center for monitoring, diagnostic and simulation of combined cycle power plant (cmds)

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Page 1 CMDS - Iberdrola Operación y Mantenimiento, S.A. Center for Monitoring, Diagnostic Center for Monitoring, Diagnostic and Simulation of Combined Cycle and Simulation of Combined Cycle Power Plant Power Plant (CMDS) (CMDS) DS - Iberdrola Operación y Mantenimiento, S.A. May 2003 May 2003

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Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS). May 2003. CMDS - Iberdrola Operación y Mantenimiento, S.A. IBERDROLA. CMDS - Iberdrola Operación y Mantenimiento, S.A. Iberdrola today. - PowerPoint PPT Presentation

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Page 1: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 1CMDS - Iberdrola Operación y Mantenimiento, S.A.

Center for Monitoring, Diagnostic Center for Monitoring, Diagnostic

and Simulation of Combined Cycle and Simulation of Combined Cycle

Power PlantPower Plant

(CMDS)(CMDS)

CMDS - Iberdrola Operación y Mantenimiento, S.A.

May 2003May 2003

Page 2: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 2CMDS - Iberdrola Operación y Mantenimiento, S.A.

IBERDROLA IBERDROLA

CMDS - Iberdrola Operación y Mantenimiento, S.A.

Page 3: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 3CMDS - Iberdrola Operación y Mantenimiento, S.A.

– Iberdrola Group is a listed public joint company with a market capitalisation of more than Euro 13.000 M created in 1992 with the merger of Hidroelectrica Española and Iberduero.

The most cost-effective generation mix among Spanish producers

– Iberdrola Group is one of Europe´s leading electricity companies, providing a full range of power services involving the generation, transmission, distribution and retailing of electricity.

– As of December 31, 2000, Iberdrola had a total installed capacity of 16.062 MW, and an expansive transmission and distribution network offering service to 8.76 million customers in Spain.

– In 2000, Iberdrola generated net revenues in excess of Euro 7.000 M.

– Solid financial profile with a rating of A1/ A+ / AA- (Moody’s / S&P / Fitch IBCA).

– International activity is one of the key factors of the strategy, alongside with growth on our traditional markets, improved efficiency and diversification.

Iberdrola also has specific local partners in its international investments.

– As part of our new strategy, Iberdrola plans to invest Euro 12 bn within the period 2002 - 2006 to double its size, growing in Spain, Europe, Latin America as well as in the USA.

Iberdrola today

Page 4: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 4CMDS - Iberdrola Operación y Mantenimiento, S.A.

Fuente: IDAE

Generation

Installed Capacity in 2000 %

Hydro 8.367 MW 50,6%

Nuclear 3.267 MW 41,8%

Fuel/Gas 3.191 MW 38,8%

Coal 1.441 MW 12,8%

TOTAL 16.266 MW 37%

Production 2000: 46.641 GWh

Market share: 28,53%

T&D Assets (2000)

Transmission lines

- 220/380 kV 5.155 km.

- 3/132 kV 94.880 km.

Nº Substations 798

Transf. Capacity 53.880 MVA

Distribution - Commercial (2000)

Sales: 69.912 GWh

Clients: 8,7 Millions

Hydro

Thermal

Nuclear

Distribution Area

FreeMarket29%

Tariff71%

Iberdrola in Spain

Page 5: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 5CMDS - Iberdrola Operación y Mantenimiento, S.A.

GUATEMALAEEGSA (39,2%)

BRASILCoelba (42,8%), Celpe (79,5%) Cosern

(34,8%)

BOLIVIAElectropaz (57,1%)

Elfeo (95%)

Electric Distribution

Gas and Water Distribution

COLOMBIAGas Natural (15,8%) Transcogás

(22,5%)

BRASILGas: CEG (9,9%) and Riogás

(13,1%)

CHILEESSAL (51%)

Sanitary Services

URUGUAYMaldonado

Sanitary Services

Electric Generation

MÉXICOMonterrey (100%): 1000 MWAltamira (100%): 1000 MW

BRASILItapebí (29,2%): 450 MWTermoaçu: 520 MWTermopernambuco: 250 MW

CHILECentral Hidroeléctrica Ibener (26,3)

NICARAGUAAmayo (80%) - Wind Turbines

(In construction)

Iberdrola in America

Page 6: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 6CMDS - Iberdrola Operación y Mantenimiento, S.A.

