Gaspar Bibiloni, P.E. Engineering Manager Electrical …ccug.users-groups.com/AnnualMeetings/2013/Presentations/Performanc… · EcoEléctrica A Better Environment with Natural Gas

EcoEléctrica A Better Environment with Natural Gas

Gaspar Bibiloni, P.E. Engineering Manager

Electrical and Instrumentation Maintenance Manager


Topics • Facility Description • Monitoring Systems • Performance Monitor • OEM Monitor

– WinTS – LTP Engineer – Performance Instrumentation


Facility Overview o Facility

507MW Combined Cycle Power Plant LNG Import Terminal 2MGD Water Production Plant

o Commercial 100% contracted with PREPA for 22

years 93% availability / 45% thermal efficiency

contracted guarantee Facility dispatched from 54% to 100% Energy priced fixed annually up to 76%

dispatch, above 76% dispatch price is based on spot offers

o Staffing 78 total number of EcoElectrica

Employees 70 positions in the O&M Organization 30 positions form O&M allocated to the

power plant USWA represents 36 technicians in the

O&M areas

78


Operational Experience o Power Plant

Base loaded power plant with daily load following dispatch.

> 90% service factor, ~80% capacity factor. ~ 107k EBH, 2nd W501F fleet leaders Three fuel capability, on-line fuel transfers from NG to

Diesel and from NG to LPG.

o LNG Terminal ~99.5% annual availability with >99.9% reliability. 185 LNG ship unloading w/out safety incidents. Exceeding security requirements from Federal Agencies Annual inspections from FERC and USCG consistently

w/out material findings or recommendations.

W501F


Regulating Agencies o Fed Energy Regulatory Commission (FERC)

LNG Terminal Operations in accordance with 18CFR 153 & 380 and NFPA59A

Semiannual reporting requirement and annual audit

o Homeland Security / USCG / Customs Facility security compliance in accordance with 33CFR 101-

105 & 33CFR 127 Annual inspections on security and maritime operations

according to MTSA LNG unloading inspection on every LNG unloading

o Environmental Protection Agency (EPA/JCA) Air – Title V permit requirements. Water – NPDES Hazardous Waste - RECRA Periodic Reporting Requirements and Continuous Emissions

Monitoring System Annual RATA test and unannounced inspections on air and

water compliance

o DOT / PHMSA / CSP 49CFR193 & 192 Annual reporting and inspections.

o Puerto Rico Police Department (PRPD)

Explosive license requirements Law - 134 Biannual audit

o Puerto Rico Fire Department (PRFD) Firefighting systems – Law 143 Annual inspection and certification

o Puerto Rico Department of Labor (PRDL) Pressure vessels code compliance – Special Rule #1 & #2 Annual certification of facility pressure vessels & cranes

o Occupational Safety & Health Administration (OSHA) Safety standards – 29CFR1910 & 29CFR1917 Required trainings, fall protection, confined spaces,

electrical safety, PPE, etc.

o Department of Health (DOH) Potable Water Standards compliance Sanitary License Monthly sampling and monitoring reporting requirement


Safety Critical Elements ERP, Fire Brigade, MOU’s, Escape Plan Emergency Response Arrangements

Secondary Containment, Impoundments Plant Layout, VDZ, TDZ

PRV’s, Fire Protection / Suppression, OSTV’s MCV’s, ICV’s

ESD’s, Leak & Fire Detection Systems Ignition Control, Safe Removal of Inventory

O&M Standard Operating Procedures Operators Qualification and Certification

DCS / SCADA Standalone PLC’s, Operations Checklist’s

NFPA 59A&75, 49CFR 192&193, ASME B31.8 HAZOP, HAZID, FMEA, QRA, MOC, etc.


Results o Reliable operation in compliance with PPOA warranties and within best

comparable operations worldwide.

o Excellent relation with Communities, Federal and Local Regulating Agencies.

o Since 2008 Insurance companies facility ranking by the risk evaluation method improved to a very good risk.

o Excellent safety record on the LNG Terminal Management.

o ~ 9 years w/out lost time accidents in the facility.

o ISO 14,001 & OSHAS 18,001 certified.

o 2008 EPA Environmental Excellence Award.

o Well balanced O&M team, best in sector.


o First IPP integrated to the electric system and only power plant on natural gas.

o 9% of the electric system installed capacity of 5,839MW.

o 13 – 16 % of the island annual energy production of 23,579MkWhr (FY2010).

o Environmentally cleanest and best thermal efficiency power plant on the island.

o Ancillary services provider as any other power station on the electric system.

