Great Catches:How Equipment HealthDetection & DiagnosticSystems are ImprovingPlant AvailabilityCoal Gen 2010Ray JohnsonNeu...
Optimization Software & AvailabilityOptimization helps improve availability/reliability by:  Using predictive analytics to...
MaintenanceOpt®What it does:    Automatically alerts users to symptoms of potential equipment health    issues (efficiency...
Equipment TypesMaintenanceOpt may be used to detect problems in a fossilgenerating power plant associated with the followi...
Examples of Potential ProblemsThe types of problems that can be detected aredependent upon the type of equipment. For exam...
Indicators of Potential ProblemsThe following process values associated with an airheater are monitored as part of an earl...
Problem IdentificationModel is used to predict equipment performanceModel output is compared to actual performanceIf diffe...
Diagnosis Flow ChartA flow chart for diagnosinga potential problem isshown                     Proprietary and Confidential
How Alerts areManaged & Maintained      Proprietary and Confidential
NeuCo Customer SupportAnswer any questions related to the productsProvide software updatesUpdate system configurationProvi...
Automated Alerts ManagementProcessLink at Site                                           Customer Support                 ...
Automated Reporting Helps         Extract Maximum ValueKPIs Reflect Your Asset Management Metrics  EFOR/EFOR-D  Heat Rate ...
MaintenanceOpt Weekly Report           Proprietary and Confidential
Example Recent CatchesHigh ID fan motor temperatureLow oil on a fan bearingCondenser air evacuation problemIncreasing turb...
MaintenanceOpt: ID Fan Motor Temperature  Unit: PRPA Rawhide Unit #1, 300 MWs.  Usage: The following problem was identifie...
ID Fan ProblemID Fan problem is shown on the MaintenanceOptHome page.                  Proprietary and Confidential
Issues to ScreenThe ID Fan problem is also shown on the MaintenanceOptIssues to Screen page along with the context data.  ...
Alert DataReviewing the alert data, the problem had started threeweeks earlier and had been getting progressively worse.Th...
Diagnosing the ProblemBy clicking “show causes”, we are able to investigate thepotential causes of the problem. The rule f...
Identifying the ProblemThe temperature of both ID fan motor stators are analyzed. Thetemperature on ID Fan 102 is increasi...
Customer Support Sends Warning               Proprietary and Confidential
Verifying the ProblemAn operations crew inspected the filter. It was foundto be dirty and is thus subsequently replaced. T...
Good Catch   Proprietary and Confidential
Low Oil ExampleUnit: NRG Limestone Unit 2, 913 MWUsers: Maintenance Supervisor and PerformanceEngineer.Usage: Both work 4/...
Problem Alerted by MaintenanceOptIn a routine login to MaintenanceOpt, the users find an alert for abearing on a primary a...
Checking AlertChart shows the actual temperatures for all bearings on this fan.Also shows expected value for the bearing o...
Actual vs. ExpectedActual and expected (neural network) value of applicable bearingtemperature shown. Incident starts Frid...
Diagnosing the ProblemOne likely cause is inadequate lubrication or cooling. Rule clauses arehighlighted below. Temperatur...
Fixing the ProblemCustomer fixes the low oil problem within hours of finding it. Temperaturereturns to normal.
Closing the AlertThe alert is closed and a comment is posted in MaintenanceOpt’s database.                                ...
Turbine Bearing VibrationUnit: APS Four Corners Unit #4, 800 MWUsage: Routine checks of MaintenanceOpt madedailyIncident: ...
Vibration AlertVibration on bearing #7 has triggered. Note that alert had beentriggering >50% of the time over the past we...
Increasing VibrationTurbine bearing vibration increasing for past month (green). Neural modeladapting to the change but no...
Monitoring the Problem          User has flagged problem so that it stays on the Issues to Screen tab. The          user a...
Benefits of ProcessLink® IntegrationPerformanceOpt indicates equipment degradation through high-fidelitymodel of thermal p...
Condenser ProblemUnit: APS Four Corners Unit #2, 190 MWUsage: During a check of PerformanceOpt andMaintenanceOpt by NeuCo,...
M’Opt and P’Opt In Action         Routine review of triggers show alerts on condenser backpressure and         cleanliness...
Condenser CleanlinessCondenser Cleanliness significantly changes fromexpected at around 10 am.                  Proprietar...
Condenser BackpressureCondenser backpressure also significantly changesat the same time.                  Proprietary and ...
DiagnosisLow condenser cleanliness and high condenser backpressureindicates inadequate air removal equipment performance. ...
ResolutionMaintenance crew reconnects the vacuum pump andperformance returns to normal.                    Proprietary and...
Questions?  Proprietary and Confidential
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NeuCo's MaintenanceOpt Great Catches

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This presentation describes the value of equipment health anomaly detection and diagnostic systems, such as MaintenanceOpt®, in alerting plant personnel to equipment problems and expediting problem diagnosis and remediation. Several examples are provided including high ID fan motor temperature, low oil on a fan bearing, turbine bearing vibration, and condenser air evacuation issues.

