ER Process – Remote Monitoring

About Duke Energy

The role of Performance Monitoring in Equipment Reliability

Fundamental support for the cultural transition from a reactive to a proactive

organization

Provides advanced notice for potential equipment and process failures • Allows increased reactionary time, additional analysis / troubleshooting, planning, and

resource allocation – all resulting in a lower cost of impact

Requires the ability to effectively and efficiently identify and react to equipment and system issues prior to significant failure or degradation

Large scale deployment of Performance Monitoring programs can be resource intensive

Favorable area to leverage advancements in internal and external industry technology

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Performance Monitoring - How Can It Help?

M&D Center Scope of Work

There are separate M&D Centers for the regulated and the commercial sides of the business.

The M&D Center for regulated generation is divided into three functional areas:

Thermal Performance and Testing

Real time performance monitoring and analysis

Field testing and support

Dispatch heat rate curve automation

Reliability and CBM

CBM process development and ownership (EPRI Maintenance and Reliability Model)

CBM analysis and support for the fleet

Advanced Pattern Recognition Monitoring Program

SmartM&D (new sensors monitored by the APR group)

Scope and project development

Installation and implementation

M&D Center Thermal Performance Team Mission

We help the plants maintain a competitive position in the market by providing real time heat rate monitoring, on-site testing and in-depth analysis of plant performance.

We use first principles modeling software to monitor plant and system thermal performance. The software compares actual plant efficiency to their desired targets.

We provide turnkey expertise and resources to test equipment and system performance on site. Our service ranges from individual components to total systems.

We partner with the stations to help them understand what factors are hurting performance and what they can do to restore it to the desired level.

We perform studies for the plants to determine the efficiency and operating performance impact of proposed changes in the plant configuration.

We ensure that the unit heat rate curves used for dispatching accurately reflect unit performance and seasonal conditions.

Real Time Controllable Loss Summary

Updated every 10 minutes

Targets are based on design or achievable

Deviations are displayed in $ and in MW impact at base load

Dashboards allocate thermal and output impacts by component

Real Time Cycle Performance Summary

Component Level Screens

Available by drill down or direct selection

Displays actual vs expected at device level

Displays values corrected to standard conditions when applicable.

Compressor Performance Curves

Used by stations to

determine when washing is

needed:

• Red – Target

• Yellow – History since

cleaning

• Blue - Actual

Valid at Baseload Conditions:

Component Level- Pump Performance Curve

•Component level screens allow

users to zero in on performance

issues

•Design head and efficiency are

compared to current operation

Component Level - Footprint Displays

Footprints help operations visualize operating trends to make decisions

Historical X-Y display of condenser back pressure

Cyan – Clean Yellow – Fouled Red - Current

M&D Center APR Team Mission

Our mission is to help the plants improve long term reliability and cost by predicting equipment problems that will evolve from fault to failure 24 hours or more into the future.

We use Advanced Pattern Recognition software to monitor plant equipment operation. The software detects subtle deviations from normal operation that can be used as early indicators of future problems.

We partner with the stations and fleet technical support to capture their knowledge of the equipment. We build this knowledge into our models to free the plants from repetitive monitoring. This allows them to focus on emerging issues instead.

We are part of the fleet-wide Maintenance and Reliability process that manages risk and reliability at the lowest possible cost.

Evolution of the APR Program

Legacy Progress

Started with the CT fleet in 2004

Expanded to the fossil fleet in 2007

Process Data – Instep PRISM APR tool

Legacy Progress – 27 Fossil Units (now 15), 10 CC’s, 140+ CT’s

>3500 APR Models

>35,000 points monitored every 5 minutes

Dedicated resources assigned to APR and Thermal Performance monitoring

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Evolution of the APR Program

Expansion After the Duke merger Legacy Duke – 29 Fossil Units, 4 CC’s,

63 CT’s, 8 PS, 9 Hydro

>3000 APR Models

>30,000 Points monitored every 5 minutes

Regional Locations, Charlotte, Raleigh, Indianapolis

5 team members dedicated to APR. Mix of new employees, field support and plant experience.

Roughly 35 unique model types

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Evolution of the APR Program

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21 8 29 HRSG

APR Philosophy

Maintain credibility by reviewing and screening all APR alarms before sharing with the stations

Focus on reliability finds

Avoid any commitment to operational finds that would evolve in less than 24 hours

We are not an extension of the operators. We are an extension of CBM.

