lifecycle automation solution for power plants · 2020. 11. 5. · dcs and scada, bms, turbine...

Lifecycle Automation Solution for Power Plants

Satyendra Dubey12th December 2008

Honeywell Proprietary

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2Document control number

Structure and Key Message

• Key Challenges• New approach• Operations readiness• Business readiness

– Operations effectiveness– Production optimization

• Lifecycle improvement• Summary & Benefits

Holistic view of IT & Automation solutions to support operationsand business readiness delivers benefits at no extra cost

As opposed to point solutions for performance upgradation

Holistic view of IT & Automation solutions to support operationsHolistic view of IT & Automation solutions to support operationsand business readiness delivers benefits at no extra costand business readiness delivers benefits at no extra cost

As opposed to point solutions for performance As opposed to point solutions for performance upgradationupgradation


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Key Challenges

• Key risk factors with new project– Over budget– Schedule slippage

• Capacity utilization and efficiencies during operations– Poor handover (incidents and equipment failures)– Sub-optimal operations once commissioned


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Safe & Secure Environment

New Paradigm

DCS/Field on Cost & Schedule

Traditional

1D Mindset:• Project Centric (Cost, Schedule, Risk)

3D Strategy:• Project Focus (Cost, Schedule, Risk)• Ops Focus: Flawless Startup & 1st Yr Ops Focus• Business Focus Safety, Reliability, Efficiency

Operations Readiness

Business Readiness

New

THREA

TS

THREA

TS


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New Paradigm- How to achieve


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Manufacturers

Licensors

Process Design

Steady State Design Model

Dynamic Model

Operator TrainingModel

BTG BOP

Models for PADO

PADO

ProceduralOperations

Operations Readiness OperationsEffectiveness

Production Optimization

CollaborativeOperations

New Paradigm- How to achieve

FEED


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Typical Simulation Benefit Areas

• Design verification• Control system verification• Loop tuning• HAZOP Studies

Higher Operating Rate

Typical Start - Up

Faster Start - Up

Earlier StartPoint

Smoother Operation

Increased Profits

Project TimelineProject Timeline

Ope

ratin

g R

ate

Ope

ratin

g R

ate

• Start up / shut down procedure evaluation

• Operator Training

Faster Commissioning - >25% improvements reportedFaster Commissioning Faster Commissioning -- >25% improvements reported>25% improvements reported


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Lifetime of the PlantLifetime of the Plant

Avoiding AccidentsResponding to Upsets Identifying Malfunctions

Regain Capacity Faster

Less Downtime

No More Equipment Damage or Penalties

$

$$$

$$

Operating R

ateO

perating Rate

Upgrade Operator Skills


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Safety

Reliabilityxxxyyy

EnvironmentalCorrosion

Design

Process

Users of Limits

PVLO Alarm Limit

Procedures

Operating Alarms

Maintenance Rounds

Environmental Monitoring

PADO Limit

Joe Operator UserAlert Limit

Operational Target

Source of Limits

Location of Limits

Collaborative OperationsTypical ApproachTypical Approach


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MechanicalSafety Limits

Dependent Operating Variables

Independent Operating Variables

Environmental Limits

Operating Envelope

Operating Boundaries Form a Multi-Dimension Operating Window

Staying within the Safe and Reliable Operating Zone is key to Profitability

Operating Boundaries


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Alarm Limits

Operating Envelope

Planning Targets

The operating envelope changed but the planning targets didn’t – a potential

contributor to reliability problems

The operating envelope changed but the planning targets didn’t – a lost

chance to increase throughput

Operating outside of the planning range – some economic costs for

ineffective operation

Why? - Operating Envelope Management


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Analysis Diagnostics and Optimization

Plant Historian – e.g. PHD.

DCS and SCADA, BMS, Turbine Control

UnitPerformance

Optimizer

AdvancedTemperature

Control

Advanced Combustion

Control

MasterPressureControl

Simulation

Sensors and Field Solutions

Boiler StressEvaluator

Advanced PlantPerformance

Monitor

Advanced PlantPerformanceDiagnostics

HoneywellEnergy Solutions

Plant Performance

Optimizer

SootBlowing

Optimizer

CollaborativeManufacturing

KPIManagement


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TimeDesign & Implement

Maintain

$Loss of value with increasing maintenance costs

Major replacementproject

Revolution style upgradation curve


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TimeDesign & Implement

LCM

$ Increasing value with stable and known maintenance costs

Automation plan ofsmall projects, upgradesand technology refreshesIn line with original FEED

Evolution style upgradation


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Benefits-How to Get There

Traditional ProjectNew approach

Sustained BenefitsFaster

Startup

ReduceCAPEX

HigherProfitability

Earlier Breakeven

Proj

ect R

etur

n

FEED forAutomation

OperationsReady

OperationAssurance

Business Ready

Lifecycle Safe, Reliable, Efficient

EPC Design/Construct Owner/Operator Ramp-Up Performance Degradation

22% reduction in automation project cost2.5 days faster/process unitAvoid 20B$ in annual abnormal situations in the US alone

Proven benefits from PADOAnd evolution style upgradesBenefits thru collaborative

manufacturing


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SolutionsB

enefitsBenefits-How to Get There

Proj

ect R

etur

n

Design/Construct

• FEED Svcs• Simulation• AutomationEngineering tools

•Single point accountability•Integrated solution•Reduced engineering• Improved design• Reduced cost

Startup

• OTS• ASM• Proc Ops• Round Automation

•Faster/more consistent startups•Trained operators•Accelerated checkout

Optimize

•Collaborative manufacturing•KPI management•ERP Integration•PADO

•Accelerated deployment of PADOFaster benefitsImproved Asset AvailabilityFull Production Sooner

Operate

• Integrated Support Contracts•Remote Performance Monitoring Services

•Increased Throughput•Sustained Benefits•Improved Production Agility•Real Time KPI Monitoring•Improved Decision Making•PADO Maintenance

Same set of solutions with FEED & standardization

lifecycle automation solution for power plants · 2020. 11. 5. · dcs and scada, bms, turbine...

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