Brussels Institutional and

Regulation Office

Headquarters(Madrid/Bilbao)

Zurich Origination

Office

Mexico PlatformHQ

Brazil Platform HQ (Guaraniana)

Iberdrola has established several offices abroad to go forward with its strategy of becoming a main energy player in America and Europe

Geographic Presence

Page 7: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 7CMDS - Iberdrola Operación y Mantenimiento, S.A.

MULTIPLE

14,431

4,157

1,604

x2

x2,1

x1,9

6,978

1,960

831

Revenues(in Euro m)

EBITDA(in Euro m)

Net Income(in Euro m)

20062000

11,878

50

641

40

--

51,6

535

57

Accumulative Investment (in Euro m)

Leverage

(%)

Dividends (in Euro m)

Pay-out (%)

Shareholder`s equity 7.744Net financial debt 8.177Total Assets 19.671

Market Capitalization at 22/1/02 12.531

Other Financial Figures

(Euro m in 2000)

Financial Targets

Page 8: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 8CMDS - Iberdrola Operación y Mantenimiento, S.A.

Capacity (MW)

Production (GWh)

Supply (GWh)

SPAIN

2000

16.000

50.000

70.000

2006

22.000

75.000

86.000

Multiple 00-06

x1,4

x1,5

x1,2

Capacity (MW)

Supply (GWh)

BRAZIL(39%)

-

8.000

830

10.600 x1,3

Capacity(MW)

Production (GWh)MEXICO -

-

5.000

35.000

Capacity (MW)OTHERS - 3.000

TOTALCapacity (MW)

Production(GWh)

16.000

50.000

30.800

120.000

X1,9

X2,4

Energy Targets

Page 9: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 9CMDS - Iberdrola Operación y Mantenimiento, S.A.

Business & Geographical growthBusiness & Geographical growth

2000

Generation

46%

Dist. / Com.

44%

Others 10%

2006

Generation

63%

Dist. / Com.

31%

Others 6%

More focused on Generation

More focused on GenerationMore focused on Generation

2000

2006

International

25%

International

6%

Domestic 75% Domestic 94%

Strategy Plan: 2002 - 2006

Page 10: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 10CMDS - Iberdrola Operación y Mantenimiento, S.A.

Generation. Power & EnergyGeneration. Power & Energy

2000 Nuclear 20%

Hydro

50%

Thermal 27%

2006

CCGT’s

35%

Hydro

31%

Installed Capacity (MW)

Production (GWh)Production (GWh)

2000

2006

RR.E.E. 3%

RR.E.E. 14%

Thermal 8% Nuclear 12%

Nuclear 49%

Hydro

25%

Thermal 24%

RR.E.E. 2%

Hydro 12%

RR.E.E. 7%

Thermal 5%

Nuclear 21%

CCGT’s

55%

Strategy Plan: 2002 - 2006

Page 11: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 11CMDS - Iberdrola Operación y Mantenimiento, S.A.

CronogramasCronogramas

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

CCGT CASTELLÓN800 MW

SEPT. 2002

CCGT CASTEJÓN400 MW ABRIL 2003

CCGT BASF - TARRAGONA400 MW (50% IBD)

JUNIO 2003

CCGT ESCOMBRERAS800 MW

DIC. 2004

CCGT SANTURCE400 MW

MARZO 2004

CCGT ACECA

400 MW ( 100% IBD)JUNIO 2004

CCGT BBE800 MW (25% IBD)

MARZO 2003

CCGT CASTELLÓN II800 MW

DIC. 2005

PUESTA EN SERVICIO: 2002 2003 2004 2005 2006 2007 2008 2009

TOTAL ANUAL (MW) 800 800 1.600 800 -- 600 -- 600 ACUMULADO (MW) 800 1.600 3.200 4.000 4.000 4.600 4.600 5.200

CCGT ARCOS A 800 MW

OCT 2004

Strategy Plan: 2002 - 2006

Page 12: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 12CMDS - Iberdrola Operación y Mantenimiento, S.A.

