Remote Monitoring and Diagnosis Centres-POWERGEN 2009.pdf

8/11/2019 Remote Monitoring and Diagnosis Centres-POWERGEN 2009.pdf

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REMOTE

MONITORING AND

DIAGNOSIS CENTRES

POWER-GEN Europe 2009, Colonia (Germany)

Ana Isabel Glvez, Fernando Mer ino, Franc isco Javier Saiz

Energy Technologies

INDRA Sistemas, S.A. (Spain)


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POWER-GENEurope2009,Colonia(Germany)

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Content

01 Introduction: Electrical Generation Environment

02 MDCs: Benefits, Functionalities and Work Flow

03 Systems: Information Management, Performance Monitor ingand Condition Monitoring

04 Conclusions

REMOTE MONITORING AND DIAGNOSIS CENTRES


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Content

INTRODUCTION

01 Introduction: Electrical Generation Environment02 MDCs: Benefits, Functionalities and Work Flow

03 Systems: Information Management, Performance Monitoringand Condition Monitoring

04 Conclusions


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1

Introduction

PRODUCTION COSTS:

Maintenance Unavailability

Fuel

Personnel

KEY ASPECTS TO MANAGE:

Increase availability

Minimize Maintenance costs

Reduce Fuel costs

Comply with emission targets

Asset Management

Decision-making process

INTRODUCTION


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Context of Power Generation

TechnologyDevelopment

Free market.Competition

Environment andStandards

Social constrains

Resource optimization.Services & ProductsOutsourcing.

Plan Plant Availability

Integration Operation Maintenance

New analysis Techniquesand tools

Management focusing on

margin Procedures standardization

Context of Generation Management Model

CONTINUOUS

PROCESS TOADAPT TO

THE CHANGE

INTRODUCTION


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Management of the Power Production

Performance

Staff

Maintenance

Outage planningAsset condition

Alerts Management

Fuel quality

Design

Manufacturers

Environment

PARAMETERS

Able to manage

Knowledge&

Applicatio

ns

PARAMETERS

Unable to manage

TECHNOLOGIC

SOLUTIONS

BUSINESSKNOWLEDGE

EXPERTISE

Integrated

Monitoring

Center

+

-

INTRODUCTION


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Content




04 Conclusions



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Allows an integrated management of the Fleet

Make use and promote the specialized knowledge of all the staff.

Maximize the value of the information and the tools.

Supports the O&M at the Power Plants

Facilitates benchmarking and unifications of practices.

Makes possible to anticipate to un-availabilities Modular conception and scalable which allows the step by step

implementation of functionalities.

Contribute to improve Fleet efficiency and flexibility

A Monitoring and Diagnosis Center integrates a human team with

tools aiming to technically support the management of Fleetexploitation in a coordinated way

Benefits of a Monitoring Center

MONITORING AND DIAGNOSIS CENTRES


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POWER-GENEurope2009,Co

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PLC, DCS

Plant Information System

Monitoring & Diagnosis Center

SimulationPerformance

Asset

Management

Data

acquisition

Fuel &

Combustion

Inf

ormationsha

ring

Information flow



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Architecture of a Monitoring Center

Local serverLocal user

Plant B

LANLAN

Plant A

Internet /

Intranet

Clientes Web

LAN

Remote DMC

WEB Servers

Local serverLocal user



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Remote

supervision

Qualified

persons

Plant usually does not have neither

resources nor time to analyze

daily data

O&M staff can plan in advance theinterventions (savings in

maintenance)Provide with supervision

equip. to the Plant

Operationparameters

Decision-making

PLANT OPERATION & MAINTENANCE

MDC

Validates & confirms diagnosis.Search possible solution

Quantifies the risk &economic impact

Assures information is right(no false indications)

Detects deviations or anomalies.Preventive diagnosis of failure

Process the information.

Actives alert status

Issues recommendations (necessityto actuate, maintenance frequency,

in order to avoid non-scheduledmaintenance)

Working flow of a MDC

PLANT



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Summary

MDC, MISION

Assure the optimalexploitation

Symptoms andsignals ofongoing failures

INPUTS

On-line Off-line

Solutions andrecommendationsfor:

Plant Management

Operation

Maintenance

OUTPUTS

Specialis

ts

Toolsan

d

system

s

A reliable decision-making process



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Content



03 Systems: Information Management, Performance Monitor ingand Condition Monitoring

04 Conclusions



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INTRODUCTION:

PI is a software tool that provides the ability to store all of our datain the same place, with high performance tools in order to show,

analyse and spread information in a useful way. Its main

characteristics are:

Plant Information Integration

Access to information in an arranged and transparent way to the differentphysical and logical origins.

