Fleet Optimization through Process Information. Sumanth K. Makunur 2/13/13

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1 Fleet Optimization through Process Information Sumanth K. Makunur 2/13/13

2 DTE Energy Process Controls & Technology Fleet Optimization. through Process Controls & Technology The Process Technology Enablers 2

3 Why Focus on Controls & Technology? We operated for years without Process Information! Information in capable hands always yields benefits. Every facility and group has an effect on the company. The company is affected by outside influences. Fleet Optimization requires awareness of Process Costs, Performance, Asset Health, Reliability and Market Value. Small investments in Technology yields large returns. 3

4 Today s Agenda Fleet Optimization through Process Information Remote Monitoring Center Control & Technology Framework Application Examples Work in Progress PI Asset Framework Integrated applications environment: Consistent framework for data, analysis, reporting and consistent user graphical interface. KPI s Dashboards Fleet Optimization Business Intelligence Reliability Outage & De-rate Maintenance & Market Expert Systems Predictive Monitoring, Optimization System Dashboards Fleet Status Assessment WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data Panel Discussion 4

5 Power Plants & Performance Center Monroe 3,135 mw Belle River 1,260 mw Harbor Beach 103 mw Expanding Renewable Portfolio Trenton Channel mw Performance Center 11,588 mw St Clair 1,417 mw River Rouge mw Greenwood 785 mw Fermi 1,100 mw 5

6 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB Fleet Optimization Process Costs Asset Health, Market Value 20% Business Intelligence Outage & De-rate (UCF) Maintenance & Market Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment System Dashboards Fleet Status Assessment WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data People Making right decisions when it matters! 25% Drives Performance Excellence Fleet Optimization Process Costs, Asset Health, Reliability Operational Performance, Market Value Relate all Data Sources PI AF (PI, ProcessGuard, Maximo, SAP, UCF, P3M, Predictive Monitoring, NeuCo, LIMS, Plant View..) 60% 90% Advanced Analysis & Process Optimization Reliability Academy Equipment, Process, Performance, Reliability Models Closed Loop Process Optimization 100% 90% Fleet Drill down Subject Matter Experts 90% Standard User Interface WEB Visualization Process Discrete Data Engineering Applications PMAX, DFTS, enote, Fuel Cost Framework, Alarm Management Post Event Analysis DCS, PLC & PI % Complete 6

7 The Performance Center The Door into the Fleet Performance Center Mission Equipment Performance Optimization of the Fossil Generation Portfolio through continuous real time and predictive asset condition monitoring to maximize the asset market value. Performance Center Vision Fossil Generation s Fleet-wide Mission Control Center for continuous monitoring and optimization of plant equipment performance Virtual Control Room Operating View of Fleet Drives consistent practices (UCF) Market interface w/moc Proficient users of technology SME rotation mutually beneficial Reliability tools (SmartSignal & Plant View) Input in the budget process 7

8 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 8

9 PI Servers at all Generation Sites Belle River PI St Clair PI Greenwood PI PI Harbor Beach Corporate/ Wind PI PI EMS Ranger PI Ann Arbor PI Performance Center PI PI PI Monroe Trenton Channel River Rouge 9

10 Plant Controls & Technology Center Interconnected / Interdependent DCS Operator Consoles NeuCo PMAX ProcessNet ProcessGuard EPRI Plant View Multiple Data Sources ABB DCS PI PLC PI Interfaces PMAX Controllers PLC CEMS SmartSignal 10

11 Raw PI Data Analysis PI Yields Benefits Post trip analysis Process monitoring Optimization Early warning Alarming 11

12 PI Advanced Metering Infrastructure (AMI) Implemented an extensive PI Infrastructure for AMI data MSP Interface to capture 8 Server PI Farm 1 Million Plus meters data 25 Million PI tags and growing 12

13 Challenge - Process Data Everywhere! DCS installations on nearly every unit Nearly 800,000 process data tags PI Systems at each plant PI Interfaces to DCS & many PLC s What is that data screaming at us? How do you effectively utilize the data? How do you turn data into information? 13

14 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data 90% Discrete data Limited value ABB Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 14

15 Engineering Applications PI Thermal Performance Calc Engine Digital Fuel Tracking System Tracking Emissions Operator Rounds 15

16 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Drive Performance Excellence Drive Performance Excellence Fleet Optimization Fleet Perspective Methods Applications Discrete data Limited value ABB WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 90% Involves Operation Performance MISO Market Reliability Maintenance Reporting Budget 16