Período Construcción Carbón Importación

Período Construcción CCGTProceso Autorización

ARCOS (*) 400 MW/1.600 MW

CASTEJÓN B 400 MW

ESCOMBRERAS C 600 MW

ESCOMBRERAS B 400 MW

LADA V 600 MW

CASTELLÓN C 800 MW

SANTURCE B 800 MW

ACECA B 400 MW

PASAJES 400 MW

ENERO 2006

ENERO 2007

ENERO 2008

ENERO 2009

ENERO 2010

ENERO 2011

ENERO 2012

ENERO 2013

ENERO 2014

2202

2203

2204

2205

2206

2207

2208

2209

2210

2211

2212

2213

2214

Strategy Plan: 2006 - 2014

Page 13: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 13CMDS - Iberdrola Operación y Mantenimiento, S.A.

RM&D RM&D ScopeScope

MonterreyMonterrey III III 1000 MW

Abr’02

TermopernambucoTermopernambuco 500 MW

Dic’03

TermoaçúTermoaçú350 MW

Dic’03

EscombrerasEscombreras800 MW

Dic’04

CastellónCastellón800 MW

Sep’02

Tarragona PowerTarragona Power400 MW

Jun’03

CastejónCastejón 400 MW

Abr’03

SanturceSanturce 400 MW

Mar’04

AltamiraAltamira III y IV III y IV 1036 MW

Oct’03

AcecaAceca400 MW

Jun’04

Arcos AArcos A800 MW

Oct’04Arcos BArcos B800 MW

Jul’05

Castellón BCastellón B800 MW

Dic’05

BBEBBE (25%) (25%) 800 MW

Mar’03

Remote Monitoring & Diagnostic Center – CMDS

Page 14: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 14CMDS - Iberdrola Operación y Mantenimiento, S.A.

CMDSCMDS

CMDS - Iberdrola Operación y Mantenimiento, S.A.

Page 15: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 15CMDS - Iberdrola Operación y Mantenimiento, S.A.

DEFINITION Goals Functions Mission Training Simulator Forum

HOW TO ACHIEVE THE GOALS??

IMPLEMENTATION

Diagnostic Instrumentation

Lay-out of CMDS Systems

Telecommunication System

PI System

PI ICE

Other Applications (R-Link; IT Monitoring)

SUMMARY

Page 16: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 16CMDS - Iberdrola Operación y Mantenimiento, S.A.

DEFINITION

Goals

Functions

Mission

Training Simulator

Forum

Page 17: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 17CMDS - Iberdrola Operación y Mantenimiento, S.A.

Controlling the load

is not the main goal

of the CMDS

Its main goal is to carry out

O&M recommendations based

on the cumulative operational

experiences of all the CCPP

CMDS

IS NOT A REMOTE CONTROL CENTER

Remote Monitoring & Diagnostic Center – Definition

1. CMDS1. CMDS

Page 18: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 18CMDS - Iberdrola Operación y Mantenimiento, S.A.

SIMULATION, MONITORING & DIAGNOSTIC CENTER (CMDS):

CMDS is a Technology Center which will act as a core technological competencies, that is, where IBERDROLA POWER GENERATION knowledge, skills and facilities are concentrated to optimize Combined Cycle Power Plant operation and maintenance.

Remote Monitoring & Diagnostic Center – Definition

1. CMDS1. CMDS

Page 19: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 19CMDS - Iberdrola Operación y Mantenimiento, S.A.

GOALS OF RM&D CENTER:

Maximize the efficiency, reliability and availability of CCPP, and in this way lengthen the intervals between planned plant maintenance shut down (reducing plant outages).

All the above based on more reliable and precise information on plant equipment condition and whole plant thermodynamic condition.

2. Goals2. Goals

Remote Monitoring & Diagnostic Center – Definition

Page 20: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 20CMDS - Iberdrola Operación y Mantenimiento, S.A.