Integrate with the plant Maintenance and Reliability process

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• Fan Amps

• Motor Winding

Temp

• Motor OB Bearing

Temp • Fan OB Bearing

Temp

• Inlet Vane Position

• Ambient Temp

• Air Flow

Plot-0

4/6/2008 4:39:21.791 PM 4/9/2008 4:39:21.791 PM3.00 days

60

62

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70

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58

78

96

108

86

102

107

113

94

102

46

64

0

14

110

170

52

70

25

75

• Motor IB Bearing

Temp

• Fan IB Bearing

Temp

• Select related points

• Pull raw data from Pi

• Typically data sets will be 5 min samples for 1 year

APR Modeling Process – Cleaned Data Set

• Cleaned data set represents operation during all ambient / MW loading conditions

Summer

Winter Spring

Fall

Plot-0

10/7/2007 9:17:30.977 AM 10/10/2007 9:17:30.977 AM3.00 day s

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85

90

95

75

100

108

126

100

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90

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400

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0

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•Feed historical data to APR algorithm to build prediction

•Feed Real-time values to APR algorithm every 5 minutes

•Algorithm predicts output values and compares real time with

predicted

Predicted values • Fan OB Bearing Temp • Fan IB Bearing Temp • Motor IB Bearing Temp • Motor OB Bearing Temp • Motor Winding Temp • Amps • Discharge Press

APR Modeling Process – Model Algorithm

First Pattern Recognition alarm, residual exceeded 10 C

• Subtract actual value from the predicted value to calculate the residual

Traditional Alarm @ 140 C

M&D Find – L-1 Blade Covers

Site alerted of vibration step change

SME & site personnel verified prox probe

and casing vibration both had changed

Analysis indicated loss of mass, suspected

shroud material based on unit history

Decision to operate unit through very cold

time at reduced output

Unit brought offline and boroscope

inspection performed

M&D Find – L-1 Blade Covers

Boroscope inspection verified missing

shroud material

Decision made to remove turbine

shells

When shells were removed there were

several shrouds missing and others ready to

liberate

M&D Find – CT Combustion Hardware Failure

• Blade Path temperature spread

began to increase

• Spread increase was caused by 1

of 16 thermocouples trending low

Filtered Data > 40 MW

4/22 – 5/16/2012

Blade Path Spread

Blade TC #2

CR 1&2 Fire & Major Damage – Jan 2010

Major Catastrophic Failure $$M’s plus 4 months lost generation

SmartM&D Technology could have prevented this failure

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$200 RF Bus Temp Device

on SmartM&D Network

Existing Program Gaps

Equipment Specialists

Current specialists spread too thin – hard to replace

Current manual predictive programs

80% data collection, 20% diagnostic

60,000 manual vibration data collections per month!!

M&D Center Limitations

Currently limited only to DCS available data

Need more instrumentation to expand capabilities

Industry Gap – lack of cost effective automated

monitoring technologies on critical equipment.

Plant

SmartGen

PlantDCS

Control Network

M&D Network

Sensors

Sensors

Sensors

Sensors

I/O

I/O

I/O

I/O

Manual

PdM

Collection

s

Vib

Oil

Motor

IR

PI

PlantView

Region, Plant,

Unit , & System

Health Views

Fleet M&D Center Plant

System Owners/ CBM – Perform Equipment Assessments

Tech

Exams

Smart M&D – Functional Model

~

30

NI

Module

New On-line

Sensor Data

Existing

Process Data PI

Module

PRISM

APR

EPRI DA

PlantView

Vib

Oil

MCSA

IR

Visual

Tech

Exams Tech

Exams Tech

Exams

Equipment

Assessment

Manual Review of NI data

Automating Data Collection & Analysis

EtaPRO

Perf

M&D Centers Manual

Testing

M&D Infrastructure (19 of 44 Plants installed)

Sensors – Vib & Temp(over 12000 sensors/ 1200 nodes)

Advanced Sensors – EMI, MCSA, IR

Analytical Interface – CBM

Connectivity to M&D Center

Diagnostics & Prognostics

Integration & Visualization

Will be ongoing Advanced Sensor Applications

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Smart M&D – Overview Status

Smart M&D - Scope of Monitoring

Generators

Steam Turbines

Combustion Turbines

Motors

Pumps

Fans

Transformers

Iso-phase Bus Ducts

Electrical Buses

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NI CRIO Hardware (cRIO 9074)

