About Duke Energy M&D Center Scope of Work There are separate - PowerPoint PPT Presentation

M&D Center

About Duke Energy

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 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 Cycle Performance Summary Cycle Performance: Heat balance • Component Drill • Down

Standard CT Screens Performance Parameters: • Gross MW • Heat Rate • Compressor Efficiency • Pressure Ratio

Real Time Controllable Loss Summary Controllable Loses: MW Impact • $/hour •

Compressor Performance Curve Baseload Efficiency: • Red – Target • Yellow – Clean • Blue - Actual

BOP Equipment - Pump Performance Curve • Performance of equipment can be monitored • Design head and design efficiency are compared to current operation

Dispatch Curve Automation Project  Moves from an annually Trend of Input-Output Curves updated dispatch curve to being performance driven VirtualPlant vs. EtaPRO Calculation  Uses thermodynamic modeling software to estimate energy input to cycle  Reflects current equipment performance and ambient conditions. Yellow – Dispatch Curve Cyan – Current Operation

M&D Center Thermal Performance Deliverables  Real-time controllable loss and cycle performance reports will be readily available to any plant user.  Monthly controllable loss summaries will be provided at the unit level and the region level.  Dispatch curve review and adjustment is triggered when the notified and the real time heat rate curves deviate by 1% or more.  The center is developing more rigorous cooling tower and heat exchanger models.  The virtual plant model is capable of “what-if” parametric studies.

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 – 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 13

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 14

Evolution of the APR Program 15

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 16

• Examples of data available • Exhaust Temps Plot-0 78 108 102 113 102 64 14 170 70 75 76 • Exhaust Pressure 74 72 70 68 66 64 • Compressor Pres 62 • Vibration 60 • Compressor Temps 58 96 86 107 94 46 0 110 52 25 4/6/2008 4:39:21.791 PM 3.00 days 4/9/2008 4:39:21.791 PM •Thrust Position • Bearing Temps • Oil Temps • Disc Cavity Temps • Cooling Air Valve Positions • Rotor Cooling Air Temp • MW Output • Ambient Temp • Humidity • Lube Oil Parameters • Gas Temps • Generator Data • Gas Pres

• 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 Spring Winter Fall

APR Modeling Process – Model Algorithm • Feed historical data to algorithm • Feed Real-time values to algorithm every 5 minutes Plot-0 • Algorithm compares Real-time with historical and outputs 100 126 125 123 111 90 160 400 92 90 predicted values 95 90 85 80 75 108 100 114 101 55 0 100 72 0 10/7/2007 9:17:30.977 AM 3.00 day s 10/10/2007 9:17:30.977 AM Predicted values • Fan OB Bearing Temp • Fan IB Bearing Temp • Motor IB Bearing Temp • Motor OB Bearing Temp • Motor Winding Temp • Amps • Discharge Press

• Subtract actual value from the predicted value to calculate the residual Traditional Alarm @ 140 C First Pattern Recognition alarm, residual exceeded 10 C

M&D Center Issue Notification Process  In the long term, the M&D Center will initiate Tech Exams for all finds as part of the EPRI Maintenance and Reliability Process. Owners at the stations will utilize these Tech Exams to determine what needs to be done to the equipment.  In the short term, the M&D Center uses Email and a notification matrix to determine who to notify at each station.  The center is developing a report tool that can customize reports to users based on attributes such as region, unit, system, component or technology type.  The Thermal Performance group issues monthly Controllable Loss reports for major plant systems and provides real time thermal performance displays to the plants.  Performance testing groups provide turnkey testing and analysis for a wide range of performance issues.

CR 1&2 Fire & Major Damage – Jan 2010 $200 RF Bus Temp Device on SmartM&D Network  Major Catastrophic Failure  $MM’s+ 4 months loss generation  SmartM&D Technology could have prevented this failure 23

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.

SmartM&D Strategy  2010 Progress Energy Executive Challenge: to better leverage technology to address increasing reliability demands and to optimize our workforce  2012 Duke Energy Long Term Enterprise Strategy: Modernize generation and grid infrastructure  2013 IT Strategic Goal: Enable Business Model Evolution  Build an advanced M&D infrastructure capable of a significant advancement in remote equipment monitoring, smart diagnostics, and prognostics • Provide a “Force Multiplier” to leverage fewer specialists to analyze fleet critical equipment Shaping our Future – Technology Innovation & Workforce Optimization

Evolution of the APR Program – SmartM&D  Additional Expansion planned for Phase 2 (SmartM&D) implementation  >5000 APR Models for SmartM&D  Advanced Sensor Types – Vibration – Temperature – Electromagnetic Interference (EMI) – Motor Diagnostics – Thermography – Visual Cameras – Additional sensors for performance monitoring (press, flow, etc.) – National Instruments Compact Remote I/O Devices (CRIO)  >65 new model types 26

Avoided Cost Chart Tracks Value