FUNCTIONS OF RM&D CENTER:

Operation & Maintenance monitoring and reliability tracking of CCGT

Diagnosis of the key plant parameters (performance and condition monitoring of CCGT)

Detection of malfunctions before they lead to trips and serious faults in the plant (avoiding catastrophic failure)

Archive and retrieval of M&D and O&M data

Generation of reports on performance and incidents

Carrying out of O&M recommendations

3. Functions3. Functions

Remote Monitoring & Diagnostic Center – Definition

Page 21: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 21CMDS - Iberdrola Operación y Mantenimiento, S.A.

THE MISSION IS TO DEVELOP AN ANALYSIS PROCEDURE WHICH ALLOWS US TO:

Identify the degradation and malfunctions in the performance of Combined Cycle Power Plants (CCPP) by means of symptoms and indicators of initial stage problems that by providing solutions and operational and maintenance recommendations in time allow the optimization of CCPP performance.

REMOTE MONITORING & DIAGNOSTIC SYSTEM

4. Mission 4. Mission

Remote Monitoring & Diagnostic Center – Definition

Page 22: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 22CMDS - Iberdrola Operación y Mantenimiento, S.A.

Alstom SimulatorAlstom

SimulatorGE

Simulator GE

Simulator

Training Simulator

Gain operating experience,

confidence and accuracy when

operating the plant in normal/abnormal

conditions Gain confidence to handle the controls system and plant

equipment in normal and abnormal

conditions

Follow operating procedures for given normal and critical

situations and therefore practice the response and

recovery actions to manage various

malfunctions

Reduce the outages time cost

by operational errors and improve the productivity of the unit through

optimize operation for all load conditions

5. Training Simulator5. Training Simulator

Remote Monitoring & Diagnostic Center – Definition

Page 23: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 23CMDS - Iberdrola Operación y Mantenimiento, S.A.

CMDS

6. Forum 6. Forum

Meeting point for

Alstom and GE

Users to exchange

knowledge, best

practices and

experiences

Technological forum

within the area and a

place to exchange

information with

different

Universities of Spain

The international

exchange is reflected

by the staff itself of

the CMDS: personnel

of Mexico and Brazil

Meeting point and

front-office with the

Monitoring Center of

GE in Atlanta (USA).

IBERDROLA is one of

the “key customer” of

General Electric.

Remote Monitoring & Diagnostic Center – Definition

Page 24: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 24CMDS - Iberdrola Operación y Mantenimiento, S.A.

HOW TO ACHIEVE THE GOALS??

Page 25: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 25CMDS - Iberdrola Operación y Mantenimiento, S.A.

CONCEPT OF REMOTE MONITORING & DIAGNOSTIC (RM&D) IMPLIES:

Access to and collection of operation and maintenance data of the CCPP,

its transmission to the RM&D Center,

the analysis and diagnosis by means of a combination of automatic analysis and the M&D specialists,

the editing of condition and performance reports,

and provision of operational and maintenance recommendations.

How to achieve the goals??

Page 26: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 26CMDS - Iberdrola Operación y Mantenimiento, S.A.

Network Plant

TELECONTROLGATEWAY

VibrationTransaducers

Gas TurbineControlSystem

Steam Turbine Control System

………Control System

MachineProtec.Syst.

Transducers

………..

Client Applications

DataAcquisition

Devices

PLANT INFORMATION

SYSTEM

M&D application client

Performance application

client

ROUTER

SIMULATION MONITORING & DIAGNOSTIC

CENTRE

How to achieve the goals??

Page 27: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 27CMDS - Iberdrola Operación y Mantenimiento, S.A.

IMPLEMENTATION

Diagnostic Instrumentation

Lay-out of CMDS Systems

Telecommunication System

Plant Information System

PI ICE

Other Applications (R-Link; IT)

Page 28: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 28CMDS - Iberdrola Operación y Mantenimiento, S.A.

IMPLEMENTATION OF THE MONITORING & DIAGNOSTIC SYSTEM OF COMBINED CYCLE POWER PLANTS:

I.- Diagnostic Instrumentation (special+standard)

II.- Lay-out of CMDS Systems

III.- Telecommunication System

IV.- Plant Information System

V.- PI ICE

VI.- Other applications (R-Link; IT Monitoring)

Implementation

Implementation Implementation

Page 29: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 29CMDS - Iberdrola Operación y Mantenimiento, S.A.

