Software for Modeling & Problem Analysis

1. Software for Modeling & Problem Analysis

2. AEP Participants: • Chao Lin • Charles Olsen • Bill Reinhart • Tom McCartney

3. Discussion Topics: • Computational Fluid Dynamics (CFD) analysis • Finite element analysis • Heat balance analysis • Reliability analysis

4. CFD Analysis • CFD analyses are done both in-house and contracted to outside vendors • AEP uses FluentTM software • CFD useful for designing modifications and enhancements to improve unit performance

5. CFD Analysis Example – Dam Spillway • Ran 2-Dimensional model to estimate trajectory of water to assure no erosion impact on surrounding soil • Ran as transient, allowing water level to rise until the height of water over the spillway approximated a worst-case postulated scenario

6. CFD Analysis Example – Dam Spillway

7. CFD Analysis Example – Ash Collection • Muskingum River Unit 5 has problems with large ash particles plugging SCR catalyst plates. • This has resulted in forced outages to clean the catalyst plates, which impacts NOx emissions and energy revenues • Ran CFD analysis to assess effectiveness of adding hoppers in the ductwork

8. CFD Analysis Example – Ash Collection

9. CFD Analysis Example – Ash Collection

10. CFD Analysis Example – Ash Collection

11. Finite Element Analysis • FE analyses are done both in-house and contracted to outside vendors • AEP uses ANSYSTM software • FE useful for designing modifications and assuring we are operating equipment within design limits

12. FE Thermal Analysis Example – Cook Nuclear Plant Thermal Barrier

13. FE Thermal Analysis Example – Cook Nuclear Plant Thermal Barrier

14. FE Stress Analysis Example – Mitchell Unit 2 Flow Accelerated Corrosion in Feedwater Pipe

15. FE Modal Analysis Example – Cardinal Unit 3 Economizer Tube Vibration

16. FE Modal Analysis Example – Cardinal Unit 3 Economizer Tube Vibration

17. Heat Balance Analysis • Many heat balance analyses done in-house • AEP uses ThermoflowTM and PEPSETM software • Heat balance analyses include existing and new units • Evaluate equipment upgrades • Evaluate savings from modified operation • Optimize design of heat cycle

18. Heat Balance Analysis – Control Valve Upgrade • The control/stop valves on the AEP 1300 MW series units have a higher than design pressure drop. • Used PEPSETM to estimate heat rate improvement, generation gain for replacement valves with lower pressure drop. • Installation of replacement valves improved heat rate by 17 kJ/KWH

19. Heat Balance Analysis – Control Valve Upgrade • Installation of replacement valves improved heat rate by 17 kJ/KWH • Efficiency improvement enhanced generating capability by 3.8 MW • Decreased pressure drop improved generating capability by 28.1 MW, for a total of 31.9 MW

20. Heat Balance Analysis – Other Examples • Evaluate turbine rotor design upgrades • Evaluate steam generator performance with different fuel blends • Evaluate improvements in startup steam utilization • Run heat balance model to evaluate reasons for off-design unit performance

21. Reliability Analysis • RaptorTM operations analysis software • Simulate reliability of power plant systems • Model reliability and cost effects of preventative maintenance, installed spares, equipment failures, etc. • Model failed components that cause other components to fail