Application of Advanced Diagnostic Techniques for Plant Performance - - PowerPoint PPT Presentation

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Application of Advanced Diagnostic Techniques for Plant Performance - - PowerPoint PPT Presentation

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Application of Advanced Diagnostic Techniques for Plant Performance and Availability Improvement Michael Fox Douglas Eakle Supervisor, Data Utilization Performance/CBM Engineer FirstEnergy Corp. FirstEnergy Corp. IDEA Center Harrison Power

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Application of Advanced Diagnostic Techniques for Plant Performance and Availability Improvement

USAID Clean Coal International Conference

21 & 22 November 2013

Michael Fox Douglas Eakle Supervisor, Data Utilization Performance/CBM Engineer FirstEnergy Corp. FirstEnergy Corp. IDEA Center Harrison Power Station Ron Griebenow, P.E. Director, Energy Services GP Strategies Corporation

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SLIDE 2
  • Six million customers
  • 18,000+ MW capacity
  • Operations in six states
  • 65,000 square mile

service territory

  • 20,000 miles of high-

voltage transmission

  • $50 billion in assets
  • $15 billion annual revenue
  • 16,500 employees
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SLIDE 4

“Integrating People, Processes & Technologies”

  • Performance Improvement Leader since 1966
  • Servicing 1/3 of Fortune 500
  • Energy, Manufacturing & Government Sectors
  • Headquartered in Columbia, Maryland
  • 3,000+ Employees in 13 countries
  • $400M US Revenues (2012)
  • NYSE: GPX
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SLIDE 5

Our Office Locations: Where We Operate:

GLOBAL PRESENCE

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SLIDE 6

Energy Services

Improving Plant & Workforce Performance

ASSET PERFORMANCE WORKFORCE PERFORMANCE

“More than 150 Power Generation SME’s.”

HUMAN PERFORMANCE MANAGEMENT

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7

  • FirstEnergy has utilized on-line performance

monitoring since the late 1980s

  • Allegheny Energy (now FirstEnergy) implemented APR

for validation of on-line data in 1998

– Expanded to on-line equipment health monitoring in 2004

  • Performance And Condition Monitoring included

multiple, independent systems

– Each required maintenance, training and application expertise – diagnosis of a specific problem often required the subject matter expert (SME) to switch back and forth between the systems

  • Standardized on EtaPRO Suite in 2011
  • Established Information Diagnostic Evaluation and

Analysis (IDEA) Center

Background

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SLIDE 8

2010 2012 2004

Synergistic Technologies

THERMODYNAMIC MODELING

The EtaPRO System

Core Technologies

ANOMALY DETECTION MACHINERY DYNAMICS

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SLIDE 9

On-Line Performance Monitoring

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Thermodynamic Modeling

Design Data Engineering Principles VirtualPlant™ Model

  • Boiler
  • Steam Turbine
  • Feedwater Heaters
  • Condenser
  • Air Heaters
  • Steam Seal System
  • Boiler Feed Pumps
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SLIDE 11

11

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SLIDE 12

Machinery Health Monitoring

Asset Sensors Signature Processing Unit Fault Symptom Monitoring

Dynamic Sensors measured

  • Vibration
  • Air gap
  • Flux
  • Current
  • Phase reference

Semi Static Data imported

  • Power, Active, Reactive
  • Inlet pressure
  • Flow
  • Bearing and Winding Temps. etc.
  • Processes dynamic signals

into machine signatures using advanced signal analysis techniques.

  • Compares new data with

pre-classified references.

  • Send changes to the

EtaPRO Predictor Server for warning, diagnosis, prediction and storage.

EtaPRO Predictor

  • As supplement to the alarm

system, the Plot Manager provides advanced diagnostic presentation and analysis tools for fault symptom forecasting

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SLIDE 13

EtaPRO Predictor AutoDiagnosis

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Advanced Pattern Recognition

Asset Sensors History APR Model

  • Power Output
  • Reactive Load
  • Exhaust

Temp

  • IGV Position
  • Inlet DP
  • Bearing Temp
  • Bearing

Vibration

  • Wheel Space Temps
  • Etc.
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SLIDE 15

Expected Value Measured Value Alarm Range Difference between expected and measured Alert

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  • Concern History
  • Multi-concern

View

  • Asset/Hierarchy

Views

  • Expected

Values

– APR – VirtualPlant – EtaPRO – Predictor

Concern Management

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SLIDE 18

FirstEnergy Case Studies

  • All Examples from Harrison Power Station

–

3x650 MW Original Rated Capacity

–

Foster Wheeler Opposed-Wall, Coal-Fired, Supercritical Boilers

–

Westinghouse Single Reheat Turbines

–

Turbine Upgrades (~670 MW)

  • Closely track issues identified, resolution and value, based on

EPRI guidance

–

Fleet Wide Monitoring for Equipment Condition Assessment (TR-1010266, March 2006)

–

On-Line Monitoring Cost-Benefit Guide (TR-1006777, November 2003)