PUESTA EN SERVICIO: 2002 2003 2004 2005 2006 2007 2008 2009

TOTAL ANUAL (MW) 800 800 1.600 800 -- 600 -- 600 ACUMULADO (MW) 800 1.600 3.200 4.000 4.000 4.600 4.600 5.200

REMOTE MONITORING & DIAGNOSTIC CENTER

COMMUNICATION SERVER

INFORMATION SERVER

(DATA BASE,USER SOFTWARE,..)

WORK STATION

O&MSPECIALISTS

DIAGNOSTIC ENGINEERS

TELECOMMUNICATION SYSTEM

COMBINED CYCLE POWER PLANT

PLANTOPERATORS

MAINTENANCEPERSONNELPlant Instrumentation

PLANT INFORMATION SYSTEM (PI)

Implementation

PP22II22 + Telecom + Telecom

Page 30: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 30CMDS - Iberdrola Operación y Mantenimiento, S.A.

I.- Diagnostic Instrumentation:(additional instrumentation beyond of the scope of EPC)

Partial Discharge Analysis (PDA)

Vibration Analysis

Gas Analyzer (Gas Chromatograph)

Emission and inmission Monitoring

Offline portable systems

I. Instrumentation I. Instrumentation

Implementation

Page 31: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 31CMDS - Iberdrola Operación y Mantenimiento, S.A.

STANDARD INSTRUMENTATIÓN

DISTRIBUTED CONTROL SYSTEM

(DCS)

GEN

MONITORING & DIAGNOSTICS CENTRERemote workstation

PLANT INFORMATION

SYSTEM

PLANT NETWORK

Performance monitoring

Optical fiber thermometer

Proximity / seismic transducer VIBRATION MONITORING PANELCombustion chamber dynamic pressure

Partial discharge sensor

Blade tip clearance measurement sensor

Combustion viewing probe

Optical pyrometer

OPTICAL PYROMETER

DATAADQUISITION

Implementation

Page 32: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 32CMDS - Iberdrola Operación y Mantenimiento, S.A.

II. Lay-out II. Lay-out

Implementation

M&D LAN - Ethernet

S D

Professional Workstation 6000

PRO

VIBRATIONSERVER

S D

Professional Workstation 6000

PRO

PDADATABASE

PDA SERVER

VIBRATIONDATABASE

SD

Professional Workstation 6000

PRO

IT MONITORDATABASE

IT MONITORSERVER

SD

Professional Workstation 6000

PRO

PIDATABASE

PI SERVER(HISTORIAN)

BN 3500PDA DATA

ADQUISITIONUNIT

VIBRATIONSENSORS

PDASENSORS

DCS(ENGINEERINGWORKSATION)

MARK VICONTROLLERS

SENSORS SENSORS

IBERDROLAWAN

FRAME RELAY2 Mbps

Redundant

CENTRALVIBRATION

SERVER

S D

S D

ESC

DLT

PROLIANT 8000

CENTRALPDA

SERVER

S D

S D

ESC

DLT

PROLIANT 8000

CENTRALIT MONITOR

SERVER

S D

S D

ESC

DLT

PROLIANT 8000

CENTRALPI SERVER

SD

SD

ESC

DLT

PROLIANT 8000

APPLICATIONSSERVERS

EXPERT SYSTEM

OTHERS SYSTEMS

S D

H E W L E T T

P A C K A R D

S D

H E W L E T T

P A C K A R D

Lay-Out"on-site"

Lay-Out"on-CMDS"

Page 33: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 33CMDS - Iberdrola Operación y Mantenimiento, S.A.

III.- TELECOMMUNICATION SYSTEM:

by means of a warning from plant itself when the malfunction is automatically detected

In a continuous mode “in real time”

In a periodical transmission of information according to the selected frequency rate

Monitored by the IT Monitoring

III. Telecommunication System III. Telecommunication System

Implementation

Page 34: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 34CMDS - Iberdrola Operación y Mantenimiento, S.A.

