Risk Mitigation in Gas Natural Fenosa Power Generation. Sevilla, 14 th June 2013

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2 Risk Mitigation in Gas Natural Fenosa Power Generation Sevilla, 14 th June

3 Content 1. GNF Power Generation Fleet and Organization 2. Continues Monitoring and Diagnostics Processes 3. Operations and Maintenance Supervision Center (CESOM) 3

4 GNF Power Generation Fleet and organization 4

5 14 GW Net capacity including all conventional technologies Net capacity by technology and location (excluding wind, solar and third party assets) MW 567 MW 299 MW MW MW MW MW MW 634 MW Combined cycles Thermal coal Hydraulic Nuclear Diesel Engines Total Capacity Spain México Other countries 5

6 Power Generation Organization Power Generation Managing Director O&M Integration and Supervision O&M Energy Nuclear Hydro Coal Combined Cycle Natural Resources The D.G. Generación is responsible of the operation, maintenance of all generation assets for the GNF Group. DGG guarantees the application of the best practices for each technology and ensures the optimization of the main indicators of the activity of generation, availability, costs and life time of the assets for GNF Group. Managing Director of Power Generation report directly to the CEO of GNF.

7 O&M Integration and Supervision (ISOM) ISOM Technical Services and CESOM Transversal Projects Wholesale Markets Relationship QHES ISOM monitors the operations and maintenance activities of Gas Natural Fenosa s power generation fleet worldwide, fostering cross-technology know how transfer and supporting KPI improvement. Ultimate target is to satisfy the end client demand, whether internal (Wholesale Markets) or external (PPA off takers)

8 Tasks related to the risk mitigation in Generation are under ISOM responsibility Trasversal Project Responsible of the valuation of the operational risk to roll out in the market by the Risk Direction, additionally responsible of the assessment in the claims in order to reduce the outage time and costs. Responsible of the development and manage collaborative tools. QHES Technical Services and CESOM Responsible of the analysis and mitigation of the environmental and regulatory risks of generation. Responsible of the monitoring and technical analysis of the generation assets through intelligent systems for early warning detection of anomalies transferring the know how between the technologies and countries.

9 Continues Monitoring and Diagnostics Processes 9

10 Continues Monitoring & Diagnosis Processes Sensor/transducer/Manual entry Data acquisition Data Manipulation External systems, data archiving and block configuration State Detection Health Assessment Prognostic Assessment Technical displays and information presentation Advisory Generation 10

11 Monitoring & Diagnosis Processes Current situation in GNF Power Generation. Data Acquisition (DA) Collects analog, digital and manual data. Converts analog data to digital data. Data Manipulation (DM) State Detection (SD) Health Assessment (HA) Prognostic Assessment (PA) Performs signal processing (filtering, FFT, ) Performs algorithmic calculations Calculate current values of conditional indicators Evaluates state. Estimates current health grade Diagnoses faults and failures Generate recommendations, evidences and explanations Estimates future health grade Predicts faults, failures and remaining life. 11

12 Operations and Maintenance Supervision Centre (CESOM) 12

13 Scope of Monitoring Center signals monitored on real time and 149 turbines of all technologies and OEM. México CCPP MW (incluye La Caridad) Domenican Repiblic Diesel Engines198 MW Spain CCPP MW Coal MW Hydro MW In service Costa Rica Hydro 100 MW (incluye Torito) Panamá Hydro 32 MW Puerto Rico CCPP 507 MW South Africa Mining Kangra Coal Kenia Diesel engines 109 MW Service in progress SSTT & CESOM staff are 16 people with full time dedication hours of assets supervision / year. 13

14 Scope of Monitoring Center. Assets monitored (MW) Monitored In progress Total Number of signals Thermal 2,061 2,061 46,860 CCPP 9,322 9, ,454 Hydro 1, ,962 30,168 Total 13,263 13, ,482 Turbines by Manufacturer GE Siemens S-W Alstom Mitsubishi Gas Turbines Steam Turbines Hydro Turbines

