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

Transcription

1 DTE Energy Fleet Optimization. through Process Controls & Technology Presented by Sumanth K. Makunur

2 Today s Agenda Process Controls & Technology Control & Technology Framework Application Examples Work in Progress KPI s Dashboards Fleet Optimization Business Intelligence Reliability Outage & De-rate Maintenance & Market Expert Systems Predictive Monitoring, Optimization System Dashboards Fleet Status Assessment WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data Successes Questions & Discussion PI Asset Framework Integrated applications environment: Consistent framework for data, analysis, reporting and consistent user graphical interface.

3 Profile of DTE Utility Business DTE Electric Ninth largest electric utility in the U.S. with 2.1 million customers Over 11,080 MW of power generation, primarily coal fired 54,000 GWh in electric sales ~$8.79 billion in revenue DTE Electric Distribution Services DTE Gas Distribution Services Overlapping Distribution Services Detroit DTE Gas Fifth largest natural gas utility in the U.S. with1.2 million customers 170 Bcf of gas sales 12% of national gas storage capacity with 124 Bcf of regulated gas storage

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

5 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB Fleet Optimization Process Costs Asset Health, Market Value 20% Business Intelligence Outage & De-rate (UCF) Maintenance & Market Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment System Dashboards Fleet Status Assessment WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data People Making right decisions when it matters! 25% 60% Drives Performance Excellence Fleet Optimization Process Costs, Asset Health, Reliability Operational Performance, Market Value Relate all Data Sources ProcessNet Framework (PI, ProcessGuard, Maximo, SAP, UCF, P3M, Predictive Monitoring, NeuCo, LIMS, Plant View..) Advanced Analysis & Process Optimization Reliability Academy Equipment, Process, Performance, Reliability Models Closed Loop Process Optimization 90% 100% 90% Fleet Drill down Subject Matter Experts 90% Standard User Interface WEB Visualization Process Discrete Data Engineering Applications PMAX, DFTS, enote, Fuel Cost Framework, Alarm Management Post Event Analysis DCS, PLC & PI % Complete

6 The Performance Center The Door into the Fleet 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 Virtual Control Room - 23 Units Operating View of Fleet Drives consistent practices (UCF) Market interface w/moc Proficient users of technology SME rotation mutually beneficial Reliability tools (SmartSignal & Plant View) Input in the budget process

7 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data

8 Control & Technology Infrastructure Plants DCS Operator Consoles NeuCo PMAX ProcessNet ProcessGuard EPRI Plant View Multiple Data Sources ABB DCS PI PLC PLC PI Interfaces PMAX CEMS SmartSignal Controllers

9 Control & Technology Infrastructure Wind Parks Gratiot Wind Park Data Flow Maintenance O&M Building Remote Maintenance Sigel OEM Remote Maintenance WFMS Customer Master Remote Substation PI Data Flow PI Minden DTE Mckinley Echo Smart Signal 3 rd Party Operator Denotes cloud networking Regulatory Monitoring Pheasant Run II UCF

10 Raw PI Data Analysis PI Yields Benefits Post trip analysis Process monitoring Optimization Early warning Alarming

11 Challenge - Process Data Everywhere! DCS installations on nearly every unit Over 1,000,00 process data tags PI Systems at each plant (~20 PI collectives) 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?

12 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 90%

13 Fleet Performance Analysis (PMAX) Thermal Performance Calculation Engine

14 Digital Fuel Tracking System On-line Fuel Analyzer

15 NOx Emissions Strategy NOx Reduction with Improved Heatrate Before Implementation After Implementation Primary focus is NOx reduction only Focus on operating near NOx budget curve

16 Electronic Operator Rounds RFID Technology / PI Manual Logger RFID Tags Industrial PDA (Symbol MC9060S) Tablets PI Manual Logger

17 PI to PI Process Data Conduit Belle River PI St Clair PI Greenwood PI Harbor Beach PI EMS ESO Detroit & Wind PI PI PI Ann Arbor PI Wind Parks Monroe PI Trenton Channel PI River Rouge PI

