1q03_iberdrola_cmds

7/29/2019 1q03_iberdrola_cmds

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A S S E T M A N A G E M E N T

3 0 O RB IT 1Q 03

In todays deregulated and com-petitive power generation market,power producers are continuallylooking to gain an edge over theircompetitors. This environment isforcing power producers to rethinkhow they manage their plant assets

and what decision-making processesare needed to operate their plantsmore efficiently and cost-effectively.They are asking themselves howto minimize the risk of asset damage,how to improve plant availabilityand reliability while reducing main-tenance costs and extending servicelife, and how to assess the remainingvalue of fixed assets.

Iberdrola Generacin, S.A., Spainssecond largest power generatingcompany (Europes eighth largest),believes that the key to success isin how well we integrate the threemain aspects of a power plant; namely,operations, power generationasset management, and the decisionmaking process (Figure 1). We haverecognized that in most cases oper-ations is almost exclusively focused

IBERDROLAs Center for Monitoring, Diagnostic andSimulation (CMDS) of Combined-Cycle Power Plants

DiagnosticOptimization

Monitoring

Decision-MakingProcess

Operation

PowerGenerationAssetManagement

An Asset Management Vision Becomes a Reality

INTEGRATING THE CRITICAL FACTORS OF POWER GENERATION PLANT

MANAGEMENT | FIG. 1

ByPablo Mendivil Ruas and

Toms Alvarez Tejedor (Iberdrola

Generacin, S.A.) in collaboration with

Rafael Sandrea andJose I. Garcia

(Bently Nevada)

on the process in order to maximizeperformance, maintenance is focusedon the maintenance tasks to improveasset maintainability, while plantmanagement is focused on pro-ducing electricity in a cost-effectivemanner.

We asked ourselves, are operationsand maintenance working in thesame direction? Do they require the

same information? Do they havethe required information at the righttime to make the best decisions? Arewe managing our plant assets proac-tively, rather than reactively?

Iberdrola Generacins approach tomanage its growing global portfolioof combined-cycle power gener-ation assets is to integrate operationsand asset management with a reliable


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1Q03 ORBIT 31

decision-making process (method-ology). They accomplish this throughthe use of plant information systemsand asset condition managementsystems capable of providing the

exact information required by theright people and at the right time.Bently Nevada refers to this typeof information as Actionable Infor-mation. Continuous online conditionmonitoring systems that collect,measure, and display key processand asset condition variables in realtime are used to link operations withasset management. Key metrics suchas reliability, availability, and main-

tainability (RAM), along with thermalefficiency, are well integrated intothe methodology. All the incomingdata is correlated and continu-ously analyzed in real time byknowledge-based asset conditionmanagement systems, diagnostictools, and specialists who are enabledto effectively and systematicallyconduct root-cause analysis anddetermine corrective actions. Actionable

Information is transmitted to theappropriate people in operations,maintenance, engineering, instru-mentation and plant management.Finally, plant asset optimization

takes place and lessons learned canbe embedded in the knowledge-based systems to improve, validate,and automate the diagnostics anddecision-making process. The

knowledge-embedding process isaccomplished through custom rulesdeveloped for each asset underspecific operating parameters.

With a solid power generation assetmanagement vision and a com-mitment to be a world-class technologyleader, Iberdrola Generacin, S.A.launched a remote monitoring, diag-nostic and simulation center (CMDS)in Castelln, Spain in 2002. The

CMDS will be networked to all ofour combined-cycle power plants(CCPPs) worldwide (total plannedcapacity is 13,000 MW). The CMDSmission is to identify asset per-formance degradations andmalfunctions in our CCPPs by meansof symptoms and indicators of initialstage problems and to provide timelysolutions and recommendationsto plant management, operations,

and maintenance that will enablethem to optimize their CCPP per-formance. CMDS will concentratespecialized resources from variousfunctional areas, knowledge, and

skills for the benefit of our CCPPs.

At the heart of the CMDS is themonitoring and diagnostic room(Figure 2) from which combined-cycle power plants will receive

continuous, around-the-clock support.The CMDS remote monitoringand diagnostic system (RM&Dsystem) allows the CCPPs operatingconditions to be kept under con-stant control. This RM&D systemautomatically detects incipient devi-ations of both performance andcondition from normal operationat an early stage, thus enabling plantmanagement to avoid and reduce

performance losses and more seriousdamage on the assets.

