application of advanced diagnostic techniques for plant

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

• 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

“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

Our Office Locations: Where We Operate:

GLOBAL PRESENCE

Energy Services Improving Plant & Workforce Performance

ASSET PERFORMANCE

WORKFORCE PERFORMANCE

“More than 150 Power Generation SME’s.”

HUMAN PERFORMANCE MANAGEMENT

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• 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

2010 2012 2004

Synergistic Technologies

THERMODYNAMIC MODELING

The EtaPRO System

Core Technologies

ANOMALY DETECTION

MACHINERY DYNAMICS

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

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

EtaPRO Predictor AutoDiagnosis

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.

Expected Value Measured Value

Alarm Range

Difference between expected and measured

Alert

• Concern History • Multi-concern View • Asset/Hierarchy Views • Expected Values

– APR – VirtualPlant – EtaPRO – Predictor

Concern Management

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

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


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


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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EtaPRO 10.1 • Tags added to existing LP steam turbine model on April 2, 2013

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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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EtaPRO 10.1 • High temperatures lead to LP turbine vibration issues


EtaPRO 10.1 • Vibrations did not hit alarm levels


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


• 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

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 other systems

• Probability-weighted benefit of $436,440

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)

Knowledge. Performance. Impact.

Questions?

Ron Griebenow, P.E. Director, Energy Services 724 Whalers Way, Suite H100 Fort Collins, CO 80525 (970) 226-0812 [email protected]

application of advanced diagnostic techniques for plant

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