18 PI Advanced Metering Infrastructure (AMI) Implemented an extensive PI Infrastructure for AMI data MSP Interface to capture 8 Server PI Farm 1.5 Million Plus meters data 27 Million PI tags and growing

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

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

21 PI to PI (AGC) AGC Automatic Generation Control 7 largest Fossil units & Peaking Units are ramped through PI Set Point control

22 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Drive Performance Excellence Drive Performance Excellence Fleet Optimization Fleet Perspective Methods Applications Discrete data Limited value ABB WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 90% Involves Operation Performance MISO Market Reliability Maintenance Reporting Budget

23 Fleet Status PI WEB enabled

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

25 PI enabled - Event Re-play Re-play events using historical PI data

26 PI Coresight Displays

27 Real-Time Wind Turbine Display

28 Mobile Work Force Mobile Work Force PI WEB reports available on your Mobile Device

29 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Discrete data Limited value ABB Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90%

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

31 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment 60% System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Discrete data Limited value ABB Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90%

32 Advanced Pattern Recognition Equipment Condition Monitoring SmartSignal PI Dependent Expert Systems Combustion Optimization NeuCo Objective Coal pile to stack Optimization Closed loop Neural Net Optimization In Service St Clair Unit 7 (Neural Mode November 2007) Installation in progress on Belle River 2 (2008) Planned for Monroe Units 1-4 (High PRB Utilization Project) Similarity Based Modeling

33 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Business Intelligence Outage & De-rate (UCF) Maintenance & Market 25% Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment 60% System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Discrete data Limited value ABB Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 90%

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

35 Unit Capacity Framework (UCF) Manages all Unit Capacity and De-rates - Interfaces to MISO, P3M & EMS Automatically Generated Status Report Dynamically linked with Outage and de-rate process

36 Enterprise Business Systems (EBS) Maximo & SAP SAP Financial Information Human Resources Supply Chain Maximo Work Management System

37 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s People Fleet Making right decisions when it matters! Optimization Process Costs Asset Health, Market Value 15% Business Intelligence Outage & De-rate (UCF) Maintenance & Market 25% Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment 60% System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Discrete data Limited value ABB Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90%

38 No Shortage of Information! Laboratory Information PI Data Historian Operator Logs Project Management SAP Work Management Document Management PI Asset Framework 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

39 Common Methodology Standard GUI Single Method PI Asset 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 ECG AccuTrack 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 Process Information Business Systems Market Data

40 Common Structure Process Information Business Systems Market Data

41 Fleet Performance Analysis and Optimization Pulverizer Dashboard Process Information More information is need for Analysis

42 Pulverizer Assessment What information is needed? Pulverizer Milling Costs Process Costs Production Costs EAF SmartSignal Watch List Work Performed & Work Pending Alarms

43 Pulverizer - Multiple Data Sources Consistent Reporting Common Methodology Common Structure Unit Capacity Alarms EPRI PlantView Maximo SAP PI P3M Documentum SmartSignal

44 Common Thread Equipment Hierarchy Primary System Secondary System Sub System Equipment Equipment Hierarchy Hierarchical System Index (HSI) Work Breakdown Structure (WBS) Sub Equipment

45 Pulverizer - Multiple Data Sources Consistent Reporting Common Methodology Common Structure Unit Capacity Alarms EPRI PlantView Maximo SAP PI P3M Documentum SmartSignal

46 Asset Framework Expanded System Dashboard Health Assessment Health PI KPI s DCS Trends SmartSignal Watch List Alarms

47 PI Asset Framework (AF)

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

49 Application Framework Expanded System Dashboard Health Health Assessment PI KPI s DCS Trends SmartSignal Watch List Alarms

50 Logical Display Flow

51 Fleet Overview

52 Plant Overview

53 Unit Overview

54 Coal Mill

55 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

56 QUESTIONS?

57 Sumanth K. Makunur Supervisor DTE Energy

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