38 points maximum:

• up to 18 Accelerometers (NI 9232, qty 6)

• up to 16 Voltages, +/- 0.2 to 10V (NI 9205)

• up to 4 Currents, 4-20mA (NI 9219)

Rugged Com Router

WAP – Wireless Access Point

IT&T Parts 60% of boxes do not have IT

Hardware . Wired to next box

Plant Server

Local Storage

PGN Business

Network

Accelerometer

& Cable

Further Cost Reduction

• MEMS Accelerometers

• Short Range RF

• Energy Harvesting

Wireless or Wired

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Balance of Plant (BOP) Details Smart M&D – Network Infrastructure

Smart M&D - Typical I/O Enclosures & cRIO

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National Instruments “InsightCM” Software

National Instruments is developing condition monitoring software to provide:

A user interface for various sensors

Data to PI for M&D Center monitoring

NI software & hardware will accept multiple input types

Looking for other vendors to partner and develop new sensor inputs

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Smart M&D – Sensor Technologies

Vibration Monitoring

BOP

Turbine/Generator

Electro-magnetic Signature Analysis (EMSA)

Motor Current Signature Analysis (MCSA)

Oil – dielectric / particle counter

Ultrasonic (Leak detection)

Temperature

Fixed Point

Infrared Camera

Visual Cameras

Additional sensors for performance monitoring (press, flow, etc)

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Smart M&D - Turbine Monitoring (VDMS)

IT&T Parts In most cases requires only

A LAN cable (CAT 5) to plug

Into existing network.

Dependant on network

Infrastructure at site.

PGN Business

Network Plant Server

Local Storage

NI CRIO Hardware (cRIO 9024 / cRIO 9114)

24 points maximum:

• up to 3 Keyphasor™ (NI 9232)

• up to 21 Vibration (Accel, Prox, etc) (NI 9232)

Protection System 37

Installed

VDMS

Monitor

Smart M&D – BOP Vibration

Accelerometers provide overall vibration and temperature

Low cost and robust sensors

Widely deployed where no sensors were deployed before

Smart M&D - Electromagnetic Signature Analysis

Monitors generators, transformers

and other >13.6KV equipment

Provides early indication of insulation

and connection degradation

Utilizes the ground leads and equipment

housing as antenna

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1 ,200 MW Generator with severe arcing of shaft grounding braids

0.1 0.01 1 100 10 0.1

1

10

100

1000

10000

With Arcing Shaft Grounding Braid

Power Line

Carriers

W/O Arcing

Electromagnetic Signature Analysis

Smart M&D - Motor Current Signature Analysis

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Monitors motors with accessible CT leads

Provides early indication of rotor and electrically detected issues

Utilizes a low cost split core CT for quick installation

Calculated motor parameters such as torque, phase angle etc

Motor Current Signature Analysis

Smart M&D - Oil Analysis

Oil Particle Sensor

Provides ISO class particle

monitoring

Moisture

Oil Dielectric Sensor

4-20ma output

Oil Level Sensor

4-20ma output

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Smart M&D - Ultrasonic/Acoustic

Leak Detection

CT enclosure (piping, casing leaks)

Boiler/HRSG (tube leaks)

Electrical Bus Monitoring

Bus monitoring for arcing, corona

CT Foreign Object or Domestic

Object Detection (FOD/DOD)

Used to hear impacts in a CT caused

by foreign or domestic debris

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Smart M&D – Fixed Point Temperature

RF Temperature sensor

Lug mount

RF signal to a receiver mounted

in same panel

Fiber Optic Temperature sensor

Utilizes Fiber-Bragg gating

technology

Can measure temperature at many

locations on a single strand

Can be up to a kilometer long

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Smart M&D - Infrared Thermography

FLIR A65 IR Camera

Network connection

POE

Low cost

National Instruments 1457 CRIO

Network connection

Dual Gig E Inputs

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CVS-1457RT

Thermography

Smart M&D - Visual Camera

Axis PTZ camera

Operator assist

Equipment monitoring

Can use added intelligence

for enhanced monitoring or

trending.

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46

Smart M&D - Visual Camera

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Smart M&D - Visual Camera

Avoided Cost Chart Tracks Value