Patrick Abbott@GEAR.Energy

Mission & Purpose

Mission, Purpose, Overview:

A strive towards “Event Free” operations; “Aproblem identified is a Problem Half Solved”– Ben Franklin

Help prevent initiationor propagation of boiler damagemechanisms through on-line diagnostics.

Help Synergize with SME’s and NDEassessments being conducted during outages to ensure we are unified, focusing onconcerned areas, alerting potential damagemechanisms& proactively developing action plans forboth operations & reliability performancetogether.

Objective is to help achieve design life out ofcomponents by deploying operations QA/QCactions. .

Current Pilot Project

Instrument Audit; 1-year Historical Archive Purpose

1) To ensure the TBM monitoring & diagnostic models could be configured and installed in GP Strategies’ ETA pro Software.

2) To prove through historical data simulation that TBM principles would deliver valuable results and help guide Duke Energy Engineering and Operations avoid circumstances proactively to avert potential boiler damage mechanisms in the future.

3) To help justify instrument repairs and recommendations.

4) To help expedite and understanding the immediate benefits of TBM as well as explore future advancements

Boiler Team Coordination & Support

1) Assess instrumentation audits and instrumentation required to protect components

2) Make recommendations to system owners at the station

3) To proactively avert potential damage mechanisms in the future through prognostic reporting

Information

Management

Instrument Audit

Historical Data Archive

Plan & StrategizeModel

Development

(Prioritize Focus)

Develop and

Implement Model

Using Conditional

Analysis Tool

Activate Model & BeginAnalysis

Local Condition

Monitoring Plan

Enhance BTF Defense Strategy

EtaPRO TBM Dashboard

Implemented Damage Mechanisms (DM)

1. 10 DM Types

2. 15 DM Instances

a. 4 Online

b. 3 Online (Partial)

c. 8 Offline

ALARM STATE

1. Update is Instantaneous once DM threat is observed.

Triggered by implemented logic.

2. Alarm States:

a. UNIT OFFLINE

b. NORMAL OPERATION

c. ALARMED!

3. ALARMED! when implemented model’s logic is satisfied.

MONTHLY DURATION

1. Duration when unit

experiences DM

(ALARMED!) is accumulated

and will be reset monthly (or

any time interval)

2. This information can be

used in monthly report.

** EtaPRO can auto generate a

monthly report with all user’s

defined information.

EtaPRO TBM Dashboard

Tracking/ Investigation:

1. User can do a single click on the “Corrosion Fatigue” label.

2. This will bring up EPLog

MONTHLY DURATION

1. When Unit DM is ALARMED!,

accumulation for duration

starts/continues.

EtaPRO TBM – EPLog

ALARMED! event

occurred

ALARMED! event

cleared

Timestamp

EPLog contains key information for:

Tracking:

1. Each ALARMED! event is logged and time-stamped.

2. Conditions/ parameters causing the ALARMED! event are recoded

along with their allowable limits

3. Log entry is also created when ALARMED! event is back to normal

and this occurrence is time-stamped as well.

Operations QA-QC Guidance

1. Recommendation(s) is/are provided to correct the ALARMED! event

.

Corrosion Fatigue – Diagnostics Builder

Tracking/ Investigation:

1. User can do a single click on the “Corrosion Fatigue” label.

2. This will bring up EPLog

EtaPRO TBM – Long-Term Overheating (RH)

The sum of the “area under the curve” of Temp greater than 1032°F. Calculation formula:

xi is Temp > 1032°F, (1.0/60.0) 1min in an hour; dividing 1000.0 is make the summation value small. Note that the change is step-wise. This sum of the “area under the

curve” can be treated as an index value. Hence, NA is being used for engineering unit instead of (°Fxh) and dividing each component by 1000.0. E.g. for Temp = 1050°F, xi

will be (1050 x 1/60 )/ 1000.0 = 0.0175.

i 1000.0

x 1.0 / 60.0

i

Trend of Num Alarms

(Panel in alarm) and unit

load in floating time for

last 8 hours

All values on screen

are trend-able.

Total accumulated duration of Individual Panel Temp exceeds 1032°F. This accumulation is a manual reset point, which means it accumulates ‘forever’ unless the value is reset. This helps to estimate the remaining useful of tube.

