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Power Optimization CenterLeveraging plant process data for advanced analytical diagnostics

June 16, 2016

POWER OPTIMIZATION CENTER: OVERVIEW

Jamie Dugan

Equipment Reliability Manager

Mike Batte

Fleet Performance Manager


Power Optimization Center Overview Video

11Masters

19Bachelors

2PhDs

8PEs

17Engineers

> 650 yearsCombined Operations and

Technical Experience

12 Experienced Control

Room Operators

4MBAs

25 Operations, Equipment, Performance and IT

Subject Matter Experts

500,000+Current Points Monitored

26,686Log Entries

36Open Log Entries

158Issues in Tracking

POWER OPTIMIZATION CENTER: BY THE NUMBERS

$178MM


Optimization from 24/7 Emergent Issue Identification

and Notification

• Optimal, targeted maintenance spending

• Critical Equipment Reliability

• Protect Unit Reliability

Cost Reduction and Increased Efficiency

• Decreased Maintenance Costs

• BTU/kWh Heat Rate Improvement

• Annual Fuel Savings

• Reduce Emissions (from reduced fuel consumption)

ASSETS AND SYSTEMS MONITORED BY THE POC:

Mechanical Systems

Electrical Systems

Performance Models

• Circulating Water Pumps

• Condensate / Condensate Booster Pumps

• Feed Water Heaters and Drains

• Boiler Feed Pumps – Electrical and Turbine

• Heater Drain Pumps

• Electro Hydraulic Control Pumps

• High Pressure and Low Pressure Turbine

• Generator / Exciter

• HVAC Fans, Chillers, and Coolers

• Air Preheaters

• Draft Equipment

• Pulverizers

• Absorbers

• Scrubbers

• Electrostatic Precipitators

• SCRs

• Combustion Turbines

• HRSGs

• Reactor Coolant Pumps

• Recirculation Pumps

• Jet Pumps

• Centrifugal Charging Pumps

• Service Water / Closed Cooling Water


Mechanical Systems

Electrical Systems

Performance Models

• Main Power Transformers

• Station Transformers

• Unit Transformers

• Main Generator & Exciter

• Control Rod Drive MG Sets

• Recirculation MG Sets and ASDs

• Diesel Generators



APR Modeling

Thermal Performance Modeling

Start Up Reviews

Coast Down Reviews

POWER OPTIMIZATION CENTER: Operational Levels of Defense

Statistical-Based Alarm

Rate of Change Alarm

Identify Long-Term Equipment Issues

Identify Process Changes

Identify Emergent Equipment Issues

Identify Faulty Instrumentation

Long to Near Term Response Time



Extended Response Time



Near Term Response Time

Control Room AlarmCrisis Control

Limited Response Time

Control Room

Shift Supervisor

Engineering Support

Control Room

Shift Supervisor

Engineering Support

Engineering Support

Plant Management

POWER OPTIMIZATION CENTER: Operational Levels of Defense E

quip

ment C

onditio

n

Time

OK

F (=Functional Failure)

P (= Potential Failure)The P-F Curve

Mechanical Systems

Electrical Systems

Performance Models



• Thermodynamic

• Feed Water Heaters

• Main Condenser

• Pumps

• Boilers

• Air Preheaters

• Combustion Turbines

• Compressors

• Heat Exchangers

• HRSG

POWER OPTIMIZATION CENTER: Thermal Performance Improvement

• Base Line Assessment

• Cycle Isolation

• Daily monitoring

• In-depth Reviews

• Prioritized Improvement

• Heat Rate Awareness

• Targeted O&M Repairs

• Efficient Capital Spend

Cost Reduction and Increased Efficiency

• Decreased Maintenance Costs

• BTU/kWh Heat Rate Improvement

• Annual Fuel Savings

• Reduce Emissions (from reduced fuel consumption)

BTU/kWh Heat Rate Improvement Program Elements:

POC assists in reducing yearly O&M costs by:

OPERATIONS SUPPORT

FLEET SUPPORT

THERMAL PERFORMANCE

EQUIPMENT RELIABILITY


• Emergent issue identification providing

Actionable Intelligence 24/7

• Automated notifications

• Foster relationships with Operations, Engineering,

Maintenance, and Plant Management

• Deployment and maintenance of Advanced

Pattern Recognition asset models

• Identification and tracking of instrument issues

• Coast down and Startup reviews

• Equipment Reliability Monitoring and Consultation

• Thermal Performance Assessment

• Heat Rate Review

• Maintenance of Thermal Performance Tool

• Unit Startup and Monthly In-Depth Review

• Online Cycle Isolation Monitoring

• Thermal Performance Monitoring and Consultation

• Monthly cost avoidance report

• Monthly review with Fleet support organization

• Fleet Watchlist

• Track all identified issues to closure

• Knowledge transfer across Fleet

• Course of Action Program


Human Capital (PLU)