The benefits that we are realizingand expect to gain through theCMDS and improved asset man-agement strategies are as follows:

r Planned maintenance and proactive

intervention made possible by the RM&D

system

r Optimized plant thermal efficiency,

reliability, and availability

r Reduced and improved control of O&M

expenses

r Extended intervals between planned

maintenance

CMDS MONITORING AND DIAGNOSTIC ROOM | FIG. 2


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3 2 O RB IT 1Q 03

r Reduced duration of scheduled outages

r Improved prediction of life cycles

r Reduced unplanned outages

All these benefits are achievable byimplementing a condition-based,proactive asset management strategyand a reliable decision-making processwi th the right informat ion and

the right people to act on it. Figure3 illustrates a functional diagramof the CMDS remote monitoringand diagnostic system developedfor large industrial gas turbine gen-erator trains.

The Analysis Module shown inFigure 3 is considered the mostimportant element of the RM&Dsystem. Its primary function is to

Condition Evaluation/Malfunction Detection

TelecommunicationSystem/Remote

Warning

Detailed Analysis

and Diagnosis

Operational

Follow up

IncidentAnalysis

IncidentReports

O & MRecommendations

O & M Reports O & M Monitoring/

Reliability

Tracking

Online Data Processing and Validation

Online Data Acquisition System

Generator

ThermodynamicAnalysis

Hot Gas SectionMonitoring

VibrationAnalysis

GeneratorMonitoring

Remote Access

and Retrievalof Plant Data

Communication

System

ConfigurationM & D System

(Local/Remote)

M & DDatabase

Combined-Cycle Power PlantMonitoring & Diagnostic

Center

M & DDatabase

ANALYSIS

Deviation InferenceEngineBaseline Rules

Intranet

Network

FUNCTIONAL DIAGRAM OF THE CMDS REMOTE MONITORING AND DIAGNOSTIC SYSTEM | FIG. 3

assess the mechanical, rotor dynamic,and thermodynamic performanceof the assets. Online RAM tracking,electrical generator monitoring, andGT/ST/BOP historical data aretightly integrated into the AnalysisModule. Central to the AnalysisModule is Bently Nevadas asset con-dition management platform (System1) and knowledge-based system(Decision Support SM). Thermo-dynamic peformance monitoringis accomplished through GE Opti-mization Softwares EfficiencyMap

and ABBs Optimax sys tem.EPRI/SPS ORAPLINK reliabilitysystem is used for GT online RAMmonitoring. GT/ST/BOP processmonitoring/historian is accom-plished with GEs GT Historian

and OSIsofts ProcessBook. Onlineelectrical generator monitoring ismade possible by GEs PDA systemand ABBs PAMOS system.Instrumentation consists of theonline and off-line data acquisitionsystems and the online data pro-cessing and validation system. Onlinedata collection systems collect process,thermodynamic, mechanical, elec-trical, and rotor dynamic assetcondition data. Report data frominspection and testing, oil analysis,thermography, surveys, and portablevibration instruments is collectedoff-line.A communication network linksplant staff (plant management, oper-ations and maintenance) and theCMDS.


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1Q03 ORBIT 33

The CMDS will also be used as atuition-based training center forfuture operators of combined-cyclepower plants. We are using twodynamic simulators from two dif-

ferent technologies: one developedby ALSTOM and the second oneby General Electric.These simu-lators will make it possible to:

r Gain experience, confidence, and

accuracy when operating the plant

r Gain confidence when operating the

control system and the assets

r Monitor operation processes under

normal and critical plant conditions

r Reduce outage time resulting fromoperational errors

r Improve unit productivity through

optimized operation for all load

conditions

CMDS conference room will alsobe used to hold technical sym-posia in the areas of CCPP technologyand asset management by sharing

MONTERREY III.

IBERDROLAS FIRSTCOMBINED-CYCLE

POWER PLANT

FIG. 4

lessons learned from operations,maintenance, plant management,and diagnostics specialists. Tech-nology-leading manufacturersand service providers will be able to

present and share their knowledge,experience, and advances in tech-nology.

Iberdrola Generacin is currentlymonitoring a 1000 MW CCPP(Monterrey III, Mexico Figure 4)and a 800 MW CCPP (Castelln,Spain Figure 5) from the CMDS.At the cutting edge of technology,the CMDS represents a commitmentto the future. It brings together

the most modern asset managementtechniques, providing high-qualityservices that will meet the challengesof the 21st century. The great potentialof the CMDS lies in the 13,000megawatts of combined-cycle powerplants that Iberdrola Generacin isdeveloping in Spain, Mexico, andBrazil.

Generator

Generator

Generator

GEEfficiencyMapTM

OSIsoft

PI System

PI ProcessBook

Bently Nevada

System 1TM

Decision SupportSM

Data

Data

Data

Data

GE

Cimplicity

Gas Chromatograph

Emission Monitoring

Foxboro

I/A Series AW70

Bently Nevada

Monitors / TDXnetTM

GE

Generator

Monitoring-PDA

MONITORING & DIAGNOSTIC SYSTEM FOR CASTELLN COMBINED-CYCLE POWER PLANT | FIG. 5

1q03_iberdrola_cmds

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