Access to information from a single console (integration of the different usergraphical interfaces in the plant)

Real time database

Alarm management

Instant values analysis Long Term Historical Database

Quick access

High storage capacity

Subsequent incidence analysis

PI PLANT INFORMATION

PLANT INFORMATION (PI)


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Environment integration:

Process control and business network

Connection capacity with multiplesystems (more than 400 available drivers):

ABB (ABB Advant, ABB Accuracy, ABB Power

Systems, Bailey), Emerson Electric (Fisher-Rosemount,Intellution), ESCA, General Electric, Habitat,Honeywell (TPS, TDC3000, Measurex, PHD), Rockwell

Automation (Allen-Bradley) , Siebe IntelligentAutomation (Foxboro, Wonderware), Siemens,Westinghouse, Yokogawa etc.

Interconnection between process network

and Management network

Improves operation supportprocesses

Sends information to decision-making areas

Scalable




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Nueva Generadora del Sur (2004) Spain

Unin Fenosa Generacin (2004) Spain and Mexico

LNG SEGAS (2003) Egypt

LNG SAGGAS (2004) - Spain

Unin Fenosa Gas (2005) - Spain

Bizkaia Energia (2006) - Spain

INFI90 (ABB)

FREELANCE 2000 (ABB)

RTU's CORA (SAC)

FIX (Intellution)

RS3 (Rosemount)

Alpha (Telvent) SIMATIC S5/S7 (Siemens)

Teleperm XP(Siemens)

Mark VI (General Electric)

Advant (ABB)

Diasys (Mitsubishi)

Centum CS 3000 (Yokogawa)

Others

InterfacesReferences. Projects

INDRA IS AN INTEGRATOR WORLD-WIDE

PARTNER OF OSI-SOFTWARE




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Introduction

Performance Monitoring tools are systems aiming to calculatethe Key Performance Indicators: efficiencies, energy lossesand other facility condition indicators.

They are fed with the information coming from the process.

INDRA has agreements with suppliers of development tools for

performance monitoring systems in real-time.

Calculations of efficiencies, heat rate, energy losses and other key performance indicators

(based on ASME PTC codes and other standards) from process measures, gives a valuable

extra information of the equipment condition (maintenance) and the operation efficiency

(controllable losses)

PERFORMANCE MONITORING


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Fuel costs may mean up to 70 %of production costs

This percentage has sharply risenin the last few years for gas firedpower plants

Cycling and older plants are moresusceptible to efficiency losses

1% HR improvement is worthmore than $300,000 annually fora 300 MW unit based on:

Fuel Cost = 3 / million Btu

Capacity Factor = 30%

Why is important the surveillance of performance?

Deregulation Competition (Who gets

dispatched first)

Reduced power costs forspot sales

Profitability Heat rate is an important

part of a cost reductionprogram

Heat Rate is used toquantify the overall plantefficiency

Technology Company



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1

Uses

ON-LINE:

Surveillance of the equipment degradation through the evaluation offollow-up parameters

Detection of losses subject to be recovered (operation related)

Automatic reporting for following up the instrumentation, theequipments and the Facility.

Trends for performance and instrumentation data Predictive model self-calibration with actual data.

PREDICTIVE:

Evaluate the impact of upgrades or design modifications on anyparameter of the facility (generally electric power) maintaining theheat power

Obtain an expected value for the current conditions to be comparedwith the actual instrumentation data

Anticipate the electric power to be produced under othercircumstances



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Benefits

Detection of fuel quality impact on power output and heat rate

Detection of degradation impact in major components (compressors,turbines, air heaters, feed water heaters, etc). Usage for cost-benefitanalysis for maintenance repair schedule

Design modification analysis, based on predictive models, andhistorical data

Detection of operation problems (open valves, steam leakages, airin-leakages) based on on-line results

Optimization of performance recovery actions (like gas turbinecompressor wash), based on actual economical impact Detection of instrumentation malfunction: uncertainties, repetitive

and progressive errors (drift). Evaluation of spare parts life (like gas turbine air filters), and its

impact in performance data Performance Indicators for Performance-Based Maintenance

Programs

Automatic performance reporting, including results and deviationsfrom targets

Performance Monitoring is a key tool for continuous improvement policies in power plants.



