Power Optimization Center
Transcript of Power Optimization Center
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
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
POWER OPTIMIZATION CENTER: OVERVIEW
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
POWER OPTIMIZATION CENTER: OVERVIEW
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
POWER OPTIMIZATION CENTER: OVERVIEW
ASSETS AND SYSTEMS MONITORED BY THE POC:
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
Identify Emergent Equipment Issues
Identify Faulty Instrumentation
Extended Response Time
Identify Emergent Equipment Issues
Identify Faulty Instrumentation
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
POWER OPTIMIZATION CENTER: OVERVIEW
ASSETS AND SYSTEMS MONITORED BY THE POC:
• 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
POWER OPTIMIZATION CENTER: OVERVIEW
• 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
POWER OPTIMIZATION CENTER: OVERVIEW
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 Fan
High Vibration
Plant notification and subsequent investigation
Component
POC Indication
Action Taken
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Primary Air Fan
High Vibration
Plant notification and subsequent investigation
Added oil, replaced bearing during planned outage
Component
POC Indication
Action Taken
Corrective Action
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Main Power Transformer
High Winding Temperatures
Plant notification and subsequent investigation
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Main Power Transformer
High Winding Temperatures
Plant notification and subsequent investigation
Cooling pumps and fans returned to service
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Forced Draft Fan
Reservoir Level decrease
Contacted plant control room
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Forced Draft Fan
Reservoir Level decrease
Contacted plant control room
Dispatched operator, corrected level
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Bowl Mill Motor
Bearing temperature increase
Contacted plant control room
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Bowl Mill Motor
Bearing temperature increase
Contacted plant control room
Plant dispatched operator, removed mill from service
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Turbine Drain Valve
Plant notification and subsequent investigation
Turbine High Backpressure
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Turbine Drain Valve
Plant notification and subsequent investigation
Controller restored to automatic operation
Turbine High Backpressure
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Main Steam System
Cycle Isolation Losses
Prioritized cycle isolation valve list provided
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Main Steam System
Cycle Isolation Losses
Prioritized cycle isolation valve list provided
Valves repaired during outage
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Feedwater Heaters
Turbine Cycle Heat Rate Increase
Plant notification and investigation
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Feedwater Heaters
Turbine Cycle Heat Rate Increase
Plant notification and investigation
Vented Feedwater Heaters
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Circulating Water Pump
Lower than expected backpressure
Investigation and recommendation
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Circulating Water Pump
Lower than expected backpressure
Investigation and recommendation
Secured one Circulating Water Pump
POWER OPTIMIZATION CENTER: SUCCESS STORIES
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