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NeuCo's MaintenanceOpt Great Catches

  1. 1. Great Catches:How Equipment HealthDetection & DiagnosticSystems are ImprovingPlant AvailabilityCoal Gen 2010Ray JohnsonNeuCo, Inc
  2. 2. Optimization Software & AvailabilityOptimization helps improve availability/reliability by: Using predictive analytics to identify potential equipment health issues Providing early warnings for impending failures Minimizing unnecessary outages Sponsoring better use of planned down-time Reducing tube leak outages Proprietary and Confidential
  3. 3. MaintenanceOpt®What it does: Automatically alerts users to symptoms of potential equipment health issues (efficiency, capacity or reliability based) and allows quick easy drill down to uncover actionable responses to diagnose and remedy the underlying problems.Using: Neural Networks Expert Rules Other Optimizer AlertsTo Improve: Unit up-time Speed of issue resolution Efficiency Proprietary and Confidential
  4. 4. Equipment TypesMaintenanceOpt may be used to detect problems in a fossilgenerating power plant associated with the following types ofequipment: Air heaters Auxiliary equipment (ESP, FGD, SCR, crusher, etc.) Boiler Condenser Fans and drives Feedwater heaters General (flows, heat rate, etc.) Pulverizers Pumps Turbine Proprietary and Confidential
  5. 5. Examples of Potential ProblemsThe types of problems that can be detected aredependent upon the type of equipment. For example, forair heaters, the following provides a list of potentialproblems that may be identified: Inaccurate leakage calculation due to stratification or instrument error g Basket damage Ash or salt plugging Bearing inadequate oil cooling Shaft misalignment Bearing failure Proprietary and Confidential
  6. 6. Indicators of Potential ProblemsThe following process values associated with an airheater are monitored as part of an early warning system: High AH air or gas side pressure drop High AH cold end average temperature Low AH cold end average temperature Air Heater leakage increasing Increasing APH coil differential pressure Bearing temperature increasing Proprietary and Confidential
  7. 7. Problem IdentificationModel is used to predict equipment performanceModel output is compared to actual performanceIf difference is larger than a threshold, an anomaly isdetected Proprietary and Confidential
  8. 8. Diagnosis Flow ChartA flow chart for diagnosinga potential problem isshown Proprietary and Confidential
  9. 9. How Alerts areManaged & Maintained Proprietary and Confidential
  10. 10. NeuCo Customer SupportAnswer any questions related to the productsProvide software updatesUpdate system configurationProvide weekly reportsMonitor for high urgency alerts g g yMonitor performance of the optimizersProvide additional trainingand more… Proprietary and Confidential
  11. 11. Automated Alerts ManagementProcessLink at Site Customer Support Customer Email Email Trigger Email Support Server Server Service Composer Interface at Site at NeuCo Composite Historical Trigger Data Database Proprietary and Confidential
  12. 12. Automated Reporting Helps Extract Maximum ValueKPIs Reflect Your Asset Management Metrics EFOR/EFOR-D Heat Rate (rolling average, vs. targets, etc.) Emissions (cumulative tons, rolling average, vs. targets, etc.) Revenue (vs. targets, historical benchmark, etc.) Profitability (gross & net margins, vs. target, etc.)Built-In BenchmarkingB ilt I B h ki What benefits have been achieved? Additional benefits that could be achieved Changes in performance over time and implicationsDemystification Sheds Light on Key Processes What optimizers are doing and why Where the most important trade-offs are occurring How are constraints limiting benefits and what can be done? Proprietary and Confidential
  13. 13. MaintenanceOpt Weekly Report Proprietary and Confidential
  14. 14. Example Recent CatchesHigh ID fan motor temperatureLow oil on a fan bearingCondenser air evacuation problemIncreasing turbine bearing vibration g g Proprietary and Confidential
  15. 15. MaintenanceOpt: ID Fan Motor Temperature Unit: PRPA Rawhide Unit #1, 300 MWs. Usage: The following problem was identified during a routine review of MaintenanceOpt alerts. Incident: The temperature of an ID Motor Stator Temperature had increased over a p several week period. This issue was recognized by Customer Support. Early warnings were sent to the client about this issue. Based on the warnings, the client cleaned the filter and performance returned to normal.
