ER Process Remote Monitoring - Emerson Electric · EPRI DA PlantView Vib Oil MCSA IR Visual Tech...
Transcript of ER Process Remote Monitoring - Emerson Electric · EPRI DA PlantView Vib Oil MCSA IR Visual Tech...
ER Process – Remote Monitoring
About Duke Energy
The role of Performance Monitoring in Equipment Reliability
Fundamental support for the cultural transition from a reactive to a proactive
organization
Provides advanced notice for potential equipment and process failures • Allows increased reactionary time, additional analysis / troubleshooting, planning, and
resource allocation – all resulting in a lower cost of impact
Requires the ability to effectively and efficiently identify and react to equipment and system issues prior to significant failure or degradation
Large scale deployment of Performance Monitoring programs can be resource intensive
Favorable area to leverage advancements in internal and external industry technology
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Performance Monitoring - How Can It Help?
M&D Center Scope of Work
There are separate M&D Centers for the regulated and the commercial sides of the business.
The M&D Center for regulated generation is divided into three functional areas:
Thermal Performance and Testing
Real time performance monitoring and analysis
Field testing and support
Dispatch heat rate curve automation
Reliability and CBM
CBM process development and ownership (EPRI Maintenance and Reliability Model)
CBM analysis and support for the fleet
Advanced Pattern Recognition Monitoring Program
SmartM&D (new sensors monitored by the APR group)
Scope and project development
Installation and implementation
M&D Center Thermal Performance Team Mission
We help the plants maintain a competitive position in the market by providing real time heat rate monitoring, on-site testing and in-depth analysis of plant performance.
We use first principles modeling software to monitor plant and system thermal performance. The software compares actual plant efficiency to their desired targets.
We provide turnkey expertise and resources to test equipment and system performance on site. Our service ranges from individual components to total systems.
We partner with the stations to help them understand what factors are hurting performance and what they can do to restore it to the desired level.
We perform studies for the plants to determine the efficiency and operating performance impact of proposed changes in the plant configuration.
We ensure that the unit heat rate curves used for dispatching accurately reflect unit performance and seasonal conditions.
Real Time Controllable Loss Summary
Updated every 10 minutes
Targets are based on design or achievable
Deviations are displayed in $ and in MW impact at base load
Dashboards allocate thermal and output impacts by component
Real Time Cycle Performance Summary
Component Level Screens
Available by drill down or direct selection
Displays actual vs expected at device level
Displays values corrected to standard conditions when applicable.
Compressor Performance Curves
Used by stations to
determine when washing is
needed:
• Red – Target
• Yellow – History since
cleaning
• Blue - Actual
Valid at Baseload Conditions:
Component Level- Pump Performance Curve
•Component level screens allow
users to zero in on performance
issues
•Design head and efficiency are
compared to current operation
Component Level - Footprint Displays
Footprints help operations visualize operating trends to make decisions
Historical X-Y display of condenser back pressure
Cyan – Clean Yellow – Fouled Red - Current
M&D Center APR Team Mission
Our mission is to help the plants improve long term reliability and cost by predicting equipment problems that will evolve from fault to failure 24 hours or more into the future.
We use Advanced Pattern Recognition software to monitor plant equipment operation. The software detects subtle deviations from normal operation that can be used as early indicators of future problems.
We partner with the stations and fleet technical support to capture their knowledge of the equipment. We build this knowledge into our models to free the plants from repetitive monitoring. This allows them to focus on emerging issues instead.
We are part of the fleet-wide Maintenance and Reliability process that manages risk and reliability at the lowest possible cost.
Evolution of the APR Program
Legacy Progress
Started with the CT fleet in 2004
Expanded to the fossil fleet in 2007
Process Data – Instep PRISM APR tool
Legacy Progress – 27 Fossil Units (now 15), 10 CC’s, 140+ CT’s
>3500 APR Models
>35,000 points monitored every 5 minutes
Dedicated resources assigned to APR and Thermal Performance monitoring
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Evolution of the APR Program
Expansion After the Duke merger Legacy Duke – 29 Fossil Units, 4 CC’s,
63 CT’s, 8 PS, 9 Hydro
>3000 APR Models
>30,000 Points monitored every 5 minutes
Regional Locations, Charlotte, Raleigh, Indianapolis
5 team members dedicated to APR. Mix of new employees, field support and plant experience.
