02 h 20 7.65 m

VK5 6 .9 598 p 14 8.10 t 0 .06 46 p 3 7 .5 45 t

PFVA
33 4 .65 p 24 9.38 t 6 24 .10 h 6.9 5 89 m 1 57 .19 h 4 .9 0 42 m 1 2 .0 00 p 1 3 .561t
4 9 .103h
10 8 6.3 h 26 5.00 m 5 8 . 0 68 h 1 2 0.89m
1 6 2.22p 2 15 .00t 0 .0 000m
31 .5 92 p 14 3.67 t
9 2 5.47h 0 .8 500m
33 6 .28 p 2 1 8.70t
31 .5 92 p 60 6 .63 h 19 2.38 m N
61 1 .94 h
94 8 .83 h 1 3 2.50m

3 3 6.28p 21 8 .70 t PK5 8 4 .9 88 h

9 4 8.83h 13 2 .50 m
1 1.7 00 p 1 3 .5 68t 0 .0 0 00 m
5 8.0 68 h 1 2 0.67m

0 .00 00 m 9
0.00 00 m 2 58 .0 68 h 11 .5 00 p 1 3.572 t 0.000 00 5 8.0 68 h G
0.00 00 m 58 .0 68 h 1 20 .67 m Q-g ro ss 0 .21 46 m

M M M
0 .00 00 m . 3 36 .28p 2 18 .70 t
M
0 .0 000m 9 9 48 .83h 2 65 .00 m

33 .0 00 p 1 1 7.46t
49 5 .16 h 1 9 2.38m
St and.Terminals Thermodynamic unit s
I : Pri m lufo Press ure p B AR
J : Sec lufo Temperature t deg C
K : A ux st eam Enthalpy h KJ/ KG
L : Proc s team Massflow m KG/S
M : Cond drai n Dry ness x KG/K G

Fig. 1. Process calculation with Turabs What If

6.3 Turabs What If

By means of Turabs What If (TWI) it is possible to calculate how a unit operates. One of
the positive side effects of modelling the units is that it is possible to illuminate how a unit will
react in other operating situations, a model can for example show how much power can be
produced at the cost of heat production and thus enable pricing of the district heat production.

In the TWI application, control valves, pre-heaters, fouling factors and pumps can be activated
and specified according to request. It is of course also possible to change the model boundary
data and thus perform consequence calculations. Subsequently it is possible to print a report
containing the main data of the power station unit, and a number of service tools have been
developed which enable individual design of reports. Finally it is possible to generate a drawing
of the unit as shown in Fig. 1. The drawing is based on AutoCad® 2004 and includes calculation
data that are configured in a database.
Fig. 2. PQ operation area Fig. 3. Cv-values in plant operation area.

7. Architecture/design

The Turabs system is located at the internal priority network with the exception of the
actual Web portal, which is placed in an administrative network to ensure easy access. The Web
portal communicates through a firewall with a server centrally in the priority network. This server
is called the "broker" as it sees to the distribution of tasks in the priority network. Both these
central servers are doubled to ensure a high reliability. In addition an SQL server (InSQL®
server) is used for storage of data. At the local power stations are servers, which typically run the
local TOL application for the individual unit. The various Web services used to obtain or
possibly store data at the unit are also located on these servers. The IT infrastructure is shown in
Fig. 4.

7.1 Database structures

The online applications applies a Microsoft® SQL Server 2000 to store information from
the System. TOL stores input data and calculated data in the central InSQL® database as well as
the corresponding measured data for validation. The visual configuration of the Web portal is
also kept in the database. For TWI, input and output are stored, if required by the user. The TPQ
application is running one time every day and the corresponding data are stored for each unit
together with a set of default data.

7.2 Web portal

The basis for the design of a user-friendly interface has been to develop a system which
secures easy access to the system everywhere in the Elsam Group and with overall control of the
user access to the system. With the choice of a Web solution implemented at Elsam’s intranet
only Elsam’s employees have access to the system.
 Systemkonfiguration
TURABS 10.11.2003
Administrative Net
Turabs Klient

Mksblok3
Turabs Turabs ActiveFactory Studstrupværket
Webportal Webportal Terminal Server Blok 3+4
Turabs Klient
Redundant

Server
Kontrolanlæg
PIX Firewall
http Port

Mksblok4

Turabs Turabs Appserver

Websserver/Appserver Websserver/Appserver
Redundant
Server
Kontrolanlæg
Prioriteret Net

Turabs Databaseserver +
Central InSQL Database +
Webserver Enstedværket
Blok 3 Fynsværket
Blok 7
Nordjyllandsværket
Blok 3