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Modules

Data Reconciliation. On-line mass andenergy balances by solving thethermodynamic equations in order to obtainvalidated measures. The scope of thismodule depend on the tool we are using.

On-line Performance Calculations of keyperformance, degradation parameters andenergy losses (external- not controllable and,operational- potentially correctable) of everycomponent and the whole Facility.

What if Scenarios. Possibility to simulate,from an actual situation obtained by on-linecalculations, potentially new steadyconditions (calculations to extrapolate fromthe current situation).



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Display examples

Thermodynamic Plant Models for fossil-fired &

Combined Cycle Power Plant


O O O


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References

Coal fossil-fired Stations:Meirama (550 MWe)La Robla II (350 MWe)Narcea III (350 MWe)Anllares (350 MWe)La Robla I (270 Mwe)

Combined cycle Stations:Hermosillo (250 MWe)Jandar (Siria) (850 MWe)SET (Italia) (400 MWe)

Liquefaction Natural Gas (LNG) stations:Planta Regasificadora de Sagunto (750.000 Nm3/h)Planta Regasificadora de Mugardos (400.000 Nm3/h)



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CONDITION MONITORING


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Predictive Monitoring anticipates finding the

Needles in the haystack

Fuel nozzle wear/pluggingCompressor foulingAbnormal bearing temp/vib

Seal failureHydraulic degradationFaulty sensorOil starvation/drain pluggingCoolant lossAir in-leakageHeat exchanger fouling

Turn 1,000s of tags into value

Detects subtle changes inequipment behavior

Uses all available sensors,

not just vibration

Including non-rotating

equipment

Early detection provides more

time to react & plan, much earlier

than traditional threshold

alarming

What is the predictive monitoring?




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SmartSignal EPI*Center System contributes toincrease plant availability and to reducemaintenance costs

Incidents early warning, days, weeks or even months in

advance to trip Allows to move unplanned to planned unavailability

Reduces maintenance cost and duration

Allows repairs decisions taking based on actual equipmentstate (i.e. enlarge time between overhauls)

Prevents Plant shutdown, reducing equivalent operationhours

Benefits



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EPI*Center


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Main steam turbine

High, Med., and Low pressure

Lubrication and vibration

Generator

Stator cooling

Rotor cooling

Bearings

Gas Turbine

Combustion

Mechanic state Gas Path

Diesel Engine

Capacity for deviation detection




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Steam condenser

Feed water pumps

Turbo pumps

Motor pumps

Fumes circuit (Steam Generator)

Model of fouling

Forced ventilators

Induced ventilators

Circulation water pumps

Feed water heaters

Heat recovery Boiler

Capacity for deviation detection




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Empirical Model

RealEquipment

Analyst Reviews Confirms

Informs

Plant

FurtherDiagnostics

ProactiveMaintenance

Automatically Identifies Diagnostics Prioritizes

Analyst

Alerts

Regular Reviews

Architecture: exploitation of the model




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Monitored more than 350.000 MW of PowerGeneration

References

http://images.google.com/imgres?imgurl=http://www.netl.doe.gov/coal/combustion/FBC/images/9616w501.jpg&imgrefurl=http://www.netl.doe.gov/coal/combustion/FBC/APFBC/APFBCintro.html&h=281&w=450&sz=174&tbnid=StGVFkumQBEJ:&tbnh=77&tbnw=124&hl=en&start=1&prev=/images%3Fq%3Dgas%2Bturbines%26svnum%3D10%26hl%3Den%26lr%3D


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Content




04 Conclusions

CONCLUSIONS


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Conclusions

The recently available Remote Monitoring and Diagnosis Centres arebecoming a great opportunity to reduce Operation & Maintenancecosts as a result of using a centralised environment

Depending on the company strategic decisions, this O&M support

activities can be either operated with internal resources orsubcontracted to an external support supplier at very competitivecosts.

According to INDRAs experience, the particular combination ofmonitoring and analysis tools depends on the specific features of the

customer and must be carefully studied before the project is launched

In the next few years some more new applications and tools based onthe plant available information are expected, thus changing forever theway companies manage their assets


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Energy [email protected]

Parque Empresarial La Finca, Edif. 4, Planta Baja

Paseo del Club Deportivo, 1

28223 Pozuelo de Alarcn. Madrid

T +34 91 210 2000F +34 91 210 2010

www.indra.es

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