RH Outlet Temperature – TBM Diagnostic Example

The current TBM Diagnostic is designed to:(1) Continuously accumulate the number of hours that a RH Outlet Temperature T/C exceeds

the target values(2) Continuously accumulate the number of hours that exceeds the target(3) Provide an Alert!(4) Notify selected personnel, once monthly, of the prior month accumulated hours above

each threshold and the total accumulated hours above each threshold.This TBM Diagnostic is replicated 40 times (there are 40 RH Outlet Tube-temp T/C's).

Time

High Alert

High-High Alert

1,032F

1,074F

Future Evaluator Tool

Component Assessment

Duration (Hrs.)

Temperature

• Stress

• Cycles

• Life Expectancy (or

even simplified damage

algorithms for creep

damage)

SME Reporting

LTOH RH Profile

RH LTOH which shows

“ALARMED : The reason for

the alarm is that RH tube

panels have encountered

temperature difference

between the panels that is

greater than 50°F.

This is the rule being used

to trigger an alarm for the

LTOH damage mechanism.

The right side of the figure

shows the temperature

difference between the

adjacent tube panels, which

can be indicative of gas or

steam flow unbalance.

Burner Flow Distribution

,EtaPRODEVFLORIDA onIMADCEPROFLDOl.5575- DevFlorida Regoon

Options View Configuration Tabs Help

0.0 °F

0.0 °F

FRONT

•tllll\t]Jj •E t a P R O "

Belews_Creek_TBM

ALLDATAPOilllTS

ACQUIREDPOlllTS

Corrosion Fa tigue

'f:t>:Flow-AcceeratedCorrosion

Long-Term Overheating

Fly -Ash Erosion

Thermal Fa tigue

Coal Partide Erosion

Sootblower Erosion

Bo er Fouling & Bridging

Boiler Slagging

• lJIScreens

C TBMSaeenC Corrosion Fatigue & FAC

C LTOH - RHMonitoring

C LTOH - RH Outfet T em. . .

LTOH - SSHMonitoring

LTOH - SSHOutletTe. ..

C CPE-Burner-To-Burner. ..

C CPE-Temperature Dst...

C CPE - FrontPA &SA F. .

C CPE - Rear PA& SA Fow

C CPE - Front-Rear Tern. .

C CPE Left-RightTemp...

• Accumulation

• Diagnostic

UNASSIGNED•

Belews_Creek_TBM

Screens

0.0 °F

0.0 °F

o.0 °F

0.0 °F

o.0 °F

0.0 °F

FURNACE

0.0 °F 0.0 °F 0.0 °F 0.0 °F

0.0 °F 0.0 °F

0.0 °F

o.0 °F

0.0 °F

o.0 °F

o.0 °FREAR

LastUpdate:5/26/2016 14:41:00 5/26/2016 14:41:40

Lessons Learned:

• Need to improve temperature control

• During the study, it was noted that many of the SH & RH thermocouples are still OOS. These

are critically important (especially under these circumstances)

• Total number of sampled points 225,408 (total thermocouples x hours)

• 168,987 (low) – Heat Rate Impact

• 15,430 (>1032) – Reliability Concern – warrants NDE (see graphs)

• 448 hours (>1074) – Reliability Concern – warrants NDE (see graphs)

• 4 (>1100) – Reliability Concern

KEEP IN MIND: These are hourly averages (meaning actual temperature excursions

could have greatly exceeded the values)

12- Month Historical PI data Audit: Re-Heater (RH)

RH

LTOH/CREEP, RH InRange

OOR

Control

Range

Regime Target Measurement

Value

981-1032 OT 1000 32 Panels 981-1032 Low High

(>1032)

High-High

(>1074)

Trip

(>1100)

Total Points

Measured

40599 168,927 15,430 448 4 225,408

Corrosion Fatigue (AVT)

Load (MW)

0.0Precursor Measurement Control Range Regime Target

Measurement

Value

Count OOR Count OOR

(Low) (High)

N/A N/A

25.00 0

N/A 23

N/A 0

N/A 0

25.00 23

Average

All

Fire to 550F

and

Hold 1 Hour

Primary Superheater Outlet Temp 0-550F AVT >120-<550F 1 hour hold @ 550F

9.4 Maintain prior to OT

<.50 To get to 550F

215

Economizer Inlet pH 9.2-9.6 AVT 9

Economizer Inlet CatCond <.50 AVT 1.5

Temperature Rate of Change - PSH

Outlet90-120 AVT +100 2

Economizer Inlet Dissolved Oxygen 0-25 AVT <25 Maintain prior to OT 275

Totals

Load(MW)

Precursor MeasurementControlRange

Regime TargetMeasurement

ValueIn Range Count OOR

AverageAll

Case:Corrosion Fatigue on AVT

6960 AVT/SU

(from midnight)

Gross Load2 PSH OUTL TEMP 1 PSO Temp. Change

SMOOTHED (°F/hr.)