17 Fleet Status PI WEB enabled 17

18 Real-Time DCS Operator Displays 6000 real time dynamic actively linked WEB DCS graphics Click & Trend 18

19 PI enabled - Event Re-play Re-play events using historical PI data 19

20 Real-Time Wind Turbine Display 20

21 Mobile Work Force Mobile Work Force PI Data on Tablets /Smartphones 21

22 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Discrete data Limited value ABB Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 23

23 System Dashboards PI Enabled 2000 real time dynamic actively linked WEB System graphics Click & Drill 24

24 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment 60% System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 25

25 Equipment Condition Monitoring SmartSignal Fleet wide 26

26 Equipment Condition Monitoring SmartSignal Fleet wide Equipment: Air Heater, Condenser, Boiler, Turbine, ID Fans, FD Fans, PA Fans, Boiler Feed Pump, Generator, Pulverizer, Feed water Heater Similarity Based Modeling 27

27 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Business Intelligence Outage & De-rate (UCF) Maintenance & Market 25% Discrete data Limited value ABB Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment 60% System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 28

28 Unit Capacity Framework (UCF) Process Flow Power Plants Day Ahead Performance Center Real Time Market Merchant Center Market Strategy Market Feedback 29

29 Unit Capacity Framework (UCF) Manages all Unit Capacity and De-rates - Interfaces to MISO, P3M & EMS Automatically Generated Status Report (Availability on BlackBerry) Dynamically linked with Outage and de-rate process 30

30 Enterprise Business Systems (EBS) Maximo & SAP SAP Financial Information Human Resources Supply Chain Maximo Work Management System 31

31 Control & Technology Framework Fossil Generation Business Unit Strategy Actionable Information KPI s Discrete data Limited value ABB People Fleet Making right decisions when it matters! Optimization Process Costs Asset Health, Market Value 15% Business Intelligence Outage & De-rate (UCF) Maintenance & Market 25% Expert Systems Predictive Monitoring, Optimization MBO/PdM/Risk Assessment 60% System Dashboards Fleet Status Assessment 90% WEB Visualizing Plant Alarm, DCS Real-time WEB Graphics Easy Access to Information 100% Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Process Discrete Data 90% Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 90% 32

32 No Shortage of Information! Laboratory Information PI Data Historian Operator Logs Project Management SAP Work Management Document Management Emissions Monitoring Alarms EPRI Plant View Combustion Optimization Outage Planning De-rate Management Fuel Cost MISO Real Time Unit Capacity Performance Analysis Emissions Monitoring MISO Day Ahead Ancillary Services 33

33 Common Methodology Standard GUI Single Method PI Asset Framework: Integrated applications environment: Consistent framework for data, analysis, reporting and consistent user graphical interface. EPRI Plant View Alarms Performance Analysis PI Data Historian Operator Logs Combustion Optimization ECG AccuTrack Laboratory Information Emissions Monitoring Work Management Project Management SAP Document Management De-rate Management MISO Day Ahead MISO Real Time Outage Planning Ancillary Services Unit Capacity Fuel Cost Process Information Business Systems Market Data 34

34 Common Structure Process Information Business Systems Market Data 35

35 Pulverizer Assessment What information is needed? Pulverizer Milling Costs Process Costs Production Costs EAF SmartSignal Watch List Work Performed & Work Pending Alarms 36

36 Pulverizer Multiple Data Sources Consistent Reporting Common Methodology Common Structure Unit Capacity Alarms EPRI PlantView Maximo PI SAP P3M Documentum SmartSignal 37

37 Common Thread Equipment Hierarchy Primary System Secondary System Sub System Equipment Sub Equipment Equipment Hierarchy Hierarchical System Index (HSI) Work Breakdown Structure (WBS) 38

38 Pulverizer Multiple Data Sources Consistent Reporting Common Methodology Common Structure Unit Capacity Alarms EPRI PlantView Maximo PI SAP P3M Documentum SmartSignal 39

39 Asset Framework Expanded System Dashboard Health Health Assessment PI KPI s DCS Trends SmartSignal Watch List Alarms 40

40 PI Asset Framework (AF) 41

41 Process Cost Drill Down EAF Dispatch Costs Plant Summary Production Costs Milling Costs Heat Rate 42

42 Logical Display Flow 44

43 Fleet Overview 45

44 Plant Overview 46

45 Unit Overview 47

46 Coal Mill 48

47 Coal Mill Health Status 49

48 Total Fleet Management Financials Work Management SAP Maximo Drives Performance Excellence Process Costs Asset Health Operational Performance Market Value Fleet Optimization Real-time Process Applications Market MISO, Fuel Coat Framework Unit Capacity Framework Expert Systems SME Status Displays WEB Portal Applications Distributed Control Systems (DCS) Distributed PI Historians 50

49 ProcessNet Demonstration Fleet Optimization is about People Making the right decisions when it matters! 51

50 Thank You

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