improving power plant availability and reliability …€œwith our great success on the turbine...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Improving Power Plant Availability and Reliability Utilizing PlantPAx

Clark Weaver & Bud Blankenship Wood Group Business Development November 5 & 6, 2012


Agenda

Results

Solution

Problem Statement

Situation Overview

Wood Group Introduction

Hawaii Electric Light Company, Inc. (HELCO) Keahole Plant, turbine controls upgrade and

combined cycle expansion project


Presentation Overview

Case study highlights: Hawaii Electric Light Co, Inc., Keahole Plant Rockwell Publication ELPVP-AP010A-EN-P – January 2012

Power generation application with unique requirements

Multi-phase project 1. Retrofit – aeroderivative turbine control 2. New Construction – combined cycle balance of plant control

How the PlantPAx platform was configured to align with customer requirements

Customer feedback 3

What you’ll hear…


Wood Group Overview

4

Three Primary Business Units: Engineering PSN GTS

$6B sales

41,000 personnel

Operations in 50 countries

Global market leader in all three business units

Serving Oil & Gas and Power Industries Worldwide


Wood Group Worldwide Presence

5

Workshops

Offices

Offices & Workshops

Controls/Automation COE ‘s

Houston, TX

11 Global Execution Centers

Loveland, CO

Greenville, SC


Wood Group Controls & Automation

≈500 full time control system engineers

>3000 support multi-discipline engineers

>500 turbine control systems installed and operating

Thousands of Rockwell control systems installed and operating

Systems integrator of the year - 2010

Ranked No. 1 – System Integrator Giants

6

Capabilities and Experience


Situation Overview HELCO

Large distribution area Small customer base Customer demand/generation asset

mismatch Distribution challenges

Keahole Plant expansion Commercial 2002/2003 Base load generation (capacity) Qty. 2 - GE LM2500 aeroderivative

turbines (responsive) Voltage stability & frequency

compensation (distribution and load management)

Combined cycle expansion 2008

7

Keahole


HELCO Situation Overview

Equipment Antiquated at installation,1990 vintage controls LM2500

Woodward 503 Brush M/AVR Bently Nevada 3300 Wilson XYCOM

DCS Bailey Infi90

Water Treatment A-B PLC5

8


Situation Statement - TMR

9

OE Turbine Control Architecture

DEVICE INPUTS I/O MODULES PROCESSORS I/O MODULES DEVICE OUTPUTS


HELCO Problem Statement

Improve reliability of turbine controls Experiencing 50% downtime Must facilitate TMR I/O devices High integrity data storage for improved operations and maintenance

Self-sufficiency Supportable (software & hardware) by onsite staff with minimal off

island expertise

Flexible/expandable solution Capable of handling future combined cycle expansion and other

prime movers and potentially displace existing DCS

Large scope upgrade Significant amount of equipment needed to be upgraded

10


HELCO Decision Making Criteria Platform

Aeroderivative compatible TMR I/O capability? DCS/BOP capable Open communication capability Reliability

Local Supportability Open software, all native code and licenses Avoid proprietary/purpose-built hardware

Cost Effective Public utility scrutiny

Vendor Proven experience, project management, full capability

11


HELCO Decision Making Criteria

Simplex vs. Redundancy vs. TMR

12

TMR Redundant Simplex

Power Supplies

Processor

I/O Modules

Field Devices X X

X X


Solution – Turbine Control Upgrade

13

ControlLogix Controller

A

B

C

Flex I/O

A

B

Voltage Regulators

A

B

Vibration Monitoring

Local HMI

Plant Data and Alarm Servers A B A B Client Operator

Stations A B A B


Solution – Turbine Control System

Turbine System Highlights Simplex CPU Redundant networks throughout TMR I/O Redundant CGCM voltage regulators Redundant Entek vibration Custom I/O cable interfaces to reduce conversion downtime Custom discrete relay interface modules All electric fuel and water metering valve conversion CDP transducer upgrade Flame detection system upgrade Turnkey site services Redundant RAID servers (UDH, PDH) with redundant Ethernet

14


Results – Turbine Control Upgrades

15

“Turbine controls related downtime at the plant dropped from a high of

around 50% to less than a few percentage points annually since the

system upgrade. And when a rare controls problem does occur, it is

quick to troubleshoot and resolve without having to cross-reference

cryptic codes and acronyms.”

“With our great success on the turbine retrofit project, we knew we

wanted to utilize the PlantPAx system for plant-wide control as well.”


Solution - Combined Cycle Expansion

16 16

Operator Work Stations

B O P

HRSG

ACC GAS TURBINE CONTROL

STEAM TURBINE CONTROL

Ammonia Control

Engineering Work Stations

UREA Control


Solution – Combined Cycle Expansion

Improve uptime availability of the system

Cost effective solution

Minimize project risk

Minimize long-term operational risk

Minimize Total Cost of Ownership

17

Balance of plant controls - goals



Standardize on Rockwell and other design criteria Full integrated plant wide controls Turbine controls Balance of plant controls Panel design, power supplies, terminal strips, etc.

Maximized utilization of existing infrastructure

Migrated legacy standards to the newest technology

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Fully integrated team approach with BOP and turbine controls

Educated the client and EPC on capabilities of the Rockwell technologies to maximize long-term operating benefits

Execution of the BOP controls regionally to the EPC

Developed FAT and SAT processes which supported an on-time startup

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Results

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“Replacement parts are easy to obtain and cost-effective to keep in stock, and our staff is more than capable of identifying and solving any problems that arise, no matter where the problem may be located in the plant. In fact, they’ve been able to identify opportunities to optimize the system entirely on their own.”

“Since each island is an autonomous grid without interconnections to

neighboring utilities, we cannot rely on the outside world to keep the lights on. With the robustness and flexibility of the Rockwell Automation solution, we do exactly that.”


Keahole Plant Today

21

240 gigawatt-hours each year - almost one fourth of entire power generation capacity available on the island

“It’s been a really pleasant ride…” - Norman Verbanic - Superintendent of Power Generation, HELCO


Take Away’s…

Capability - demanding power generation application with unique requirements

Single platform - PlantPAx applicability from the most complex aeroderivative gas turbines to complete balance of plant controls

Configuration and functional flexibility - able to align with customer needs

Customer satisfaction

Case study highlights: Hawaii Electric Light Co, Inc., Rockwell Publication ELPVP-AP010A-EN-P – January 2012 (handout)

More in-depth discussion of purpose-built vs. open platform please see Wood Group white paper (handout)

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Questions

Clark Weaver & Bud Blankenship Wood Group Business Development November 5 & 6, 2012

improving power plant availability and reliability …€œwith our great success on the turbine...

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