Working to Succeed with an Operations Information System

OSI Users’ Conference

Working to Succeed with an Operations Information System

OSI Users’ Conference www.mdctech.com

www.esb.ie

by Alan Dormer (MDC Technology) and Adrian Bannister (ESB)

Electricity Supply Board (ESB)

Covers the whole of Eire

19 Generating stations

49 Generating Units

Coal, Oil, Peat, Gas and Hydro-Electric

MDC Technology - The Company

Leading world-wide supplier of Real-Time Optimization (RTO+), Advanced Process Control (SMOC), Multivariable Statistical Process Control (MSPC+) and Information Systems (PI)

Industry Solutions:

Oil & Gas, Oil Refining, Gas Processing, Petrochemicals, Chemicals and Power Generation

Provide benefits of circa. 2 - 5% increase in profitability to the operation of our customers processes

Plant-Wide Plant-Wide OptimisationOptimisation

Unit Control Unit Control + Optimisation+ Optimisation

PerformancePerformanceMonitoringMonitoring

InformationInformationManagementManagement

Real-Time OptimisationReal-Time Optimisation

Target IndustriesTarget Industries

Petrochemicals Energy + UtilitiesChemicals

GasProcessing

OilRefining

Oil & GasProduction

Performance Monitoring and Optimization - Why?

Protect the environment

Reduce energy costs

Maximize Utilization of Assets

Power Station

Cost per unit The Market

Costs of downtime

Ambient conditions

Costs of maintenance

Costs of fuel

Plant availability

Environment

Business Drivers inPower Generation

Optimisation Opportunity

Change

Continuous

Degrees of Freedom

Many

Complexity

Complexity

System Demand

Environmental

Distribution

Power Output

Efficiency

Fuel Cost

Turndown Ratio

Load Following

ESB Project Description

Scope: To provide a performance monitoring, information management and optimization system

Industry: Power Generation

Products: APPRECIATE POWER (with embedded PI)

Payback: 1 year

Customer Objectives:

Improved Operational Efficiency

Improved Asset Management

Improved Environmental Monitoring and Control

Project Statistics

17 Sites

49 Generating Units

175 Users

20 Different DCS/PLC’s

System Architecture

Remote Locations - 17 stations

Appreciate Power

Embedded PI

Data access using PI-PI link

Central PI system

100,000 + tags

175 Users

Appreciate Power Client

Uses Process Book

Amount of DataAmount of Data

ValueValue

Raw Raw DataData

InformationInformation

KnowledgeKnowledge

Essence of Performance Monitoring

Adding Value to Process Data

“People of this age have a false sense of superiority due to the vast amount of data available to them. Distinction, however, should go not to those who merely have access to the data, but rather to those who manage its advantageous use.”

Adding Value to Process Data

“People of this age have a false sense of superiority due to the vast amount of data available to them. Distinction, however, should go not to those who merely have access to the data, but rather to those who manage its advantageous use.”

Dr. Johann GoetheGerman

Mathematician1668

DESIGNPERFORMANCE

CLEANPERFORMANCE

AS RUNNINGPERFORMANCE

ON-LINE

PERFORMANCE GAINSFOLLOWING GAS TURBINE WASHES

ON-LINE OFF-LINE WASHES

$$$$$

Model BasedPerformance Monitoring Calculate cost of lost

performance

Compare with cost of an outage

Identify opportunities for cost effective maintenance

Improve availability and extend component life

Demands

Embedded PI System

Data Reconciliation

Accurate Model Current Costs

/ Constraints

Equipment Condition

Data Validation/ Reconciliation

Model Updating

Using Process Data

Reconcile and validate data

Update process model

Calculate the true cost of performance degradation

Identify constraints

CompareCompare

Model FittingModel Fitting

EfficiencyEfficiencyData ValidationData Validation

Plant DataPlant Data GTGTModelModel

Making Information

PerformancePerformancev. Designv. Design

Up to Up to Date Date

ModelModel

$ Cost of Poor $ Cost of Poor PerformancePerformance

Design Design ConditionsConditions

EconomicsEconomics

Up to Up to Date Date

ModelModel

Creating Knowledge

EconomicsEconomics

Design Design (Clean)(Clean)

CurrentCurrent

CompareCompare

DecideDecide

Making Better Decisions

Economic Dispatch

Real-time Merit Ordering

Fuel Prices

Opportunities

Demands

Optimum Operating Costs

Current Operating Costs

Equipment Condition

Data Validation/Reconciliation

Embedded PI System

Plant Optimization

Plant Model

Data Reconciliation

Model Updating

Real Time Optimization

Economic Model

OptimizerFeedback

Equipment Downtime Costs

Risk

Equipment Life Costs

Fuel Costs

Operability

Constraints

Equipment Availability

Basic Equipment Characteristics

Contracts

Price Prediction

Strategy

Load Pattern

Economic Optimization

Benefits of Optimization

Minimize fuel costs

Optimize power output

Improve plant availability

Improve profit margins

Better planning

Minimize emissions

Benefits of Previous Applications

MDC Technology has successfully applied this technology to:

Pfizer (Kent) - energy cost down by 5%

BP (Wytch Farm) - electricity cost reduction paid for the system in months

Boots Chemicals - new Energy Center uses APPRECIATE POWER

Slough Heat and Power paid for the entire project before even going on-line