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Transcript of © 2008 Eventure Events. All rights reserved. Fleet Performance and Reliability in Generation...
© 2008 Eventure Events. All rights reserved.
Fleet Performance and Reliability in Generation Utilities
Rodney Lord, IT Solutions & Services, Siemens
Jörn Rassow, Power Plant Engineer, EnBW Kraftwerke AG
Protection notice / Copyright © Siemens AG 2008. All rights reserved.
Energy Management Suite
Siemens IT-Solutions and Energy
Page 3 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Power Plant 1 Power Plant nPower Plant 2
TIME COSTS
QUALITY
1) Available in 2008
Combining Technical and Business Information with Siemens Energy Management Suite
Instrumentation Alarming
Generation Planning & Monitoring
Technical Performance Management
Shift Management
Corrective & Preventive Maintenance
Operations & Maintenance 1)
1)
Business Performance Management
Efficiency Emissions
Availability
Flexibility
Fuel costs
Maintenance costs
Performance Operating costs
Page 4 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
. . .InternetIntranet
Power PlantManager
Process DataArchive SAP ERP Databases DCS Scheduling Energy
Trading
Systems• Plant Systems• IT systems
User Community• Executive Management • Power Plant Management• Production Management• Technical Management
MultipleGenerationLocations
ExecutiveManagement
ProductionManager
Technical Competence Center
Power Plant 1 Power Plant 2 Power Plant n
Enterprise Wide Decision Support
Page 5 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Integration of SAP Enterprise Asset Management, SAP ERP Systems and Plant Process Information provides visibility to key operational data and information
SAP
ERP
Planning&
Execution
Limited visibilityto plant operations
and metrics
Energy Management Suiteis the bridge between
plant operations and the business
Plant
Control and Operational
Systems
SAP
ERP
Energy Management
Suite
Plant
Control and Operational
Systems
Page 6 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Enterprise Wide Decision Support
Power Plant Management
ExecutiveManagement
Production Manager
Technical Competency Center
Energy Management Suite
EMS connects data from the power generation and business areas with process know how to creating transparency and flexibility. Access to this near real time information enables decision making to increase availability and profitability.
User Community• Executive Management • Power Plant Management• Production Management• Technical Management
Systems• Plant Systems• IT systems
MultipleGenerationLocations
Kraftwerk 2
Power Plant 1 Power Plant 2 Power Plant 3
Page 7 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Fleet Wide Monitoring & Decision Support- The Building Blocks
SAP Netweaver Enterprise PortalProvides a Single User Interface
EMSOperational Data
Collection and Processing
SAP ERPPlant Management
Maintenance and Workforce
. . .InternetIntranet
Process DataArchive SAP ERP Databases DCS Scheduling Energy
Trading
Plant and IT Systems
Page 8 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Energy Management Suite - Primary Functional Areas
EMS Portal
Business Performance Management
Fleet GenerationMonitoring and Planning
Fleet Performance Monitoring
Fleet-wide Diagnostics & Optimization
AlarmProcessing
Technical Perform. Mgmt.
Generation Planning and Monitoring
Process Information(OSI PI – Process Book)
PM, WCM
PS
Corrective & Preventive
Maintenance
Shift Management
Maintenance & Workforce
Enterprise Information CenterSAP Plant Management
Operational Management Plant Asset Management (PAM)
Core PAMEMS PAM Extensions
SAP Netweaver
SAP ERP
Page 9 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Enterprise Information Center
• Integrates information from multiple power plant locations into a common platform
• Provides easy access to information from other integrated ‘expert’ systems
• Allows a comprehensive view to company wide information delivered through a single user interface
• Access to near real-time information from the fleet
• High degree of integration among plant and business systems
Enterprise Information Center – Utilizing the SAP Enterprise Portal and eSOA
Page 10 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Shift Management • Planning of shifts and shift crews• Manual or automatic logging of events
and DCS signals• Replaces paper based Operator Logs• Shift Tasks e.g. operator rounds
Maintenance Strategy• Multiple maintenance strategies to select
from
Plant Management• Core Plant Management (e.g. Master
Data, Maintenance and Materials Management) integrated with SAP ERP
Siemens Energy Management Suite - Shift Log for Asset Performance Management
Availability: Maintenance and Plant Data Management Minimizing the risk of unplanned outages 900,000 €/y
Maintenance: Spare Parts and Maintenance Management Reduced lead time for planned outages 115.00 €/yReduction in spare parts inventory 1.600.000,-€/y
Savings
Page 11 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Siemens Energy Management Suite - Early Warning System for Diagnostic and Technical Performance Management
Savings of more than $8 M/Yr. Additional 50 MW capacity Improved efficiency for: Additional output of nuclear power plants:- Lignite-fired units: 2% + 2MW- Gas-fired units: 1.5% Fleet availability increased by 0.5%
Predictive Diagnostic System• Fleet-wide plant condition
monitoring and alarming system• Asset status reporting integration of
the local Vibration system with EWS• Creation and tuning of the plant
operational models• Review of selected thermal cycle
calculation system• Integrated Alarming into Shift Log
component
Page 12 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Siemens Energy Management Suite- Expert System for Generation Planning and Monitoring
5000 MW installed generation capacity Average fuel reduction of 0.5% [0.3-1.0%] Average fuel costs of 25 €/MWh Plant Utilization 60%
-> 3 000 000 €/year
Fleet Dash BoardAvailability/Capability• Event Logging - Visualization of
past capability and projections for the future
Economic Dispatch • Economic dispatch of a fleet taking
into account the current circumstances. (e.g. head water pressure, thermal heat rates, costs)
Generation Monitoring • Manage schedules and control
production. Early reaction to emerging issues
Fuel Supply - and Emissions Management
• Monitoring (calculation) of actual emissions and reporting
Page 13 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Siemens Energy Management Suite- Business Performance Monitoring
15.10.2008
Early Detection of Performance DeviationsBenefits for a typical Generation Fleet
5000 MW installed generation capacityIncrease of In-Market Availability by 0.5 %; equals 25 MW of additional generationInvest of 1.000.000 €/MW installed capacityDepreciation 10 %/year-> 2.500.000 €/year
Key Performance Indicators• Calculation and reporting of KPIs on
each unit in the fleet and component• MTBF, MTBR• IEEE, VGB, …
Technical & Maintenance Reporting• Comprehensive business reporting
• Fleet wide YTD actuals• Production forecasts• Maintenance order status
and costs• ….
Business Advisor • ‘What if‘ planning scenarios for the
fleet based on generation supply contracts and fuel targets
Page 14 October 2008
Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services
Energy Management Suite - Customer Value
Customer Benefits Customer Experience
Highly innovative solution packageintegrating production, business processesand metrics.
Faster and improved support for decisionmaking to meet the short and long termmarket needs.
Early detection of potential plant and unitissues lead to;• reduced maintenance costs• increased availability and efficiency• economic and technical optimization of plant and fleet performance• consistent management reporting
Efficienct Technical Performance:
Early Detection of deviations 500.000 €/y (800MW, coal-fired steam power
plant)
Generation Monitorong.&Planning:
Optimized Generation Schedule Planning
3.000.000 €/y (5000 MW installed capacity)
Availability Monitoring and Alarming:
Avoidance of unplanned outages, and avoided asset damage
720.000 €/y (300 MW Combined Cycle Unit)
Early Detection of Performance Deviations:
Increased Asset Utilization
2.500.000 €/y (5000 MW installed capacity)
* Actual savings achieved by an existing EWS Customer