699.79 100.27

Econ Inlet pH

Econ Inlet Dissolved Oxygen (PPB)

Econ Inlet CatCond (µmho)

407.00 0.14 9.27 90 0

0 Low High

AfterHold

Totals

Primary Superheater Outlet Temp ~550 - AVT 800

~550 After hold to N/A OT Time

N/A N/A 613

Economizer Inlet pH 9.2 - 9.6 AVT 9.2-9.6 56 134 0 9.21Economizer Inlet CatCond 0-.15 AVT <.15 to go on OT 85 0 105 0.113

Temperature Rate of Change - PSH Out. 0 AVT 0 181 N/A 9 115

Economizer Inlet Dissolved Oxygen 0-25 AVT <25 12 0 178 55

119 134 292

Off Line Layup Chemistry

Lessons Learned:

• pH is very low when unit is offline

• Boiler Layup procedure needs to be expedited to prevent damage

• Ensure analyzer is in-service at all times for pH

• 1591 = Hourly averages out of specification

Load (MW): 0 (Boiler Layup)

ID Pitting & Corrosion

Precursor Measurement Control

Range

Regime Target Measurement

Value

Count OOR Total Points

Measured

Average

All

Economizer

Inlet pH

9.4 - 9.6 AVT 9.5 Low High 1718

Economizer

Inlet pH

9.4 - 9.6 AVT 9.4 <9.4 1591 1718 8.37

AVT >9.6 0

Total 1591Hourly

Average Points

1718

Hourly

Average

Points

Coal Particle Loading (and Erosion)

OOR

CPE

Front Wall Burners

Coal Particle

Erosion & Burner

Unbalance

Control Range Regime Target Measurement

Value

In Range High

(> +/- 10%)

High-High

(> +/-20%)

Total Points

Measured

Load (MW)

Average = 971

968-1184 AU-Klb/hr. 1076 AU-

Klb/hr.

40 Burners 20 10 10 80

OOR

CPE

Rear Wall Burners

Coal Particle

Erosion & Burner

Unbalance

Control Range Regime Target Measurement

Value

In Range High

(> +/- 10%)

High-High

(> +/-20%)

Total Points

Measured

Load (MW)Average = 971

968-1184 AU-Klb/hr. 1076 AU-

Klb/hr.

40 Burners 16 13 11 80

Take it to another level

• Slag Index Integration (Temperature vs.

Slagging)

• Tube Circuit Temperatures

• Component Life Expectancy

• Gas Temperature & Pressure Variations

(slagging/fouling)

• Gas Velocity (convection pass erosion)

• SCR MIT/MOT

• ABS/SO3 Alerting

• Work Management Integration (prioritizing

repair actions)

Thermal Stress Management

Measure, Perform and Assess

Damage Prevention

• Online Data Evaluation, Assessments and Improvements

• Proactive Mitigation (Operations QA-QC)

Inspect & Repair

• Offline Data, Inspections, NDE Evaluation

• Work ManagementIntegration

Plan, Manage Risk and Component

Replacements

• Risk Assessment• Support Planning /

Outage Management

• Strategic Operations

Boiler Performance Management

Patrick D. Abbott

President529 Mourning Dove Circle,

Lake Mary, FL 32746

C: (407) 399-3235

O: (407) 321-3586

E-mail: pabbott@gear.energy

• LTOH RH & SH Outlet Temperature Monitoring - Temperature Difference, +/- Range, 900----1007----1100F

• Accumulation - Count # Events/Given Timeframe? Count Type of Event in Given Timeframe?

• Can We Perform Regression of Complex Trends?

• LTOH RH & SH Screens are cramped (May Be Others). Hard to see details. Can we Open up View to Fill Screen Area Available?

