IT-1 Energy

•CBS: Condition Based Sootblowing - Software

Benefits

IT-1 Energy's CBS Software is the most cost effective intelligent soot cleaning control system available. Through our the state of the art thermodynamic software models we can interface with any sensor array to track and calculate boiler heat transfer deterioration in real time, 24/7 in a large number of boiler tubes simultaneously and with the finest detail heat transfer mapping available in the market.

The cost reduction is achived through, decreased CO2 emissions, a reduction in tube erosion, increased efficiency, early detection of clinker build up, a reduction in shutdowns.
Descriptions
- The Software is proven to be reliable, and user friendly, with complete technical support.
- The CBS Software is online and remotly accessable & supported for troubleshooting and system tuning.
- The CBS Software uses a PLC based, open architecture, control system which seamlessly interfaces with the plant’s DCS
- CBS Software models adjust in real time to:
  - Burner configuration.
  - Differnet coal mill grades.
  - Boiler corner protection.
  - Variable power output.
  - Flue gas tempreture.
  - High spray water activation.
  - Energy mass flow.
Total calculated savings, $2.8 million per year.

•BOILER EFFICIENCY IMPROVEMENT

Benefits
- The CBS Software directly monitors heat transfer throughout the entire boiler. Soot cleaning is executed where heat transfer is not performing as expected.
- The CBS Software thermodynamic models & real time monitoring algorithms, developed through 8 year of extensive experimentation in situ at Flinders Power Partnership in Port Augusta.
- 2 years in production allows the CBS software to automatically adjust to different conditions.
- CBS Software models adjust in real time to:
- Variable power output.
- Flue gas tempreture.
- High spray water activation.
- Energy mass flow.
Descriptions
There are boiler efficiency benefits due to the following:
- Coal consumption reduced
- Capacity factor increased
- Variable production cost reduced including reduced mill throughput and maintenance
- Design heat transfer capability achieved for each heat exchanger in the steam water cycle
- Reduced NOx and CO2 emissions due to optimal heat transfer in the steam water cycle
- Reduced soot cleaning steam consumption
- Reduced Main and Reheat spray flows due to optimal heat exstraction from combustion gases
- Improved Steam Temperature Control (operation closer to set point for longer periods) with reduced pressure part life consumption due to creep damage
- Increased unit capacity on poorly designed boilers due to optimal heat transfer at each steam/water heat exchanger
- Reduced costs paid in carbon tax.
Results:

Efficiency improvement was monitored on line and improvement based by IT-1's observation of data from production was 0.5% improvement
- Fuel cost saving per year: 200MW x 8,000h x 0.30 $/MWh = $480,000
- CBS Software is providing possibility for adjusting to any power output production requirement and optimum regime of operation in regard to fuel /coal consumption/CO2 emission versus tube erosion by controlling soot build up using continuous instrumentation data analysis and heat transfer deterioration calculation. By that minimum required soot blowing activation is required and as consequences minimum erosion is expected.

•TUBE EROSION REDUCTION

Benefits
- The CBS Software activates and controls cleaning devices and targets the areas where soot builds up, correlated to the measurements and calculations of the detailed mapping of the heat transfer.
- The CBS Software enforces a minimum time window in which consecutive soot cleaning can be executed. This rule is enforced in both manual and automatic mode.
Descriptions
Erosion reduction benefits due to the following:
- Erosion due to frequent unnecessary soot cleaning is eliminated.
- Soot buildup cleaning costs reduced.
- Planned shut down repair costs reduced.
- Forced outage repair costs reduced.
- Revenue increased due to increased capacity factor.
- Improved investor confidence as plant availability and reliability is increased.
- Improved confidence in plant expenditure forecasts.
Shutdown benefits due to the following:
- Material and labour costs reduced.
- Number of forced outages per year due to erosion reduced.
- Reduced fuel oil costs for boiler restart following a forced outage.
- Reduced cost of materials (tubes) and labour for tube erosion.
- Years between planned shutdowns potentially increased subject to other compliance requirements.
- Increased revenue due to improved capacity factor.
- The software can predict shutdowns.
Erosion - time loss of production

Total calculated cost of loss in production revenue was $2,135,040

Note: not included is the cost of repair

•CLINKER FORMATION REDUCTION

Benefits

CBS software early clinker detection provides opportunity for early corrective actions and reduced costs of shut downs as a result of clinker build up.
Descriptions
Clinker prevention benefits due to the following:
- Number of clinker events per year reduced or even eliminated
- Days of production loss reduced due to increased boiler availability
- Forced outage costs reduced
- Avoidance of severe tube damage due to clinker removal using explosives or other aggressive mechanical means
- Revenue increased due to increased capacity factor
- Reduced outage costs due to early detection of furnace clinkers using automated alarms
- Operator stress reduced from not having to closely monitor furnace clinker formation.
Results:

For example, shrinking of boiler is only conducted when necessary.

Clinkers shut down loss of production:

A total calculated saving of $533,760.00

•SEMI AUTOMATIC & AUTOMATIC OPERATION

Benefits
- Through automatic sequencing, the CBS Software ensures consistent soot cleaning operation regardless of the operators on duty.
- At the same time, CBS Software offers complete flexibility to operators to request a soot cleaning operation at anytime.
Descriptions

The CBS Software is capable of executing the soot blowers automatically with or without operator’s intervention (as per configuration).

In addition, operators can manually request the CBS Software to populate the list of soot blowers to be activated based on the most recent data.

Results:

With automatic mode, CBS Software ensures no soot blowing will be missed and hence is capable of maintaining the plant at its highest efficiency.

CBS Software also completely eliminates the need for operator to manually populate soot blower for its execution sequence. Through semiautomatic mode, operator through a single click, will be able to request CBS Software to perform its analysis and populate the soot blowers which required execution most. This ensures all benefits provided by CBS are preserved even if manual intervention is required.

IT 1 Energy - CBS SOFTWARE

CBS-Software

•CBS: Condition Based Sootblowing - Software

•BOILER EFFICIENCY IMPROVEMENT

Results:

•TUBE EROSION REDUCTION

Erosion - time loss of production

•CLINKER FORMATION REDUCTION

Results:

•SEMI AUTOMATIC & AUTOMATIC OPERATION

Results:

Note on results:
CBS Software benefits are calculated based on AEMO electricity pricing data and the number of shut downs in Flinders Power Partnership in Port Augusta as well as observing operational data from before and after installation up to the present time.

IT-1 Energy

IT 1 Energy - CBS SOFTWARE

CBS-Software

•CBS: Condition Based Sootblowing - Software

•BOILER EFFICIENCY IMPROVEMENT

Results:

•TUBE EROSION REDUCTION

Erosion - time loss of production

•CLINKER FORMATION REDUCTION

Results:

•SEMI AUTOMATIC & AUTOMATIC OPERATION

Results:

Note on results:CBS Software benefits are calculated based on AEMO electricity pricing data and the number of shut downs in Flinders Power Partnership in Port Augusta as well as observing operational data from before and after installation up to the present time.

IT-1 Energy

Note on results:
CBS Software benefits are calculated based on AEMO electricity pricing data and the number of shut downs in Flinders Power Partnership in Port Augusta as well as observing operational data from before and after installation up to the present time.