Fleet Optimization. through Process Information. John C. Kapron. Sumanth K. Makunur. Senior Engineer DTE Energy. Technological Specialist DTE Energy

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1 Fleet Optimization through Process Information John C. Kapron Technological Specialist DTE Energy Sumanth K. Makunur Senior Engineer DTE Energy

Agenda About DTE Energy OSIsoft a Key Technology Enabler DTE OSIsoft Enterprise Agreement (EA) Technology Framework Current Future State KPI s Dashboards

Dashboards Fleet Status Assessment WEB Visualizing Pl ant Al arm, DC S R eal ti me WEB Gr aphics Easy Access to Information Engineering Applications PMAX,

2 Agenda About DTE Energy OSIsoft a Key Technology Enabler DTE OSIsoft Enterprise Agreement (EA) Technology Framework Current Future State KPI s Dashboards Fleet Optimization Business Intelligence Reli abilit y Outage & D e rate Maintenanc e & Mar ket Expert Systems Predictive Monitoring, Optimization System Dashboards Fleet Status Assessment WEB Visualizing Pl ant Al arm, DC S R eal ti me WEB Gr aphics Easy Access to Information Engineering Applications PMAX, Digit al F uel Trac ki ng, Fuel C ost Framewor k Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 2

3 DTE Energy Detroit Edison Detroit Edison Michigan s largest electric utility with 2.2 million customers Over 11,080 MW of power generation, primarily coal fired 54,000 GWh in electric sales $4.7 billion in revenue DTE Energy Detroit Edison Detroit 3

4 Plants & Performance Center Monroe 3,135 mw Belle River 1,260 mw Harbor Beach 103 mw Trenton Channel 730 mw Performance Center 11,588 mw St Clair 1,417 mw 4 River Rouge 527 mw Greenwood 785 mw Fermi 1,100 mw

5 History of OSI PI in DTE Energy Pilot at Monroe PP in 1998 Fossil Generation Fleet 1999 GenOps EMS Ranger 2001 SOC SCADA 2002 Fermi Nuclear 2003 DTE Subsidiaries 2007 Success! Enterprise Agreement 2007 Continuous PI Expansion Magnitude Functionality 5

6 OSIsoft a Key Technology Enabler Information and Application Integration Primary data source of process data (current & historic) Integral part of many Applications (process and business) Communication Conduit (plant status, fuel cost, control, EMS) Strategic to DTE Energy s day to day Operation Performance Center Enabling Technology Equipment Condition Monitoring SmartSignal Enables DCS Displays Process & Market Analysis DTE OSIsoft Enterprise Agreement (EA) Key to the Supply Cabinet 6

7 Why OSIsoft Enterprise Agreement? 5 Key Benefits KPI s Dashboards Fleet Optimization Business Intelligence 1. OSI is a DTE Core Technology 2. OSI s Strong Track Record & Future Direction 3. Expand DTE s Use of OSIsoft Applications 4. Normalize Budget Allocation 5. Premium Software Reliance Program Expert Systems Predicti ve M onit oring, Opti miz ati on System Dashboards WEB Visualizing Plant Alarm, DCS Real tim e WE B Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Trackin g, Fuel Cost F ra mewo rk Process Discrete to Data Distributed C ontrol Sys tems (DC S) Distributed OSIsoft PI Historians Large Population of Data 7

8 1. Core Technology Integral Part Technology Framework KPI s Dashboards Fleet Optimization Business Intelligence Expert Systems Predicti ve M onitoring, Optimiz ation System Dashboards Component of Many Applications Control Processes Business Processes WEB Visualizing Plant Alarm, DCS Real tim e WE B Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Trackin g, Fuel Cost F ra mewo rk Process Discrete to Data Distributed Control Systems (DC S) Distributed OSIsoft PI Historians Large Population of Data Performance Center Enabling Technology 8