15 Services provided by Monitoring Center Monitoring systems: Develop, implement and maintain control and remote monitoring systems. Predictive maintenance: Condition monitoring: plant condition and diagnosis. Vibration monitoring: Power train: permanent, online and real-time remote vibration monitoring. Other rotating equipment: scheduled and random control with portable devices. Performance: Performance monitoring: continuous, online, real time. Performance tests: Contractual (PPA, third party O&M) and non contractual (improvement). Provide training services on performance and predictive maintenance. 15

16 CESOM: Main Targets Improve maintenance planning and costs Diagnose failures Prevent catastrophic failures Improve performance Early detection allows an efficient planning of the required resources and minimizes costs Supports the root cause analysis of incidents, shortening unplanned outages. Early warning by real-time systems combined with data analysis by experts. Performance monitoring combined with our experts in performance. 16

17 Relationship model Power Plants Monitoring Systems CESOM Control system PI Plant Modeling - Performance - Predictive - Algorithmic calculations Monitoring Analysis Report & Advice Diagnosis Solution implemantation Feedback Know how transfer Transparency: the client (Plant Manager, client) watches what CESOM releases

18 I&T monitoring configuration Plant signals Integrated control systems Acquisition Analysis Reporting Diagnosing Plant signals DCS CEMS RTIS PMS CMS Information sharing system Other (DGA oil analysis, PDs,..) MMS External signals Inmissions, weather predictions,... Vibration analysis DCS: Distributed Control System, CEMS: Continuous Emissions Monitoring System, RTIS: Real Time Information System, PI : Plant Information, PMS: Plant Monitoring System CMS: Condition Monitoring System, MMS: Maintenance Management Systems 18

19 CESOM Systems: Data acquisition Real Time Information System 19

20 CESOM Systems Condition Monitoring System Principle and philosophy of operation The anticipated value is modelled for each sensor, the value is calculated using non parametric algorithm reference models (Similarity Based Modelling). The behaviour reference is built based upon the historical data of the different signals that configure the behaviour of a component. Alarm settings and dead band are calculated for each signal. 20

21 CESOM Systems Condition Monitoring System 2 days Findings after shutdown and inspection: rotor cracked. Early warning from system in a HP feed water pump. 21

22 CESOM Systems Condition Monitoring System Model of all parameters of main assets in the plant (turbines, generators, motors, pumps, heat exchangers, etc.). More than 100,000 parameters and 950 assets of Gas Natural Fenosa power plants are controlled online Integrated with other monitoring tools (vibrations monitoring, performance monitoring, etc.) PLANT SCOPE MAJOR EQUIPMETS ASSETS STEAM TURBINE GAS TURBINES MECHANICAL CONDENSER GENERATOR TRANSFORMER AUX TRANSFORMER COOLING TOWER FANS PRIMARY AIR FANS PA FAN 1 PA FAN 2 FORCED DRAFT FANS FD FAN 1 FD FAN 2 INDUCED DRAFT FANS ID FAN 1 ID FAN 2 PUMPS CONDENSER PUMPS COND PUMP 1 COND PUMP 2 COND PUMP 3 COND PUMP 4 TURB. DRIVEN BOILER FEED WATER PUMPS TDBFP 1 TDBFP 2 CIRULATING WATER PUMPS CW PUMP 1 CW PUMP 2 HEATERS FEED WATER HEATERS FW HEATER 1N FW HEATER 1S FW HEATER 2 FW HEATER 3 FW HEATER 4 FW HEATER 6 FW HEATER 7 DEAERATOR AIR HEATERS AH A AH B OTHER MILLS MILL 1,2 22

23 CESOM Systems Vibration Monitoring Systems Online vibration monitoring and advanced analysis of main rotating equipment (gas and steam turbines, generators) with auto-diagnosing tool including main failure modes. Vibration data analysis and diagnostic systems used in a client-server architecture basis Portable system ADRE for monitored equipments that do not have on line system installed, in case of expert diagnostic is required. 23

24 CESOM Systems Performance monitoring System Compares present performance with specific thermodynamic model for each power plant Provides data from different parts of the Power Plant in order to trace the loss of power or efficiency. Weekly report for all combined cycle and coal power plants. 24

25 Muchas gracias 25

26 Esta presentación es propiedad de Gas Natural Fenosa. Tanto su contenido temático como diseño gráfico es para uso exclusivo de su personal. Copyright Gas Natural SDG, S.A. 26