How to Make Actionable Information from Plant Floor on Power Generation Business

Transcription

1 How to Make Actionable Information from Plant Floor on Power Generation Business Presented by Miguel Chavero Ignacio Pérez

2 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle & Coal Strategy 4.- Developed Applications 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 2

3 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Developed Applications 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 3

4 IBERDROLA Installed Capacity Total Production +273% %

5 IBERDROLA Hydraulic: 51% Renewable: 3% Nuclear: 20% MW x MW Hydraulic: 22% Power Station(coal and fuel): 10% Renewable: 28% Nuclear: 7% Power Station (coal and fuel): 27% Cogeneration: 3% Combined Cycles: 29% 5

6 IBERDROLA SANTURCE 396 MW, 109FA CASTEJÓN 379 MW, 109FA We lead the construction of combined cycle power plants on Spain MW since 2001 TARRAGONA POWER 417 MW, 1FA CASTELLÓN A 782 MW, 209FA ARCOS I y II 783 MW, 2X109 FA ARCOS III 823 MW, 209FB ACECA 386 MW, 109FA CASTELLÓN B 839 MW, 209FB ESCOMBRERAS 816 MW, 209FB 6

7 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Developed Applications 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 7

8 PI System History Started on Actual Installations: 8 PI Systems in Spain s Combined Cycle 4 PI Systems in Mexican s Combined Cycle 1 PI System in Latvia s Combined Cycle 3 PI Systems in CMDS 1 PI System in Distribution Business 1 PI System in Renewable Business 3 PI Systems in Spain s Coal Power Plants 1 PI System in Spain s 100% Owned Nuclear Power Plant 4 PI Systems in Spain s Cogeneration Plant

9 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Developed Applications 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 9

10 Combined Cycle & Coal Strategy

11 La Laguna 500 MW Monterrey III 1000 MW Jun 02 Tamazunchale 1000 MW Junio 07 Altamira III y IV Altamira V 1000 MW Nov MW Jun 06 CT Pasajes 200 MW Jun 09 CT Velilla 400 MW Jun 09 Aceca MW Jun 05 Termopernambuco 500 MW Feb 04 Valladolid Santurce 4 CC Riga 150 MW 400 MW 400 MW CT Lada Jul 10 Ene MW Jun 09 Castejón 1 Arcos 1 y MW Dic 04 Arcos MW Jun 05 EW Vitoria, Aranda, EW Cartagena 150 MW Jul 10 Escombreras MW Nov MW Abr 03 Castellón MW Sep 02 CN Cofrentes MW Sep 10 Tarragona Power 400 MW Ene 04 Castellón MW Dic 07

12 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Developed Applications 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 12

13 Performance Tracking Contract Tracking System Advisor AEM (Advanced Equipment Monitoring) IT Doctor GE M&D Connection SAP Connection (PM & BW Module) EMS Connection (Dispatching Center) Daily Inspections Others.

14 Performance Tracking Expected Output Power Gas Consumption Deviation (from Expected) Power Degradation (from Base Line) Heat Rate Degradation (from Base Line)

15 Performance Tracking Expected Output Power Gas Consumption Deviation (from Expected) Power Degradation (from Base Line) Heat Rate Degradation (from Base Line)

16 Performance Tracking Expected Output Power Gas Consumption Deviation (from Expected) Real Power Expected Base Line Power

17 Performance Tracking Power Degradation (from Base Line) Heat Rate Degradation (from Base Line) Off-Line Wash needed. 1% degradation decreasing

18 AEM (Advanced Equipment Monitoring)

19 Contract Tracking Maintenance Contract Tracking FS App Lay-Out HST2CICAS DATOS ENTRADA: HST2CICAJ HSTCIARC HSTCIARC3 HSTCITAR HSTCISAN POTENCIA: G1:DWATT LLAMA: G1:L28FDX DISPARO: G1:L4T HST2CICAS HSTCIACE HSTCIPER HSTCIESC DATOS SALIDA: ALARMCMDS FS_CI_TOTAL: 10:G1:FS_CI FS_HGPI_TOTAL: 10:G1:FS_HGPI PC CLIENTE PC CLIENTE ALARMCMDS PI2CMDS PI2CMDS

20 Contract Tracking Maintenance Contract Tracking FS App

21 AEM (Advanced Equipment Monitoring) Operation Applications The plant is not operating under ideal conditions, parameters out of range for a long time Operation alerts ( test not done, on line wash needed ) Chemical parameters.

22 AEM (Advanced Equipment Monitoring) Maintenance Applications Notifications for a long time operation valves, gas parameters, environment parameters, DCS data frozen, high consumes Operation alerts Automated Reports. Performance test data, monitoring systems, number of start ups/shutdowns from different pumps

23 AEM (Advanced Equipment Monitoring) Plant Notifications GT Start up. Breaker Switch Generator Fire Base Load Reached Performance data Consumes. Reports

24 AEM (Advanced Equipment Monitoring) Plant Notifications for BB Trip detail. GT Start up. Breaker Switch Generator. Fire. Base Load Reached. Trip detail.

25 AEM (Advanced Equipment Monitoring) Others Analyzed data. Monitoring. Users interface.

26 System Advisor On-Demand Notify Lay-Out Server 26

27 IT Doctor Firs Level: SITE Second Level: Server Name Third Level: System Forth Level: Subject Fifth Level: Point

28 SAP Connection (PM & BW Module) Connection to PM (Plant Maintenance) Using R-LINK Transferring running hours Connection to BW (Business Warehouse) Using PI OLEDB with some enhancements Transferring raw data and KPIs.

29 EMS Connection (Dispatching Center) Bi-Directional connection using OPC Protocol PI OPC Server on CMDS side XISCO ICCP Server on EMS Side Transferring different type of data: In-Daily generation Output Power by Technology Out-Gas Consumptions In-Daily Market Prices Out-Expected Output Power

30 Daily Inspections WIRELESS ACCESS POINT HST2CICAS SERVIDOR PI MOVICICAS BD SQL PI MANUAL LOGGER WEB SERVICES WIRELESS DATA TRANSFER WIRELESS DATA TRANSFER PC CLIENTE Manual Logger WIRELESS DATA TRANSFER Pocket PC Manual Logger Mobile ACTSYNC DATA TRANSFER PIML DB

31 Web Access 31

32 Web Access 32

33 Web Access 33

34 Web Access 34

35 SmartPhone Access 35

36 SmartPhone Access 36

37 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Developed Applications 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 37

38 Future Scope 38

39 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Applications Developed 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 39

40 Conclusions One Combined Cycle 2x1 (2 Gas Turbines, 1 Steam Turbine): 350 M Investment Gas Prices Increasing Equipment Prices Increasing Environmental concerns increasing OPTIMIZATION IS A MUST 40

41 Conclusions 9 years PI System experience over Combined Cycle Technology: ROI 2,5 Years Increasing efficiency 1%-2% Increasing availability 0,1%-0,5% Easily exportable to another business Opening the platform for all users = A lot of value Focus on business drivers (take your time!!!) Event based monitoring Success requires cooperation between operations, maintenance and engineering 41

42 Agenda 1.- IBERDROLA Overview 2.- PI System History 3.- Combined Cycle Strategy 4.- Applications Developed 5.- Future Scope 6.- Conclusions & key lessons learned 7.- Questions and Answers 42

43 Questions & Answers Miguel Chavero Ignacio Pérez 43

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