IV.- PLANT INFORMATION SYSTEM:

The Plant Information System is a set of Server and Client based software programs designed to fully automate the collection, storage and presentation real-time plant data.

The Plant Information serves plant information to end users and software applications, quickly and efficiently, working as a real time platform.

Implementation

IV. PI SystemIV. PI System

What do we do with the PI System???

Acquire Data Store Data Process Data Display Data

Page 35: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 35CMDS - Iberdrola Operación y Mantenimiento, S.A.

ACTIONABLE DATA

M&D EXPERTS

MAINTENANCE PERSONNEL

PLANT MANAGEMENT

OPERATORS

Information tailoredto the specific customer needs

Process data

RAW DATA

IV. PI SystemIV. PI System

Implementation

Page 36: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 36CMDS - Iberdrola Operación y Mantenimiento, S.A.

PI-to-PI configuration

Implementation

IV. PI SystemIV. PI System

Generator Monitoring

Generator Monitoring

Generator Monitoring

PDH

UDH

PIHistorian

M&D LAN

GT1 GT2 ST1

DCS

HMI1 HMI2 HMI3

Ethernet Card #1(HW Redundant)

Ethernet Card #2(HW Redundant)

Ethernet Card #3 (HW Redundant)

B.O.P. Points

Mark VI Points

Page 37: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 37CMDS - Iberdrola Operación y Mantenimiento, S.A.

ON-LINE DATA ACQUISITION:

The data acquisition system is the link between the monitoring system and CCPP itself, providing the necessary data for its diagnosis.

Thermodynamic and Functional Analysis

Generator Partial Discharge Analysis

Vibration and Rotor Dynamics Analysis

RAM Analysis

DATA PROCESSING AND VALIDATION:

The collected data is validated on-line and can be calculated as a mathematical function of the recorded data.

Implementation

IV. PI SystemIV. PI System

Page 38: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 38CMDS - Iberdrola Operación y Mantenimiento, S.A.

PI - DL

EXCEL

VBA

PI - PBVBA

PE, PI-ACE, SQC 

ODBC 

RDBMS

PI SERVER

SAP 

DATA ARCHIVE

RLINK

RDBMS2PI 

CONTROL SYSTEM

RELATIONAL DATA BASE

Implementation

IV. PI SystemIV. PI System

Page 39: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 39CMDS - Iberdrola Operación y Mantenimiento, S.A.

DATA ANALYSIS AND DIAGNOSTIC INFERENCE:

There are two levels of malfunction detection: The detection of malfunction at an initial stage by means of an immediate

flagging system which is carried out by the PI- Alarm View to acknowledge and view the alarms in real time/historical.

The detection of malfunction over a longer timescale is carried out by M&D experts in the RM&D Center trough an Expert System which is 100% compatible with the PI System

Implementation

IV. PI SystemIV. PI System

Dependability Server

Performance Monitoring in two levels: Monitoring raw data (PI-PB)

Through processed data running on a thermodynamical model 100% compatible with the PI System (PI-Advanced Computing Engine)

Performance Server

Page 40: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 40CMDS - Iberdrola Operación y Mantenimiento, S.A.

Generator

COMBINED

CYCLE

POWER

PLANT

MONITORING

&

DIAGNOSTIC

CENTRE

FUNCTIONAL DIAGRAM OF REMOTE MONITORING & DIAGNOSTIC SYSTEM

on-line data acquisition system

on-line data processing and validation M&DData Base

Thermodynamic Analysis

Hot Gas sectionMonitoring

VibrationAnalysis

GeneratorMonitoring

Base-line Deviation RulesInference

Engine

ANALYSIS

Condition evaluatión/malfunction detection

Telecommunicationsystem/remote

warning

Remote accessand retrieval of Plant Data

Configuration M&D system

(local/remote)

Detailed Analysis and Diagnosis

Operational follow-up

Incidents Analysis

O&M Monitoring/ reliability

tracking

M&DData Base

O&MData Base

Generation of O&M Reports

O&M Recommendations

IncidentsReports

Communication system INTRANETNETWORK

Page 41: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 41CMDS - Iberdrola Operación y Mantenimiento, S.A.

