Electric Power Research Institute About Us
The Institute
Office Locations

2016 Corporate Social Responsibility Report

EPRI completed a full corporate social responsibility assessment in 2015 culminating in release of its first Corporate Social Responsibility report. The report (and companion video) provides a comprehensive look at EPRI's social responsibility culture and actions around four focus areas: community, employees, operations, and research.

Our Work Events Newsroom Careers EPRI Journal

Product Abstract

Statistical Use of Existing DCS Data for Process Optimization

Product ID:1016494
Date Published:21-Aug-2008
Pages:64
Sector Name:Generation
Document Type:Technical Results

This product is available at no cost to funding members only. If you are a member, you must Log in to access.

Price:$ 4,750 (US Dollars)

If you are a non-funding individual or entity and wish to purchase this document, please contact the EPRI Order Center at 1-800-313-3774 Option 2 or 650-855-2121. You may also send an e mail to orders@epri.com.

Abstract
This report demonstrates the way in which historical data describing normal and abnormal operations of cyclone furnaces can be leveraged for furnace optimization. The project centered around the optimization of cyclone barrel temperatures for all seven cyclones of Unit 4 at Alliant’s Edgewater Generating station in Sheboygan, Wisconsin—a late-1960s vintage 340-MW variable-load cyclone-fired unit.

Objective

The purpose of this project was to demonstrate effective methods for leveraging the large amount of information that is stored in historical databases, recording often minute-by-minute values of hundreds of parameters describing the operation of the boilers. Using historical data and existing control technology (for example, digital control systems (DCS)), operations can be fine-tuned and optimized to achieve significantly better operations without the need to undertake expensive engineering projects.

Approach

Approximately nine months’ worth of 6-minute interval operational data describing coal flows, loads, and primary, secondary, and tertiary air flows as well as cyclone flame temperatures—more than 140 parameters in all—were extracted for the project. After careful data cleaning and validation to remove erroneous and unreliable data points, various nonlinear (data mining) modeling algorithms were applied to the data, followed by specialized optimization algorithms. These algorithms were intended to achieve robust cyclone barrel flame temperatures with smaller than historical variability and generally higher cyclone barrel flame temperatures, with which fewer slagging and other reliability- and emissions-related issues are expected.

Results

The results show that the data analysis and optimization methods effectively identified specific ranges for a relatively small subset of operational parameters. Significantly improved and stable operations resulted for all cyclones.

Application, Value and Use

These methods provide a way to achieve cost-effective and “realistic” (virtually immediately obtainable) boiler optimization given the existing data and control systems—without the need for further boiler modifications or hardware and/or software purchases—requiring only modifications to the parameters and “equations” guiding existing control system software.

EPRI Perspective

The methods described in this report for performance optimization can be expected to achieve robust performance so as to make key performance parameters (such as flame temperature, NOx, CO, and emissions) less sensitive to uncontrollable operational inputs and variability such as changes in fuel quality and variations in crusher or pulverizer performance. By applying these methods systematically to all critical systems of a unit (for example, systems for NOx reduction and overfire air), overall improvements in system performance and robustness can be expected.

Program
Program 71   Combustion and Coal Quality Impacts
Keywords
  • Digital control system
  • Process optimization
  • Cyclone boiler
Report
000000000001016494
Note

For further information about EPRI, call the EPRI Customer Assistance Center at (800) 313-3774 or email askepri@epri.com

 Having Trouble Downloading?

Internet Explorer Information Bar

If using Internet Explorer the browser automatically blocks downloads by default, instead displaying an "Information Bar" at the top or bottom of the page.

Click "Download File" on Information Bar if using Internet Explorer 8 or older. If using version 9, click “Save” button on Information Bar and then select “Open” once downloaded.

Pop-up blocker software

You can hold down the CTRL key when selecting Download to bypass your pop-up blocker.

You may also configure your pop-up blocker to allow EPRI.com to open new windows.

Recommended Software

EPRI recommends using the latest version of Adobe Reader for best performance.

 Support Services

EPRI Customer Assistance Center (CAC):
800-313-3774 or 650-855-2121 Option 4
askepri@epri.com

Hours of Operation:
8:00 AM - 6:00 PM Eastern Time (GMT-5)

Order and Conference Center:
800-313-3774 or 650-855-2121 Option 2
orders@epri.com