EcoElectrica in the System


Diagnostic Monitoring Systems

• GCM-X • Generator Condition Monitor GCM-X uses real-time detection to

give early warning of generator overheating and potential failure. High concentrations of submicron particles (pyrolytic products) are produced whenever any materials within the generator are heated sufficiently to produce thermal decomposition

• Air Gap Flux Probe • Generatortech Model G50 Remote Analysis System uses data from

the air gap flux probes on all three generators to detect shorted turns in generator’s rotors.



• Generator FOVM2a (Fiber Optic Vibration Monitoring)

• A set of optical vibration sensors generating a vibration signal indicative of a vibrational frequency and amplitude of the generator; and obtaining a beat frequency from the vibration signal by storing and processing time interval data representing the time intervals between zero crossings of the vibration signal.

• Bently Nevada 3500 and System 1

• Key indicators of machinery vibration, position, speed condition. Also, for combustion dynamics monitoring



• Emerson DCS Wave System

• Application that allows remote access via VPN connection to the Plant DCS in read only mode. Next year we will migrate to the EDS system with added capabilities.

• WinTS or Power Diagnostic

• Allows Siemens personnel to monitor the Combustion Turbines in real time and report out of parameters conditions, unit response to grid events, startup or shutdown performance, etc.



• GE Hydran

• Online dissolved gas and moisture content analysis in oil immersed power transformers.

• Alber MPM 100

• Battery diagnostic system identifies conditions requiring further investigation, such as cell voltage, overall string voltage, current, temperature, and internal resistance. Automatic periodic tests verify the integrity of the battery being monitored, and an alarm is given for any out-of-tolerance condition.



• Eaton Insulgard

• Partial Discharge detection system. Installed in all dry type transformers. Plan to install them in the Generators in planning phase. It tracks partial discharge activity to provide advance warning about the wellness of electrical insulation.

• SEL Protective Relays

• Upgraded the system to install all new SEL relays, data concentrators, HMI and software tools to analyze transient events, SOE and unit response to grid events.



• To monitor, beside the protective relays, we have installed instruments to record and analyze generator’s respond to grid and internal electrical events

• Qualitrol IDM Transient Recorder • ElectroIndustries NEXUS 1500 Meters • Eaton UPS and Static Transfer Switches • Schneider ION Meter

• Most of these instruments, connected on all generating units, distribution switchgears and transmission line, beside providing metering functions, can record events, transients, waveforms, harmonics, etc.



• There are other miscellaneous systems that compliment our Facility monitoring such as:

• Rockwell PLCs • Emerson Gas Chromatograph • iMaint (CMMS) • Nisoft (Work permit software) • Sea level gage (tide gage) • Seismic Monitoring System


GCM-X Generator Condition Monitor


Generatortech Model G50 Remote Analysis System


Generator FOVM2a (Fiber Optic Vibration Monitoring)

CT2 – channel 08 TE (lime green) CT2 – channel 09 TE (navy)

CT2 – channel 10 TE (brown)


Generator FOVM2a (Fiber Optic Vibration Monitoring)

CT2 – channel 08 TE (lime green) CT2 – channel 09 TE (navy)

CT2 – channel 10 TE (brown)


GE Bently Nevada BN-3500 and System 1 for Vibration Monitoring and Combustion Dynamics


Emerson DCS Wave Application


Siemens Power Diagnostics or WinTS


GE Hydran M2


Alber MPM-100


Eaton Insulgard


Schweitzer Engineering

Laboratories (SEL) Relays


Qualitrol IDM Transient Recorder


ElectroIndustries Nexus 1500 Power Meter


EATON UPS


Schneider Electric ION Meter


Performance Monitor • We are currently using General Physics EtaPRO ver 9.2. • EtaPRO with APR (Advance Pattern Recognition) uses models to detect

anomalies in plant or equipment conditions by continuously comparing current values to detailed empirical models of "normal" data.