Technology Framework Actionable Information KPI s Discrete data Limited

Reliability, 4 Block Outage & De rate (UCF) Maintenance & Market Expert

Access to Information Distributed Control Systems (DCS) Distributed

Excellence Process Costs, Asset Health, Operational Performance, Market

System Dashboards Fleet Status Assessment Engineering Applications PMAX,

Relate all Data Sources Analysis Framework (PI, ProcessGuard, Maximo,

.) 50% Advanced Analysis & Process Optimization Equipment and Process

Subject Matter Experts 90% Standard User Interface WEB Visualization

9 Technology Framework Actionable Information KPI s Discrete data Limited value KPI s Dashboards Fleet Optimization 15% Business Intelligence Reliability, 4 Block Outage & De rate (UCF) Maintenance & Market Expert Systems WEB Visualizing Plant Alarm, DCS Real time WEB Graphics Easy Access to Information Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data Drives Performance Excellence Process Costs, Asset Health, Operational Performance, Market Value, Fleet Optimization 25% Predictive Monitoring, Optimization 60% System Dashboards Fleet Status Assessment Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Relate all Data Sources Analysis Framework (PI, ProcessGuard, Maximo, SAP, UCF, P3M, Predictive Monitoring, NeuCo, LIMS, Plant View..) 50% Advanced Analysis & Process Optimization Equipment and Process Monitoring Closed Loop Process Optimization 100% 90% Fleet Drill down Subject Matter Experts 90% Standard User Interface WEB Visualization Process Discrete Data PMAX, DFTS, enote, Fuel Cost Framework, Alarm Management Post Event Analysis DCS, PLC & PI % Complete 9

10 How Does Technology Enable You? Mobile Work Force PI WEB reports available on your BlackBerry 10

11 Fleet Performance Center Performance Center Mission Equipment Performance Optimization of the Fossil Generation Portfolio through continuous real time and predictive asset condition monitoring to maximize the asset market value. Performance Center Vision Fossil Generation s Fleet wide Mission Control Center for continuous monitoring and optimization of plant equipment performance Located in Ann Arbor Michigan 7x24 hour operation (February 2006). Plant interface with Merchant Operation Center. Oversight of Outage and de rate coordination. 11

12 2. Track Record & Future Direction OSIsoft Exceptional Track Record Worldwide and Multi Industry Exceptional System Availability Open and Fast Data Access for Analysis Unlimited Interfaces (PLC, DCS, Corporate Systems) Future Direction Multi Industry Leverage Managed PI High Availability (HA) PI System Analysis Framework 12

13 3. Expand Use of PI Applications Currently Application in Use PI Data Historian Fleet Wide 300,000 tags ProcessBook, DataLink, Active View, PI ManualLogger, PI Alarm, PI SMT Multiple PI interfaces, Data Access Pack, API and SDK Planned Expansion Expand PI tag count (Process Data, Operator Rounds, Application data...) IT Monitor Analysis Framework Advanced Computing Engine (PI ACE) PI Module Database RtPortal (WEB Visualization) Required Expansion NERC Critical Infrastructure Protection Market Interface Environmental Reporting Regulations 13

14 4. Normalize / Reduce Budget Capital Budget Application Expansion Strategic Technology Approval Facilitates stable budget forecast O&M Budget Support Fixed Budget Known Future Budget Impact Product Cost Significant Discounts Unlimited Usage 14

15 5. Premium SRP (Software Reliance Program) Enterprise Project Manager and Enterprise Account Manager Remote Monitoring Proactive Problem Resolution Specialized Performance Reports Access to Center of Excellence Unlimited Tags & Standard Interfaces Software Update System Quarterly Reviews Access to all CBT s and Webinars, Training and Event vouchers 15

16 Why OSIsoft Enterprise Agreement? KPI s Dashboards Fleet Optimization Business Intelligence 1. A DTE Core Technology Expert Systems Predicti ve M onit oring, Opti miz ati on System Dashboards WEB Visualizing Plant Alarm, DCS Real tim e WE B Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Trackin g, Fuel Cost F ra mewo rk Process Discrete to Data 2. OSI s Strong Track Record & Future Direction 3. Expand DTE Use of OSIsoft Applications 4. Normalize Budget Allocation Distributed C ontrol Sys tems (DC S) Distributed OSIsoft PI Historians Large Population of Data 5. Premium Software Reliance Program 16

17 How Did We Get Here? Lets take a closer look under the hood. 17

18 Challenge Process Data Everywhere! DCS installations on nearly every unit Nearly 300,000 process data tags PI Systems at each plant PI Interfaces to DCS & many PLC s What is that data screaming at us? How do you effectively utilize the data? How do you turn data into information? 18

19 Technology Framework Benefits Actionable Information KPI s Annual Savings Discrete data Limited value Distributed OSIsoft PI Historians Large Population of Data Data Analysis $3,000,000 19