Roughly 35 unique model types
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Evolution of the APR Program
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21 8 29 HRSG
APR Philosophy
Maintain credibility by reviewing and screening all APR alarms before sharing with the stations
Focus on reliability finds
Avoid any commitment to operational finds that would evolve in less than 24 hours
We are not an extension of the operators. We are an extension of CBM.
Integrate with the plant Maintenance and Reliability process
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• Fan Amps
• Motor Winding
Temp
• Motor OB Bearing
Temp • Fan OB Bearing
Temp
• Inlet Vane Position
• Ambient Temp
• Air Flow
Plot-0
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• Motor IB Bearing
Temp
• Fan IB Bearing
Temp
• Select related points
• Pull raw data from Pi
• Typically data sets will be 5 min samples for 1 year
APR Modeling Process – Cleaned Data Set
• Cleaned data set represents operation during all ambient / MW loading conditions
Summer
Winter Spring
Fall
Plot-0
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•Feed historical data to APR algorithm to build prediction
•Feed Real-time values to APR algorithm every 5 minutes
•Algorithm predicts output values and compares real time with
predicted
Predicted values • Fan OB Bearing Temp • Fan IB Bearing Temp • Motor IB Bearing Temp • Motor OB Bearing Temp • Motor Winding Temp • Amps • Discharge Press
APR Modeling Process – Model Algorithm
First Pattern Recognition alarm, residual exceeded 10 C
• Subtract actual value from the predicted value to calculate the residual
Traditional Alarm @ 140 C
M&D Find – L-1 Blade Covers
Site alerted of vibration step change
SME & site personnel verified prox probe
and casing vibration both had changed
Analysis indicated loss of mass, suspected
shroud material based on unit history
Decision to operate unit through very cold
time at reduced output
Unit brought offline and boroscope
inspection performed
M&D Find – L-1 Blade Covers
Boroscope inspection verified missing
shroud material
Decision made to remove turbine
shells
When shells were removed there were
several shrouds missing and others ready to
liberate
M&D Find – CT Combustion Hardware Failure
• Blade Path temperature spread
began to increase
• Spread increase was caused by 1
of 16 thermocouples trending low
Filtered Data > 40 MW
4/22 – 5/16/2012
Blade Path Spread
Blade TC #2
CR 1&2 Fire & Major Damage – Jan 2010
Major Catastrophic Failure $$M’s plus 4 months lost generation
SmartM&D Technology could have prevented this failure
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$200 RF Bus Temp Device
on SmartM&D Network
Existing Program Gaps
Equipment Specialists
Current specialists spread too thin – hard to replace
Current manual predictive programs
80% data collection, 20% diagnostic
60,000 manual vibration data collections per month!!
M&D Center Limitations
Currently limited only to DCS available data
Need more instrumentation to expand capabilities
Industry Gap – lack of cost effective automated
monitoring technologies on critical equipment.
Plant
SmartGen
PlantDCS
Control Network
M&D Network
Sensors
Sensors
Sensors
Sensors
I/O
I/O
I/O
I/O
Manual
PdM
Collection
s
Vib
Oil
Motor
IR
PI
PlantView
Region, Plant,
Unit , & System
Health Views
Fleet M&D Center Plant
System Owners/ CBM – Perform Equipment Assessments
Tech
Exams
Smart M&D – Functional Model
~
30
NI
Module
New On-line
Sensor Data
Existing
Process Data PI
Module
PRISM
APR
EPRI DA
PlantView
Vib
Oil
MCSA
IR
Visual
Tech
Exams Tech
Exams Tech
Exams
Equipment
Assessment
Manual Review of NI data
Automating Data Collection & Analysis
EtaPRO
Perf
M&D Centers Manual
Testing
M&D Infrastructure (19 of 44 Plants installed)
Sensors – Vib & Temp(over 12000 sensors/ 1200 nodes)
Advanced Sensors – EMI, MCSA, IR
Analytical Interface – CBM
Connectivity to M&D Center
Diagnostics & Prognostics
Integration & Visualization
Will be ongoing Advanced Sensor Applications
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Smart M&D – Overview Status
Smart M&D - Scope of Monitoring
Generators
Steam Turbines
Combustion Turbines
Motors
Pumps
Fans
Transformers
Iso-phase Bus Ducts
Electrical Buses
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NI CRIO Hardware (cRIO 9074)