IV.- PI Interactive Configurable Environmental:

CMDS uses PI ICE to build up its intranet web: CMDS on-line.

What for?? To keep our clients informed

To keep the Managers informed

To know the real status of all the CCPP wherever you are

Implementation

V. PI ICEV. PI ICE

Page 42: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 42CMDS - Iberdrola Operación y Mantenimiento, S.A.

Implementation

V. PI ICEV. PI ICE

CMDS

Cisco.7500Cisco Systems

PI-CENTRALCluster w2000

Node 1 Node 2 Dependab.Server

Cisco.7500Cisco Systems

Perform.Server

Cisco.7500Cisco Systems

VibrationServer

WAN IBERDROLA

MonitoringServer

WEB SERVER-IIS-SQL

PI-ICE

Combined Cycle Power Plant

Combined Cycle Power Plant

MANAGEMENT

INTERNET

Page 43: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 43CMDS - Iberdrola Operación y Mantenimiento, S.A.

Implementation

Page 44: Center for Monitoring, Diagnostic and Simulation of Combined Cycle Power Plant (CMDS)

Page 44CMDS - Iberdrola Operación y Mantenimiento, S.A.

R-LINK Real time performance management:

The R-Link is the link between the Plant Information System and SAP R/3 using the interface RDBMS-to-PI. What for??

Generates the work orders of the operators of the plants automatically

Calculates de operation hours of the different plant equipment

IT MONITORING:

Tool based on IT Monitor for monitoring critical applications, communications devices, security and hardware performance of CMDS infrastructure to improve the availability, performance and security of the System

Implementation

IV. Other ApplicationsIV. Other Applications

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Page 45CMDS - Iberdrola Operación y Mantenimiento, S.A.

Implementation

IV. Other ApplicationsIV. Other Applications

PDH

Servidor IT

SISTEMA M&D"ON-SITE"

HMI1 HMI2 HMI3

Ethernet Card #1(HW Redundant)

Ethernet Card #2 (HW Redundant)

Servidor PI

Servidor Vibraciones

Servidor PDA Otros

Switch

Router

Est.Ingeniería

Est.Operación #1

Est.Operación #2

DCS

SCADA TURBINAS

Bajo Demanda

IT configuration

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Page 46CMDS - Iberdrola Operación y Mantenimiento, S.A.

SUMMARY

Diagnostic Instrumentation

Lay-out of CMDS Systems

Telecommunication System

Plant Information System

PI ICE

Other Applications (R-Link; IT)

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Page 47CMDS - Iberdrola Operación y Mantenimiento, S.A.

SUMMARY:

With all the aforementioned a communication network is set up between plant staff ( plant management, operators, maintenance personnel,.…) and RM&D Center (diagnostic engineers, M&D experts,.....) which will enable on-line technical assistance and support on-line technical assistance and support in the operation and maintenance of Combined Cycle Power Plant.in the operation and maintenance of Combined Cycle Power Plant.

Summary

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Page 48CMDS - Iberdrola Operación y Mantenimiento, S.A.

DIAGNOSISDECISION

Process Data

- Optimax Performance (by ABB)- EfficiencyMap (by Enter)

- DM2000 (by BN)- MCM2000 (by BN)- System 1

- Historian (by OSISoft)- ProcessBook (by OSISoft)- IT (by OSISoft)- PDA (by GE)- PDA (by ABB)

Optimized Operation & Maintenance

Management (O2M2)

Cost Analysis

Maintenance Management

• Inspections & Testing • Oil Analysis• Infrared Thermography Condition Monitoring• Air and gas leak and steam trap Survey • Vibration portable (offline) systems• Wear Particle Analysis Using Ferrography• Electrical equipment monitoring & diagnostics

METRICS (RAM)

ON

-LIN

E C

ON

DIT

ION

M

ON

ITO

RIN

GO

FF

-LIN

E C

ON

DIT

ION

M

ON

ITO

RIN

G

• Functional/Thermodynamic Condition

• Mecanical&Rotordynamic Condition

• RAM on-line Monitoring

• BOP/GT/ST process Monitoring/Historian

• Generator Monitoring

• Communications, HW & SW

Summary

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Page 49CMDS - Iberdrola Operación y Mantenimiento, S.A.