20 Raw Data Analysis Post trip analysis Process monitoring Optimization Early warning Alarming $ 1,890,000 One Plant 1st year savings! 20

Tracking, Fuel Cost Framework Process Discrete to Data Distributed OSIsoft PI

21 Technology Framework Benefits Actionable Information KPI s Annual Savings Discrete data Limited value Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed OSIsoft PI Historians 90% Process Analysis $4,500,000 Large Population of Data $3,000,000 90% 21

22 Fleet Performance Analysis (PMAX) Thermal Performance Calculation Engine $500,000 Annual Savings! 22

23 Digital Fuel Tracking System $1,200,000 Annual Savings! On line Fuel Analyzer 23

Implementation After Implementation Primary focus is

24 NOx Emissions Strategy $2,200,000 Annual Savings! NOx Reduction with Improved Heatrate Before Implementation After Implementation Primary focus is NOx reduction only Focus on operating near NOx budget curve 24

25 PI to PI Process Data Conduit Belle River PI St Clair PI Greenwood PI PI Harbor Beach ESO Detroit PI EMS Ranger PI Ann Arbor PI Performance Center PI PI PI Monroe Trenton Channel River Rouge 25

Energy Management System (EMS) The Plant Energy Management System is used to automatically control unit dispatch Implements data validation on

26 Energy Management System (EMS) The Plant Energy Management System is used to automatically control unit dispatch Implements data validation on all fields Performs several calculations based on PI data to determine validity of inputs. Transported to EMS Ranger via PI $120,000 Savings! 26

Before Fuel Cost Framework Market Trades Manual Process Email Fax s Phone Fuel Supply Gas Oil Coal

Calculates Fuel Blend Scenarios & Business Logic Fuel Cost Gas Oil Coal Emissions Manual Process

27 Before Fuel Cost Framework Market Trades Manual Process Fax s Phone Fuel Supply Gas Oil Coal Emissions Fuel Cost Gas Oil Coal Emissions Manual Process Gen. Ops. Calculates Fuel Blend Scenarios & Business Logic Fuel Cost Gas Oil Coal Emissions Manual Process Manual Process To 19 Units Ops Manual Process EMS Ranger PI PI to PI Plant PI Type, Type, Oops No sys error checking 27

Fuel Cost Framework $530,000 Annual Savings!

Mode Auto calculate & update Ranger ps mon pi ps tch pi ps rrg pi Blend Calculations Blend

Gas Dawn & Michcon City Gate 1 Market Data Hourly & Daily Auto update ESO PI ps eso pi 4 ps blr

28 Fuel Cost Framework $530,000 Annual Savings! Oil Current & Historic Data 2 Fuel Supply Analysis and Acquisition 3 Current Fuel Cost Default Mode Auto calculate & update Ranger ps mon pi ps tch pi ps rrg pi Blend Calculations Blend Calculations Improvements 30 to 3 people Timely data entry Zero errors Gas & Oil Price at Hubs Gas Dawn & Michcon City Gate 1 Market Data Hourly & Daily Auto update ESO PI ps eso pi 4 ps blr pi ps_hbh_pi ps grw pi Blend Calculations Blend Calculations Blend Calculations 5 Ranger PI Ann Arbor Blend Calculations ps stc pi Blend Calculations 28

29 PI to PI (AGC) $200,000 Savings! AGC Automatic Generation Control 5 largest Fossil units & Peaking Units are ramped through PI Set Point control 29

Technology Framework Actionable Information

Access to Information 100% Easy Visualization

Engineering Applications PMAX, Digital Fuel

30 Technology Framework Actionable Information KPI s Annual Savings WEB Visualizing Easy Access to Information 100% Easy Visualization $5,500,000 Discrete data Limited value Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed OSIsoft PI Historians 90% $4,500,000 Large Population of Data $3,000,000 90% 30

31 Fleet Status PI WEB enabled 31

32 Real Time DCS Operator Displays 6000 real time dynamic actively linked WEB DCS graphics Click & Trend 32

33 PI enabled Event Re play Re play events using historical PI data 33

Technology Framework Actionable Information KPI s

Assessment WEB Visualizing Easy Access to

$5,500,000 Discrete data Limited value Engineering

Framework Process Discrete to Data Distributed

34 Technology Framework Actionable Information KPI s Annual Savings System Dashboards Fleet Status Assessment WEB Visualizing Easy Access to Information 50% 100% Organized Drill Down $1,000,000 $5,500,000 Discrete data Limited value Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed OSIsoft PI Historians 90% $4,500,000 Large Population of Data $3,000,000 90% 34