• Idea: Build a Condensate Chemistry Screen for Use When Unit is Off-Line to Assure Parameter Compliance (pH, Dissolved O2)

• Accumulation: We Should Reconcile Difference Between Total Hours of Unit Operation/Timeframe and Time on OT and Time on AVT. Not Equal

• Accumulation: Must Combine Duration and Amplitude to Measure “Total Area under Curve” with Unit-less Index (TBD). Replace All Instances Where “Duration” is Used.

• Idea: Flyash Erosion: We have Economizer TC’s for use in determining where Gas is Flowing (High Temp’s.) and Where it is Not Low Temp’s.). Gas Flow Matrix set up

Left/Right/Front/Rear May Be Better.

• LTOH-RH & SH – Change “Num Alrm” Vs. Unit Load to Average Temp

“2016” BC-2 Pilot Study & Model Discussion

Make the BC-2 Pilot Project the “Model Plant” for TBM integration into our existing Eta-PRO Platform and expand the capabilities: Fully cloned model utilizing fixed unit operating dataAPH Model for predicting Performance++ (ABS, Cleanliness, Dew Point, Etc.) Integration of Turbine Excursions (TBD)

Complete Cause & Effect Training ; Establish a Boiler Tube Failure Defense Strategy as the end result of the Pilot : End result will be a summary & spider diagram with the (14) key elements and attributes of TBM (still need additional information); Pat to get Stephen the attributes list for completion and/or make another trip to site - PAT & STEPHEN Develop a quantitative risk example for boiler : Enables high-probability and high consequence component sections / areas / locations with known deficiencies to be targeted for stepped up surveillance both in-service as well as during forced and planned unit outages. Establish a sample Failure Modes and Effects Analysis (FMEA) template for boiler : To catalogue, organize and align various heat exchange components with their respective failure/damage modes, mechanisms and causes. FMEA outputs in conjunction with the “conditional” outputs (fuel, hours of operation / section, water chemistry regime, etc.) are used to construct component specific and balanced in-service and out-of-service test and inspection standards as well as operational care strategies based on all existing and incipient damage threats

Establish Plan of Action for Continuous Improvements

Optimization of Process for management of the System Configuration Inputs (BPMS): Fuels Input, LOI, Air Heater Performance (Leakage), System Air In-Leakage

Create an enhanced Combustion & Boiler Performance Dashboard: O2 distribution, Air-fuel delivery, CO distribution, Mill HP/Ton (grinding efficiency), Air-Fuel ratio Control (Fuel, PA, SA, OFA – Fuel Loading) Slagging index Integration (IR Camera Technology), ID/FD Fan Positions, de-superheating spray flows, fuel loading curve establishment, etc.

Bonus Opportunities: Get EPRI Involved (Transfer of Technology)Expand upon capability (or at least develop a road map to assist with planning for future prediction of component-specific remaining useful equipment life.

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• 19 total stuck sootblower

events with a total duration of

85 hours.

• Average noise level with

boiler at full load is ~ 61.5dB.

Penthouse noise level is ~67

dB with boiler at full load.

TBM Model is designed to

count consecutive number of

hours, (3 minimum) >

Maximum Average for each

section. The accumulation of

hours, number of series and

dB level can be reported out

with EtaPRO

Soot Blower Conditions (Acoustics, Steam Quality)

Stuck Soot

blower

Control Range Location

Average

Section

Average

Location

Maximum

Maximum

Average

Stuck(Hrs.

> Max Avg.)

Event

Count

HRs

19 85

Furnace

Walls

Wall De-Slaggers

LSW Average 62.01 61.71 85.45 80.60 R1-7, R1-4,

L1-7, L10-3

11 37

RSW Average 61.40 75.87 2 11

Front Furn.Wall

SH Platen & Pend. Retracts

Left Average 57.60 57.05 80.68 79.00 R1-7

Right Average 56.50 77.15 1 7

Left Average 61.32 62.51 85.00 99.45 R1-5

Right Average 63.70 113.90 1 5

Upper CVPE PSH Retracts

Left Average 55.92 62.88 103.40 95.93 L1-5

Right Average 69.83 88.46 1 5

Lower CVPE HRH & Econ. Retracts

Left Average 66.14 62.00 87.76 96.38 R1-5 1 5

Right Average 57.99 105.00

Penthouse

Front Average 69.60 64.45 77.40 76.51 F2-15 2 15

Rear Average 59.30 75.62