• EtaPRO is an efficiency-productivity tool. Efficiency is improved and maintained since you will know on a minute-to-minute basis how much power and steam should be generated for current ambient and operating conditions.

• EtaPRO provides a tool to monitor heat rate based on models and calculations developed by GP during the system commissioning. Deviations are calculated in terms of heat rate and generation and help us determine deterioration on units mayor components.

• EtaPRO generates the daily operating report


Daily Operations Report


Siemens Engines Performance Monitor

• OBJECTIVES

• Additional instrumentation was installed on Peñuelas CT1 and Peñuelas CT2 in order to allow for an online performance assessment.

• The goal was to develop a tool that would use data from current plant instrumentation, as well as additionally installed instrumentation, to remotely assess engine performance





New instrumentation


Siemens Engines Performance Monitor OBJECTIVES •To asses performance of an engine after an upgrade or an outage guidelines of ASME PTC22 – Gas Turbine Performance test code are followed. All critical parameters are measured during the test and then the results are corrected to the same reference in order to accurately determine performance change in the engine. • Similar approach was taken for the remote performance monitoring. Plant instrumentation as well as additionally installed instrumentation was used to collect the data. The data was then analyzed and corrected based on correction curves created using new and clean FC engine models. •Data selected for the results is filtered based on the following conditions

• Operation on the control curve • IGV fully open • Peak Firing OFF


Siemens Engines Performance Monitor Base load data was then corrected to the reference conditions provided in the adjacent table.





DATA RESOLUTIONS •Table on the right represents approximate data resolution values that are used during an instrumented performance test. • Resolution is defined best through an example. If compressor inlet temperature changes by more than 0.00015 degrees, the data acquisition system will record a new data point. • It is understandable that with plant instrumentation data resolution may not be as precise. The goal is to have resolution in WinTS to be as close as possible to the resolution provided in the table to the right. • Better data resolution will allow for lower uncertainty in the results.



Preliminary Uncertainty Analysis



Conclusions

• Remote monitoring allows the O&M Team to support the onsite personnel identifying preventive and corrective indications and respond or suggest actions that might prevent Plant upsets.

• Using the OEM software tools plus the Performance Monitor provide alternatives to predict and respond to Plant upsets, Utility dispatch, etc.

• Remote monitoring helped the Operations Department return units to service after the Engineering and Maintenance teams verify data locally or remotely. Key members which are out of the Plant can support using VPN connections and common devices such as smartphones or tablets.

• Great results are obtained when historic data, models and real time data can be use to study plant performance, recommend upgrades, plan equipment retrofit, etc.

• There are many others system that compliments the main tools such as the gas chromatograph, CEMS, Water Treatment PLC, etc.


Conclusions

• Other Techniques for Preventive and Predictive Maintenance we use: • EMI – developed by Doble Engineering. EMI data is collected from the temporary placement of a split

core radio frequency current transformer around the power conduit, safety ground or neutral lead of the component being tested.

• Typical generator and motor conditions detected with EMI Diagnostics: • Stator bar slot discharges from conductive coating erosion • Stator slot side-packing erosion • Stator bar stress grading system deterioration • Loose stator wedging (stator bars) • Loose end winding ties • Blocking and circuit rings • Loose or broken stator sub conductors • Winding contamination (dirt, oil or water) • Stator coil partial discharge • Deterioration in slots and on end • Winding contamination (dirt, oil, carbon black or coal dust) • Defective bolted or crimped stator lead connections • Broken induction motor rotor bars • Bearing problems • Misalignment • Shaft oil seal rub


Conclusions

• Other Techniques for Preventive and Predictive Maintenance we use: • Transformers Frequency Response Analysis (FRA) • Motor testing – one step further from the regular Megger®. Equipment will also

check power quality, power circuit, stator, rotor, insulation, and air gap. • Vibration monitor on pumps/motor assemblies • Infrared surveys • Ultrasound surveys

Thanks!

Documents

Gaspar Bibiloni, P.E. Engineering Manager Electrical …ccug.users-groups.com/AnnualMeetings/2013/Presentations/Performanc… · EcoEléctrica A Better Environment with Natural Gas