  16. 16. ID Fan ProblemID Fan problem is shown on the MaintenanceOptHome page. Proprietary and Confidential
  17. 17. Issues to ScreenThe ID Fan problem is also shown on the MaintenanceOptIssues to Screen page along with the context data. Proprietary and Confidential
  18. 18. Alert DataReviewing the alert data, the problem had started threeweeks earlier and had been getting progressively worse.The client had been notified about this issue. Proprietary and Confidential
  19. 19. Diagnosing the ProblemBy clicking “show causes”, we are able to investigate thepotential causes of the problem. The rule for Dirty Filter isshown below. Variables associated with this rule are highlightedincluding data for the other ID stator motor. Proprietary and Confidential
  20. 20. Identifying the ProblemThe temperature of both ID fan motor stators are analyzed. Thetemperature on ID Fan 102 is increasing while the temperatureon ID Fan 101 is normal. This is consistent with the rule for adirty filter. Proprietary and Confidential
  21. 21. Customer Support Sends Warning Proprietary and Confidential
  22. 22. Verifying the ProblemAn operations crew inspected the filter. It was foundto be dirty and is thus subsequently replaced. Thetemperature returned to normal. Proprietary and Confidential
  23. 23. Good Catch Proprietary and Confidential
  24. 24. Low Oil ExampleUnit: NRG Limestone Unit 2, 913 MWUsers: Maintenance Supervisor and PerformanceEngineer.Usage: Both work 4/10 shift Monday to Thursday.They check MaintenanceOpt each morning whenthey are at site.Incident: Low oil on a primary air fan bearingsystem was found on Monday during routine login toMaintenanceOpt.Fix: Oil was added to the bearing system severalhours after the problem was identified. Thetemperature returned to normal.
  25. 25. Problem Alerted by MaintenanceOptIn a routine login to MaintenanceOpt, the users find an alert for abearing on a primary air fan. The bearing is at 174 degrees whileit is expected to be at 150 degrees.
  26. 26. Checking AlertChart shows the actual temperatures for all bearings on this fan.Also shows expected value for the bearing of interest. Only thetemperature of bearing associated with the alert looks abnormal.
  27. 27. Actual vs. ExpectedActual and expected (neural network) value of applicable bearingtemperature shown. Incident starts Friday afternoon at around 1pm with nomaintenance personnel on site. Value stayed under the points DCS alarmtrigger value. This view is from Monday morning during a routine check.
  28. 28. Diagnosing the ProblemOne likely cause is inadequate lubrication or cooling. Rule clauses arehighlighted below. Temperature is increasing but vibrations are normal.
  29. 29. Fixing the ProblemCustomer fixes the low oil problem within hours of finding it. Temperaturereturns to normal.
  30. 30. Closing the AlertThe alert is closed and a comment is posted in MaintenanceOpt’s database. User Comment
  31. 31. Turbine Bearing VibrationUnit: APS Four Corners Unit #4, 800 MWUsage: Routine checks of MaintenanceOpt madedailyIncident: During a routine check, it was observedthat a turbine vibration was increasing. Noimmediate action was necessary but problem neededto bet b monitored d il it d daily.Fix: Problem was fixed at the next outage
  32. 32. Vibration AlertVibration on bearing #7 has triggered. Note that alert had beentriggering >50% of the time over the past week and month. Proprietary and Confidential
  33. 33. Increasing VibrationTurbine bearing vibration increasing for past month (green). Neural modeladapting to the change but not as fast as vibration increase (blue). Proprietary and Confidential
  34. 34. Monitoring the Problem User has flagged problem so that it stays on the Issues to Screen tab. The user also entered a comment. Monitoring continued until next outage.Flagged ggitemUserComment Proprietary and Confidential
  35. 35. Benefits of ProcessLink® IntegrationPerformanceOpt indicates equipment degradation through high-fidelitymodel of thermal processesMaintenanceOpt indication of equipment degradation through empiricalmodels of on-line signals as well as potential problems detected throughmanual inspectionSome problems that would escape notice through one or the othermethodology become obvious when viewed through bothMaintenanceOpt also surfaces problems detected by NeuCo’s closed-loop optimizersPerformanceOpt informs closed-loop optimizers though virtual on-lineanalyzers indicating important boiler performance parameters not directlymeasured Coal quality, boiler efficiency and heat rate for CombustionOpt Boiler cleanliness and heat rate for SootOpt Proprietary and Confidential
  36. 36. Condenser ProblemUnit: APS Four Corners Unit #2, 190 MWUsage: During a check of PerformanceOpt andMaintenanceOpt by NeuCo, we noticed a largechange in condenser performance. Plant was notifiedvia email of the problem.Incident: During routine maintenance on thecondenser, th maintenance crew h d i d t tl d the i t had inadvertentlydisconnected both vacuum pumps causing a largeincrease in backpressureFix: The maintenance crew was notified of theproblem and then properly connected a vacuumpump. Th.e performance returned to normal
  37. 37. M’Opt and P’Opt In Action Routine review of triggers show alerts on condenser backpressure and cleanliness have triggered. Backpressure is at 3.05 when expected to be 2.2, and cleanliness is at 0.55 when expected at 0.88.BackpressureAlert from M’Opt Cleanliness Alert from P’Opt Proprietary and Confidential
  38. 38. Condenser CleanlinessCondenser Cleanliness significantly changes fromexpected at around 10 am. Proprietary and Confidential
  39. 39. Condenser BackpressureCondenser backpressure also significantly changesat the same time. Proprietary and Confidential
  40. 40. DiagnosisLow condenser cleanliness and high condenser backpressureindicates inadequate air removal equipment performance. Proprietary and Confidential
  41. 41. ResolutionMaintenance crew reconnects the vacuum pump andperformance returns to normal. Proprietary and Confidential
  42. 42. Questions? Proprietary and Confidential

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