“preserving competiveness in today’s economic preserving competiveness in today’s...
TRANSCRIPT
Clinton E. Carter
DallasJanuary 13, 2017
“Advanced Monitoring & Diagnostics”
“Preserving Competiveness in Today’s Economic Reality”
The Imperative for Digital Transformation
The Revolution
“We stand on the brink of a technological revolution that will fundamentallyalter the way we live, work and relate to one another.
In its scale, scope and complexity, the transformation will be unlike anythinghumankind has experienced before…”
“The 4th Industrial Revolution”
https://www.youtube.com/watch?v=6ZOkoRuV1R0
Klaus SchwabFounder and Executive Chairman, World Economic Forum
4th Industrial Revolution –
1st Industrial RevolutionMechanization
> Water <> Steam <
2nd Industrial RevolutionMass Production
> Electric Energy <> Division of Labor <
3nd Industrial RevolutionComputer & Automation
> Electronics <> Information Technology <
1800 1900 1970 2000 2016
4th Industrial RevolutionCyber Physical Systems> Cyber Intelligence <
> Physical Production Systems <
Linear to Exponential Evolution
Sputnik to Uber
Industry transformation has become a matter of survival..!
DisruptiveTechnologies are
nowDemonetizing
theElectric Utility
Industry…
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$...
...................................
Analog
Digital
Condition BasedMaintenance
PredictiveMaintenance
MachineLearning
Broke/Fix
PreventiveMaintenance
Fault SignatureAnalytics
Pattern Recognition& Codification
AutonomousOperation
Fleet WideInternet
National
Global CooperationThe Cloud
Social Media
Main Frame Computing
Personal Computing
Standards
Legislation
Industry Self-Regulation
Regulation
SCADA
BroadbandWireless
Nano-Technologies
Microwave
Satellite
The “Industrial Internet of Things” – is enabling a new age of Operational Excellenceacross the electric utility industry
Prognostics
Advanced Monitoring& Diagnostics
Alarm /Response
Evolution & Convergence
Semi-AutomatedData Collection &
Control
Drone/RoboticData Collection
Manual DataCollection
Cyber-BasedOperators
Manual PlantControl
Power Optimization Center
State-of-the-Art Advanced Monitoring & Diagnostics
…while enabling real-time Operations Support and meaningful Cost Reductions
Advanced Monitoring & Diagnostics drives Fleet Performance improvements…
Plants We Serve:Type Units MWCoal 20 11,000Gas 26 3,400Nuclear 2 2,340
16,740
11 Years Experience
Operations
Maintenance
Engineering
BigData
ActionableIntelligence
AdvancedMonitoring & Diagnostics
Power Optimization Center
Nuclear
Coal
Natural Gas
Increase Generation
Optimize Performance
Reduce Cost
Circulating Water Pumps
Heater Drain Pumps
Condensate Pumps
Turbine / Generator
The system is expanded to monitor emerging equipment challenges
Reactor
SteamGenerators
MainCondenser
ReactorContainment
Heater DrainTanks
EHC Motors
Turbine Plant CoolingWater Pumps
Control RodDrive M/G
Sets
POC also deploys highly flexible wireless monitoring solutions…
Main Feedwater Pumps
Power Optimization Center
Recent Success Stories
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Primary Air FanComponent
“The shot heard ‘round the world…”
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Primary Air Fan
High Vibration
Component
POC Indication
“The shot heard ‘round the world…”
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Primary Air Fan
High Vibration
Plant notification and subsequent investigation
Component
POC Indication
Action Taken
“The shot heard ‘round the world…”
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Primary Air Fan
High Vibration
Plant notification and subsequent investigation
Added oil, replaced bearing during planned outage
Component
POC Indication
Action Taken
Corrective Action
“The shot heard ‘round the world…”
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Primary Air Fan
High Vibration
Plant notification and subsequent investigation
Added oil, replaced bearing during planned outage
Plant Derate: 50% load, 48 hours
Component
POC Indication
Action Taken
Corrective Action
Consequence Avoided
“The shot heard ‘round the world…”