35 System Dashboards PI Enabled 2000 real time dynamic actively linked WEB System graphics Click & Drill 35

36 Technology Framework Actionable Information KPI s Annual Savings Expert Systems Predictive Monitoring, Optimization 60% System Dashboards Fleet Status Assessment 50% Predictive Optimize $8,000,000 $1,000,000 WEB Visualizing Easy Access to Information 100% $5,500,000 Discrete data Limited value Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed OSIsoft PI Historians 90% $4,500,000 Large Population of Data $3,000,000 90% 36

37 PI Dependant Expert Systems Equipment & Process Monitoring SmartSignal Fleet wide implementation 2006 A Primary Performance Center Application Combustion Optimization NeuCo Startup on St Clair Unit 7 Installation in progress on Belle River 2 Planned for Monroe Units 1 4 $7,769,680 Annual Savings! $330,000/unit Annual Savings! 37

Business Intelligence Reliability, 4 Block

System Dashboards Fleet Status Assessment 50%

$20,000,000 (Projected Savings) 25% Expert

$11,000,000 60% $1,000,000 WEB Visualizing

38 Technology Framework Actionable Information KPI s KPI s Dashboards Fleet Optimization Business Intelligence Reliability, 4 Block Outage & De rate (UCF) Maintenance & Market System Dashboards Fleet Status Assessment 50% Annual Savings 15% Fleet Optimization $20,000,000 (Projected Savings) 25% Expert Systems Predictive Monitoring, Optimization $11,000,000 60% $1,000,000 WEB Visualizing Easy Access to Information 100% $5,500,000 Discrete data Limited value Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed OSIsoft PI Historians 90% $4,500,000 Large Population of Data $3,000,000 90% 38

39 Unit Capacity Framework (UCF) Process Flow Power Plants Day Ahead Performance Center Real Time Market Merchant Center Market Strategy Market Feedback 39

40 Unit Capacity Framework (UCF) Manages all Unit Capacity and De rates Interfaces to MISO, P3M & EMS Automatically Generated Status Report (Availability on BlackBerry) $3,200,000 Dynamically linked with Outage and de rate process 7 months 2007! 40

41 No Shortage of Information! Laboratory Information PI Data Historian Operator Logs Project Management SAP Work Management Document Management Emissions Monitoring Alarms EPRI Plant View Combustion Optimization Outage Planning De rate Management Fuel Cost MISO Real Time Unit Capacity Performance Analysis Emissions Monitoring MISO Day Ahead Ancillary Services 41

PI Data Historian Operator Logs Combustion

Management De rate Management MISO Day Ahead

42 Analysis Framework Standard GUI Single Method Analysis Framework: Integrated applications environment: Consistent framework for data, analysis, reporting and consistent user graphical interface. EPRI Plant View Alarms Performance Analysis PI Data Historian Operator Logs Combustion Optimization Emissions Monitoring Laboratory Information Emissions Monitoring Work Management Project Management SAP Document Management De rate Management MISO Day Ahead MISO Real Time Outage Planning Ancillary Services Unit Capacity Fuel Cost 42

43 Process Cost Drill Down EAF Plant Summary Unit Summary Dispatch Costs Production Costs Milling Costs Heat Rate 43

44 Expanded System Dashboard 44

Process Applications Market MISO, Fuel Coat Framework Unit Capacity Framework Expert Systems

45 Total Fleet Management Financials Work Management SAP Maximo Drives Performance Excellence Process Costs Asset Health Operational Performance Market Value Fleet Optimization Real time Process Applications Market MISO, Fuel Coat Framework Unit Capacity Framework Expert Systems SME Status Displays WEB Portal Applications Distributed Control Systems (DCS) Distributed PI Historians 45

DTE Energy. Fleet Optimization. through Process Controls & Technology. Copyr i ght 2014 O SIs oft, LLC.

DTE Energy. Fleet Optimization. through Process Controls & Technology. Copyr i ght 2014 O SIs oft, LLC. DTE Energy Fleet Optimization. through Process Controls & Technology Presented by Sumanth K. Makunur Today s Agenda Process Controls & Technology Control & Technology Framework Application Examples Work