Robust 24x7 Service

Monitoring

Service is

Primary Focus

Complete Operations

Package

Proprietary Process

• “People Like Us” – POC is staffed by experienced plant operators/engineers that deliver

Actionable Intelligence

• Relationship with Control Room

• All 24x7 monitoring is done within POC as compared to supplementing international support or

other limited service ability

• POC provides proactive identification and notification of generation critical issues

• POC has developed formal protocols and procedures for responding to emergent issues through

years of operations

• These processes serve as a vehicle to deliver immediate actionable intelligence for customers

• Continuous improvement process in place for knowledge transfer

• POC offers a complete monitoring package for multiple types of plant (Coal, Gas and Nuclear)

• Future expansion into renewables

WHAT MAKES THE POC SUCCESSFUL YEAR AFTER YEAR?

POWER OPTIMIZATION CENTER: SUCCESS STORIES


Primary Air FanComponent


Primary Air Fan

High Vibration

Component

POC Indication


Primary Air Fan

High Vibration

Plant notification and subsequent investigation

Component

POC Indication

Action Taken


Primary Air Fan

High Vibration


Added oil, replaced bearing during planned outage

Component

POC Indication

Action Taken

Corrective Action


Component Main Power Transformer


Component

POC Indication

Main Power Transformer

High Winding Temperatures

0

100

200

300

400

500

0

20

40

60

80

100

120

Winding Temperature Gross Load


Component

POC Indication

Action Taken





Component

POC Indication

Action Taken

Corrective Action




Cooling pumps and fans returned to service


Component Forced Draft Fan


Component

POC Indication

Forced Draft Fan

Reservoir Level decrease

4

4.5

5

5.5

6

6.5

7

1 5 9 13 17 21

Reservoir Level


Component

POC Indication

Action Taken

Forced Draft Fan


Contacted plant control room


Component

POC Indication

Action Taken

Corrective Action

Forced Draft Fan



Dispatched operator, corrected level


Component Bowl Mill Motor


Component

POC Indication

Bowl Mill Motor

Bearing temperature increase

0

20

40

60

80

100

120

140

160

180

200

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73

deg

F

Motor OB Bearing Temp


Component

POC Indication

Action Taken

Bowl Mill Motor




Component

POC Indication

Action Taken

Corrective Action

Bowl Mill Motor



Plant dispatched operator, removed mill from service


Component Turbine Drain Valve


Component

POC Indication

Turbine Drain Valve

Turbine High Backpressure

10,100

10,200

10,300

10,400

10,500

10,600

10,700

10,800

10,900

11,000

11,100

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

Condenser Backpressure Unit Heat Rate


Component

POC Indication

Action Taken

Turbine Drain Valve




Component

POC Indication

Action Taken

Corrective Action

Turbine Drain Valve


Controller restored to automatic operation



Component Main Steam System


Component

POC Indication

Main Steam System

Cycle Isolation Losses

0

100

200

300

400

500

600

9,600

9,800

10,000

10,200

10,400

10,600

10,800

11,000

11,200

Unit Heat Rate Gross Load


Component

POC Indication

Action Taken

Main Steam System


Prioritized cycle isolation valve list provided


Component

POC Indication

Action Taken

Corrective Action

Main Steam System


Prioritized cycle isolation valve list provided

Valves repaired during outage


Component Feedwater Heaters


Component

POC Indication

Feedwater Heaters

Turbine Cycle Heat Rate Increase

0

5

10

15

20

25

30

35

40

1 50 99

BT

U/k

Wh


Component

POC Indication

Action Taken

Feedwater Heaters


Plant notification and investigation


Component

POC Indication

Action Taken

Corrective Action

Feedwater Heaters


Plant notification and investigation

Vented Feedwater Heaters


Component Circulating Water Pump


Component

POC Indication

Circulating Water Pump

Lower than expected backpressure

2.5

3

3.5

4

4.5

5

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57

Backpressure


Component

POC Indication

Action Taken



Investigation and recommendation


Component

POC Indication

Action Taken

Corrective Action



Investigation and recommendation

Secured one Circulating Water Pump


Component POC Indication

Primary Air Fan High Vibration

Main Power Transformer High Winding Temperatures

Forced Draft Fan Oil Reservoir Level Decrease

Bowl Mill Motor Bearing Temperature Increase

Turbine Drain Valve Turbine High Backpressure

Main Steam System Cycle Isolation Losses

Feedwater Heater Turbine Cycle Heat Rate Increase

Circulating Water Pump Lower than expected backpressure

POWER OPTIMIZATION CENTER: SUMMARY

Cost Reduction

Increased Efficiency

Reduced Emissions

24/7 Actionable Intelligence

Subject Matter Experts

Continuous Improvement

power optimization center - etouches optimization center: ... bowl mill motor ... controller...

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