  • 2012 probability-weighted value of validated EtaPRO

concerns almost $2.5 million

–

total potential savings exceeded $24 million

–

first half of 2013 (January – June) = almost $500,000

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FirstEnergy Case Studies

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Feedwater Heater Isolation/Bypass

EtaPRO 10.1

  • May 23, 2013, EtaPRO alerted plant staff to a high feedwater

heater level

– Harrison Unit 2 – heater 24B

  • Heater level pots "bumped"

during teardown of scaffold

– caused the heater to isolate – bypass valves to open – no annunciator alarm was

received in control room

  • Unit derate of 5 MW

– would likely have remained isolated for one week – value of the lost generation = $29,400

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Feedwater Heater Isolation/Bypass

EtaPRO 10.1

  • Heater was returned to service12 hours after the initial alert

– actual value returned to normal

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Forced Draft (FD) Fan IB Bearing

EtaPRO 10.1

  • April 11, 2013, Unit 3 B-side FD fan inboard bearing temperature

increased measurably

– Concern being monitored – Temperature ~25oF

higher than normal

– DCS alarm point 180oF

  • Boiler tube leak outage

Week of July 2

– oil change – babbit material in oil – bearing rolled out – minor damage – Scraped, blued, and

returned to service

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Forced Draft (FD) Fan IB Bearing

EtaPRO 10.1

  • Mechanics noticed sight glass indicating normal level after draining

– sight glass connection to housing plugged with dirt and sludge

  • Following repair,

temperature dropped ~ 15oF

– Still above “normal” – no change with

continued operation

– model scheduled for

tuning

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Forced Draft (FD) Fan IB Bearing

EtaPRO 10.1

  • Loss of the FD fan = unit derate of 300 MW
  • Repair would have requires at least 48 hours
  • Would result in lost revenue of approximately $504,000
  • Conservative 10% probability, results in probability-weighted

savings of $50,400

  • Excludes likely increased costs for the actual repair, had the

bearing been run to DCS alarm level or possibly to failure

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Gland Steam Temperature

EtaPRO 10.1

  • Gland steam temperature not under automatic control
  • Requires manual valve adjustment to control gland steam

temperature

– supply ~440-460oF – temp feeding LP

turbine seals ~210-220oF

– often overlooked

after a plant start-up

– scheduled for DCS

integration

– monitor in the

meantime

Gland Steam Supply Temperature Instrument Gland Steam to LP Temperature Instrument Gland Steam Desuperheating Station

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Gland Steam Temperature

EtaPRO 10.1

  • Tags added to existing LP steam turbine model on April 2, 2013
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Gland Steam Temperature

EtaPRO 10.1

  • Alerted to high gland-steam temperature on June 3, 2013
  • Predicted value

“noise” noted as modeling concern by GP Strategies Staff

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Gland Steam Temperature

EtaPRO 10.1

  • High temperatures lead to LP turbine vibration issues
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Gland Steam Temperature

EtaPRO 10.1

  • Vibrations did not hit alarm levels
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Gland Steam Temperature

  • Model data review reveals “problem” data from 2005/2006
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Gland Steam Temperature

  • Removal of “problem” data eliminates “noisy” expected value
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Cycle Isolation

EtaPRO 10.1

  • July 7, 2012, alerted to a high drain line temperature
  • work order for

replacement during next unit outage

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Cycle Isolation

EtaPRO 10.1

  • Valve was replaced during short outage starting late on July 13
  • Drain temperature excursion immediately following unit start-

up July 18

– air solenoid

leakage

– insufficient

pressure to close the valve

– solenoid

replacement resolved problem

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Cycle Isolation

EtaPRO 10.1

  • FirstEnergy estimated 2% of the reheat steam flow was being

dumped to the condenser

– Based on the temperature, valve size and drain piping size and

length

  • Thermodynamic model analysis (e.g., VirtualPlant) used to

quantify the leakage effect on generation and heat rate

  • Resulted in increased generating costs of $38,985 per

week

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Air Heater Support Bearing

EtaPRO 10.1

  • July 7, 2012, alerted to a high air-heater support bearing temp
  • site glass indicated

normal oil level

  • Added oil after further

temp increase

  • Failure = unit trip

– Repair – 72+ hours – loss in revenue > $4M

million.

  • 10% probability of not

being identified through

  • ther systems
  • Probability-weighted benefit of $436,440
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Conclusion

EtaPRO 10.1

  • FirstEnergy estimates system licensing and implementation costs

were recovered in less than 4 months

  • Single, integrated platform has resulted in increased visibility of

issues through the availability of both performance data and equipment condition anomalies on a single platform and unlimited distribution rights of client software

  • Pilot installation in FirstEnergy nuclear operations (FENOC)

indicates similar return on investment in nuclear stations.

  • FENOC expanding equipment models for Perry Station using in-

house resources and will implement throughout the nuclear fleet (four units at three sites)

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SLIDE 37
  • Knowledge. Performance. Impact.

Questions?

Ron Griebenow, P .E.

Director, Energy Services 724 Whalers Way, Suite H100 Fort Collins, CO 80525 (970) 226-0812 rgriebenow@gpstrategies.com