38 points maximum:
• up to 18 Accelerometers (NI 9232, qty 6)
• up to 16 Voltages, +/- 0.2 to 10V (NI 9205)
• up to 4 Currents, 4-20mA (NI 9219)
Rugged Com Router
WAP – Wireless Access Point
IT&T Parts 60% of boxes do not have IT
Hardware . Wired to next box
Plant Server
Local Storage
PGN Business
Network
Accelerometer
& Cable
Further Cost Reduction
• MEMS Accelerometers
• Short Range RF
• Energy Harvesting
Wireless or Wired
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Balance of Plant (BOP) Details Smart M&D – Network Infrastructure
Smart M&D - Typical I/O Enclosures & cRIO
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National Instruments “InsightCM” Software
National Instruments is developing condition monitoring software to provide:
A user interface for various sensors
Data to PI for M&D Center monitoring
NI software & hardware will accept multiple input types
Looking for other vendors to partner and develop new sensor inputs
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Smart M&D – Sensor Technologies
Vibration Monitoring
BOP
Turbine/Generator
Electro-magnetic Signature Analysis (EMSA)
Motor Current Signature Analysis (MCSA)
Oil – dielectric / particle counter
Ultrasonic (Leak detection)
Temperature
Fixed Point
Infrared Camera
Visual Cameras
Additional sensors for performance monitoring (press, flow, etc)
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Smart M&D - Turbine Monitoring (VDMS)
IT&T Parts In most cases requires only
A LAN cable (CAT 5) to plug
Into existing network.
Dependant on network
Infrastructure at site.
PGN Business
Network Plant Server
Local Storage
NI CRIO Hardware (cRIO 9024 / cRIO 9114)
24 points maximum:
• up to 3 Keyphasor™ (NI 9232)
• up to 21 Vibration (Accel, Prox, etc) (NI 9232)
Protection System 37
Installed
VDMS
Monitor
Smart M&D – BOP Vibration
Accelerometers provide overall vibration and temperature
Low cost and robust sensors
Widely deployed where no sensors were deployed before
Smart M&D - Electromagnetic Signature Analysis
Monitors generators, transformers
and other >13.6KV equipment
Provides early indication of insulation
and connection degradation
Utilizes the ground leads and equipment
housing as antenna
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1 ,200 MW Generator with severe arcing of shaft grounding braids
0.1 0.01 1 100 10 0.1
1
10
100
1000
10000
With Arcing Shaft Grounding Braid
Power Line
Carriers
W/O Arcing
Electromagnetic Signature Analysis
Smart M&D - Motor Current Signature Analysis
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Monitors motors with accessible CT leads
Provides early indication of rotor and electrically detected issues
Utilizes a low cost split core CT for quick installation
Calculated motor parameters such as torque, phase angle etc
Motor Current Signature Analysis
Smart M&D - Oil Analysis
Oil Particle Sensor
Provides ISO class particle
monitoring
Moisture
Oil Dielectric Sensor
4-20ma output
Oil Level Sensor
4-20ma output
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Smart M&D - Ultrasonic/Acoustic
Leak Detection
CT enclosure (piping, casing leaks)
Boiler/HRSG (tube leaks)
Electrical Bus Monitoring
Bus monitoring for arcing, corona
CT Foreign Object or Domestic
Object Detection (FOD/DOD)
Used to hear impacts in a CT caused
by foreign or domestic debris
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Smart M&D – Fixed Point Temperature
RF Temperature sensor
Lug mount
RF signal to a receiver mounted
in same panel
Fiber Optic Temperature sensor
Utilizes Fiber-Bragg gating
technology
Can measure temperature at many
locations on a single strand
Can be up to a kilometer long
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Smart M&D - Infrared Thermography
FLIR A65 IR Camera
Network connection
POE
Low cost
National Instruments 1457 CRIO
Network connection
Dual Gig E Inputs
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CVS-1457RT
Thermography
Smart M&D - Visual Camera
Axis PTZ camera
Operator assist
Equipment monitoring
Can use added intelligence
for enhanced monitoring or
trending.
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Smart M&D - Visual Camera
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Smart M&D - Visual Camera
Avoided Cost Chart Tracks Value