© 2008 eventure events. all rights reserved. fleet performance and reliability in generation...

© 2008 Eventure Events. All rights reserved.

Fleet Performance and Reliability in Generation Utilities

Rodney Lord, IT Solutions & Services, Siemens

Jörn Rassow, Power Plant Engineer, EnBW Kraftwerke AG

Protection notice / Copyright © Siemens AG 2008. All rights reserved.

Energy Management Suite

Siemens IT-Solutions and Energy

October 2008

Copyright © Siemens AG 2008. All rights reserved. Siemens IT Solutions and Services

Power Plant 1 Power Plant nPower Plant 2

TIME COSTS

QUALITY

1) Available in 2008

Combining Technical and Business Information with Siemens Energy Management Suite

Instrumentation Alarming

Generation Planning & Monitoring

Technical Performance Management

Shift Management

Corrective & Preventive Maintenance

Operations & Maintenance 1)

1)

Business Performance Management

Efficiency Emissions

Availability

Flexibility

Fuel costs

Maintenance costs

Performance Operating costs

October 2008


. . .InternetIntranet

Power PlantManager

Process DataArchive SAP ERP Databases DCS Scheduling Energy

Trading

Systems• Plant Systems• IT systems

User Community• Executive Management • Power Plant Management• Production Management• Technical Management

MultipleGenerationLocations

ExecutiveManagement

ProductionManager

Technical Competence Center

Power Plant 1 Power Plant 2 Power Plant n

Enterprise Wide Decision Support

October 2008


Integration of SAP Enterprise Asset Management, SAP ERP Systems and Plant Process Information provides visibility to key operational data and information

SAP

ERP

Planning&

Execution

Limited visibilityto plant operations

and metrics

Energy Management Suiteis the bridge between

plant operations and the business

Plant

Control and Operational

Systems

SAP

ERP

Energy Management

Suite

Plant

Control and Operational

Systems

October 2008


Enterprise Wide Decision Support

Power Plant Management

ExecutiveManagement

Production Manager

Technical Competency Center

Energy Management Suite

EMS connects data from the power generation and business areas with process know how to creating transparency and flexibility. Access to this near real time information enables decision making to increase availability and profitability.

User Community• Executive Management • Power Plant Management• Production Management• Technical Management

Systems• Plant Systems• IT systems

MultipleGenerationLocations

Kraftwerk 2

Power Plant 1 Power Plant 2 Power Plant 3

October 2008


Fleet Wide Monitoring & Decision Support- The Building Blocks

SAP Netweaver Enterprise PortalProvides a Single User Interface

EMSOperational Data

Collection and Processing

SAP ERPPlant Management

Maintenance and Workforce

. . .InternetIntranet

Process DataArchive SAP ERP Databases DCS Scheduling Energy

Trading

Plant and IT Systems

October 2008


Energy Management Suite - Primary Functional Areas

EMS Portal

Business Performance Management

Fleet GenerationMonitoring and Planning

Fleet Performance Monitoring

Fleet-wide Diagnostics & Optimization

AlarmProcessing

Technical Perform. Mgmt.

Generation Planning and Monitoring

Process Information(OSI PI – Process Book)

PM, WCM

PS

Corrective & Preventive

Maintenance

Shift Management

Maintenance & Workforce

Enterprise Information CenterSAP Plant Management

Operational Management Plant Asset Management (PAM)

Core PAMEMS PAM Extensions

SAP Netweaver

SAP ERP

October 2008


Enterprise Information Center

• Integrates information from multiple power plant locations into a common platform

• Provides easy access to information from other integrated ‘expert’ systems

• Allows a comprehensive view to company wide information delivered through a single user interface

• Access to near real-time information from the fleet

• High degree of integration among plant and business systems

Enterprise Information Center – Utilizing the SAP Enterprise Portal and eSOA

October 2008


Shift Management • Planning of shifts and shift crews• Manual or automatic logging of events

and DCS signals• Replaces paper based Operator Logs• Shift Tasks e.g. operator rounds

Maintenance Strategy• Multiple maintenance strategies to select

from

Plant Management• Core Plant Management (e.g. Master

Data, Maintenance and Materials Management) integrated with SAP ERP

Siemens Energy Management Suite - Shift Log for Asset Performance Management

Availability: Maintenance and Plant Data Management Minimizing the risk of unplanned outages 900,000 €/y

Maintenance: Spare Parts and Maintenance Management Reduced lead time for planned outages 115.00 €/yReduction in spare parts inventory 1.600.000,-€/y

Savings

October 2008


Siemens Energy Management Suite - Early Warning System for Diagnostic and Technical Performance Management

Savings of more than $8 M/Yr. Additional 50 MW capacity Improved efficiency for: Additional output of nuclear power plants:- Lignite-fired units: 2% + 2MW- Gas-fired units: 1.5% Fleet availability increased by 0.5%

Predictive Diagnostic System• Fleet-wide plant condition

monitoring and alarming system• Asset status reporting integration of

the local Vibration system with EWS• Creation and tuning of the plant

operational models• Review of selected thermal cycle

calculation system• Integrated Alarming into Shift Log

component

October 2008


Siemens Energy Management Suite- Expert System for Generation Planning and Monitoring

5000 MW installed generation capacity Average fuel reduction of 0.5% [0.3-1.0%] Average fuel costs of 25 €/MWh Plant Utilization 60%

-> 3 000 000 €/year

Fleet Dash BoardAvailability/Capability• Event Logging - Visualization of

past capability and projections for the future

Economic Dispatch • Economic dispatch of a fleet taking

into account the current circumstances. (e.g. head water pressure, thermal heat rates, costs)

Generation Monitoring • Manage schedules and control

production. Early reaction to emerging issues

Fuel Supply - and Emissions Management

• Monitoring (calculation) of actual emissions and reporting

October 2008


Siemens Energy Management Suite- Business Performance Monitoring

15.10.2008

Early Detection of Performance DeviationsBenefits for a typical Generation Fleet

5000 MW installed generation capacityIncrease of In-Market Availability by 0.5 %; equals 25 MW of additional generationInvest of 1.000.000 €/MW installed capacityDepreciation 10 %/year-> 2.500.000 €/year

Key Performance Indicators• Calculation and reporting of KPIs on

each unit in the fleet and component• MTBF, MTBR• IEEE, VGB, …

Technical & Maintenance Reporting• Comprehensive business reporting

• Fleet wide YTD actuals• Production forecasts• Maintenance order status

and costs• ….

Business Advisor • ‘What if‘ planning scenarios for the

fleet based on generation supply contracts and fuel targets

October 2008


Energy Management Suite - Customer Value

Customer Benefits Customer Experience

Highly innovative solution packageintegrating production, business processesand metrics.

Faster and improved support for decisionmaking to meet the short and long termmarket needs.

Early detection of potential plant and unitissues lead to;• reduced maintenance costs• increased availability and efficiency• economic and technical optimization of plant and fleet performance• consistent management reporting

Efficienct Technical Performance:

Early Detection of deviations 500.000 €/y (800MW, coal-fired steam power

plant)

Generation Monitorong.&Planning:

Optimized Generation Schedule Planning

3.000.000 €/y (5000 MW installed capacity)

Availability Monitoring and Alarming:

Avoidance of unplanned outages, and avoided asset damage

720.000 €/y (300 MW Combined Cycle Unit)

Early Detection of Performance Deviations:

Increased Asset Utilization

2.500.000 €/y (5000 MW installed capacity)

* Actual savings achieved by an existing EWS Customer

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