A simulation-based prediction model for coal-fired power plant condenser maintenance

Many coal-fired power plants (CFPPs) face special challenges such as ageing infrastructure, neglected equipment maintenance, and reduced funding. To assist with cost-effective decision-making, an integrated, semi-empirical thermohydraulic simulation model for a CFPP was developed. The model was calibrated with actual measurements to ensure accurate predictive maintenance schedules. This model was then integrated with economics and maintenance models. Such a fully comprehensive investigation could not be found in literature. As condensers have an important impact on maximum generation output, the simulation model was used to provide new insight into the cost implications associated with delayed or premature maintenance of a condenser. The results of the thermohydraulic simulation were verified against measured plant data and was within 5% error. The model was then utilised to determine the most efficient predictive maintenance schedule for the condensers of a 60 MW and 350 MW unit. Results showed that, when applying the new predictive maintenance schedule, considerable savings can be realised. When extrapolated to the entire South African power utility fleet, the potential savings are over R900 million(1) (USD 63 million) per annum. The most important contribution of this paper is that the approach described here can be used to investigate the effect on plant performance and economic viability of any change to any component in any CFPP in a truly industrial scenario.