M&D Data Base

QueryStructuredDataset

Computer Analysis

M&D and O&M Experts

OperatorsCombined Cycle Power PlantPlant Information

SystemGateway

MONITORING & DIAGNOSTIC PROCESS

Plant Management

Summary

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Generator

BN3500Vibration Panel

Generator Monitoring

Analysis application

Gas CromatographDANA500

Inmission monitoring

system

TDXnet

Vibration Monitoring

Analysis ApplicationSystem1/Decision Supp

Performance Monitoring

Analysis ApplicationEmap Performance

CASTELLONCASTELLONCOMBINED CYCLE COMBINED CYCLE POWER PLANTPOWER PLANT

Generator

Generator

GE Cimplicity

GT2 Local HMI

GE Cimplicity

GT1 Local HMI

GE Cimplicity

ST Local HMI

BN3500Vibration Panel TDXnet

Hub

Generator Monitoring

Analysis application

Generator Monitoring

Analysis application

PI Process BookPlant Data Overview

DCS- FOX AW70

PI FOX IA I/F

PI API

Plant PI serverPI SystemTM

PI M

OD

BU

S I

/F

PI B

atch

FL

I/F

PI M

OD

BU

S I

/F

PI to PI I/F

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Generator

BN3500Vibration Panel

DCS ABB IMS

Generator Monitoring

Analysis application

Generator

BN3500Vibration Panel

Generator Monitoring

Analysis application

Generator

BN3500Vibration Panel

Generator Monitoring

Analysis application

Generator

BN3500Vibration Panel

Generator Monitoring

Analysis application

Gas ChromatographDANA500

Inmission monitoring

system

TDXnet

TDXnet

TDXnet

TDXnet

Hub

Vibration MonitoringAnalysis AplicationDM2000/MCM2000

Performance MonitoringAnalysis Aplication

Optimax Performance

A2

A6

Plant Network

MONTERREY IIIMONTERREY IIICOMBINED CYCLE COMBINED CYCLE POWER PLANTPOWER PLANT

Emission monitoring

system

PI Process BookPlant Data Overview

Plant PI serverPI SystemTMPI

MO

DB

US

I/F

PI B

atch

FL

I/F

PI to PI I/F

PI API

PI OPC I/F

ABB OPC Server

DCS ABB IMS

PI API

PI OPC I/F

ABB OPC Server

DCS ABB IMS

PI API

PI OPC I/F

ABB OPC Server

DCS ABB IMS

PI API

PI OPC I/F

ABB OPC Server

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Vibration Monitoring

Analysis Aplication

Performance Monitoring

Analysis Aplication

Remote PI serverPI SystemTM

Vibration MonitoringDM2000/MCM2000

Display client

Performance MonitoringPI-ProcessBook

Performance View

ORAP LINK, Gas Path AnalyisProcessBook PI-W

M&D Aplications Server

REMOTE MONITORING & DIAGNOSTIC CENTREREMOTE MONITORING & DIAGNOSTIC CENTRECOMBINED CYCLE COMBINED CYCLE POWER PLANTPOWER PLANT

M&D Operator (2x1) (PI-ProcessBook)

M&D Support Engineering (4 x 1) (PI-ProcessBook)

Engineering (16 x 1) (PI-ProcessBook)

PI Process BookPlant Data Overview

Plant PI server PI SystemTM

PS RLINK

MS SQL Server

PM Interface

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Page 53CMDS - Iberdrola Operación y Mantenimiento, S.A.

OPERATIONPOWER

GENERATION ASSET MANAGEMENT

DECISION MAKING

Summary

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Page 54CMDS - Iberdrola Operación y Mantenimiento, S.A.

Power Generation Asset Management

Operation

PI System

DIAGNOSTIC

SIMULATION

MONITORING

OPTIMISATION

Malfunctions implementati

on

Decision Making

Summary

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Page 55CMDS - Iberdrola Operación y Mantenimiento, S.A.

PI

OTHERS

CCGT’s (customers)

MNGT

Summary

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Remote Monitoring & Diagnostic Center – CMDS