Skærbækværket
Blok 3 Esbjergværket
Blok 3 Turabs Websserver/Appserver
InSQL IDAS Herningværket
Turabs Websserver/Appserver

Turabs Websserver/Appserver InSQL IDAS

Turabs Websserver/Appserver InSQL IDAS Turabs Websserver/Appserver InSQL IDAS Websserver/Appserver InSQL IDAS

PIX Firewall PIX Firewall PIX Firewall PIX Firewall PIX Firewall Textbaseret Seriel
Suitelink + OPC Trafik Suitelink + OPC Trafik Suitelink + OPC Trafik Suitelink + OPC Trafik Suitelink + OPC Trafik Kommunikation /
Procom Plus

Siemes OPC Server ABB OPC Server ABB OPC Server Siemes OPC Server ABB OPC Server

Kontrolanlæg /
Teknisk Net

Siemes TXP System

Siemes TXP System ABB PlantConnect System ABB PlantConnect System Siemes TXP System ABB PlantConnect System

Fig. 4. IT-infrastructure

It is possible to navigate from the TOL, TWI and TPQ applications by means of a map with
hotspots or it is possible to navigate via control bars to a TOL side where TOL can be reached for
each unit. There are similar possibilities concerning TWI and TPQ where it is possible to
navigate to the individual units. An online forum has been established where the users can
communicate with advanced users of the system or they can express their approval/disapproval of
the system or simply share their experience with the system.

Online data maintenance is a system that enables the advanced users to perform online
adjustments of the off-design model without having to shut down the portal. The advanced users
can also adjust the layout of the reports on basis of a TWI calculation. Data can be added or
removed from the report as requested.

8. Future

The Turabs system was implemented by the end of 2003 with a satisfactory trial operation
period in December 2003.

An online monitoring system gives great perspectives and a formalised cooperation has
already been initiated with the involved units concerning a training programme which will ensure
that the operating personnel is able to convert their knowledge of the system into improved
operating results. A precondition for success is a well-founded cooperation with the operating
personnel. The goal is to reach a payback time for the system of less than one year.

A number of new initiatives are in the foundry concerning modelling of boiler plants. The
component library of Turabs is to be extended also to include complex boiler and furnace
components to enable modelling of complete boiler plants including water/steam circuit and the
actual combustion process by convective transport of flue gas in the flue gas ducts of the boiler.
The aim is for Elsam Engineering to establish a pilot project focusing on expanding the online
model of SSVB3 with a complex boiler model. With access to all measuring data relating to the
boiler plant we have be best preconditions for modelling the boiler in a realistic way and
optimising both the water injection and flue gas recirculation.

9. Conclusion

The Turabs project has in many ways been groundbreaking. First of all it has contributed to
the accumulation in the Elsam Group of extensive and detailed process knowledge of Elsam’s
main units; knowledge that is further maintained in advanced mathematical models. At the same
time a unique system has been established for Elsam from where online plant data can be
retrieved from the units by means of open standardised protocols. Furthermore a database has
been established in the project where historical data are stored for analyses and other advanced
use such as data mining; and the project has laid the foundations for the creation of the priority
network which is the cornerstone in the IT architecture over which Elsam’s technical IT-systems
will be built in the future. Turabs is a part of Elsam’s strategic optimisation tool and will over
time increase the efficiency of the power plant units and be a main supplier of data to Elsam’s
global plant optimization tool. Corresponding simulated PQ diagrams provide Elsam with a
continuous picture of fuel amount and Cv-value within the operating areas of all seven power
stations, which enable optimisation of the mutual operation of the power station units. The TWI
applications are a decision tool for plant operators and the TOL applications optimise the cooling
water flow and calculate online Cv-value for pricing the district heat production. Having in mind
that the TOL application is a picture of an ideal trimmed power plant, with respect to fouling
factors, pre-heaters and turbine blades, the application will be used for online performance
analysis. Time series of measured and calculated parameters can be evaluated and if/when major
deviations occur, there is time for action.

Literature
[1] Numerical Recipes. The Art of Scientific Computing (Fortran Version), 2nd edition,
Cambridge, University Press. ISBN 0 521 38330 7.

[2] Numerical Methods for Unconstrained Optimisation and Nonlinear Equations, J. E. Dennis Jr.
and R. B. Schnabel, Prentice Hall Series in Computational Mathematics 1983. ISBN 0-13-
627216-9.

[3] Baehr & Diederichsen, Berechnungsgleichungen fuer enthalpie und entropie der komponen-
ten von luft und verbrennungsgasen, BWK bd 40 1988 nr 1/2 - januar/februar.

[4] Moelbak T. (2003). Integrated model based optimisation of a power production system.
Proceedings of ECOS 2003 Copenhagen, Denmark.