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component Main Power Transformer
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Main Power Transformer
High Winding Temperatures
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Main Power Transformer
High Winding Temperatures
Plant notification and subsequent investigation
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Main Power Transformer
High Winding Temperatures
Plant notification and subsequent investigation
Cooling pumps and fans returned to service
POWER OPTIMIZATION CENTER: SUCCESS STORIES
Component
POC Indication
Action Taken
Corrective Action
Consequence Avoided
Main Power Transformer
High Winding Temperatures
Plant notification and subsequent investigation
Cooling pumps and fans returned to service
Catastrophic Failure / Major Internal Inspection
136.04°F98.194°F117.05°FCLOSE
OPEN
HDP 1 OUTBD BRG TEMPHDP 2 INBD BRG TEMPHDP 2 OUTBD BRG TEMPHDP 1 BKRHDP 2 BKR
1/6/2014 6:00:00 PM1/5/2014 6:00:00 PM 24.00 hours
Heater Drain Pump Reverse Flow
0
100150
200250
350
Event: Unplanned HDP trip and Unit Runback• POC operators identified rapidly increasing bearing temperatures on the tripped HDP.• The POC notified the Control Room.• Operators dispatched discovered the pump rotating backwards due to a stuck open discharge check valve resulting in a loss of
bearing lubrication.• Check valve isolated. Without the assist from the POC, pump damage would have been far more extensive.
A “second set of eyes” enables mitigation of damage following power planttransients
Mitigating Consequences of Single Point Vulnerabilities with AdvancedMonitoring & Diagnostics
EventManual Reactor Trip due to Loss of S/G Level Control
Root Cause: Flow Control Valve Positioner Failure
Codification of Operating ExperienceThis Single Point Vulnerability led to new modeling and alarmsbeing established in support of all FCVs across nuclear units.
Identification & InterventionAdvanced Monitoring identifies similar issue on another FCV
months prior to failure, mitigating risk of inadvertent Reactor Trip.
Feedwater FCV PositionerFailure (October 2015)
Early Identification of FCV Issue(May 2016)
Start Up and Coast Down Reviews Identify Issues During TransientScenarios
Main Turbine Bearing Wipe (January 2016)
Identified during routine Coast Down Review
� Bearing temperatures never exceeded plantalarm set points
� Plant unaware of the issue
� Prevented further damage and avoidedadditional downtime
Bearing Wipe
Plant Request - Uncontrolled Main Feedwater Pump Oscillations
Wireless Crash Carts enable expanded real time monitoring and triage of adverseequipment conditions
POC deployed a wireless system tomonitor the condition. Thisinstallation included mountingvibration transducers on the MFPcontrol valve’s rocker arm in order tomeasure rocker arm movement.
Alarms were configured to identifychanges in behavior. This capabilitywas maintained for a number ofmonths until the machine could betaken offline and repaired.
Strategic Considerations – Deployment of Advanced Monitoring & DiagnosticTechnologies
Essential System Design Attributes:• Highly Scalable – Benefits Compounded with Fleet Expansion• Standardized Platform, Advanced Modeling & Alarming• Automated Data Collection, Analytics and Reporting
Practical Scope of Initial Monitoring Platform:• Safety-Related & Generation Critical Equipment• Integrated Plant Performance• Instrumentation and Process Controls• Single Point Vulnerabilities• Targeted Solutions based upon Individual Plant Needs• Dynamic Integration of Industry Operating Experience into Monitoring Strategies
OptimizedUtility
Operation=
DistributedEnergy
ResourcesTransmission & Distribution Demand+ +
Smart Grid
Optimizing Supply & Demand
Optimizing Equipment Reliability & Performance
Smart Generation
Optimizing Utility Value
Technological advancements combined with economic realities are bringingabout a radical transformation of the electric utility industry.
Through our leadership, the nuclear power industry can be a key contributorto meeting these challenges enabling the continued prosperity of allmankind…
… this is our destiny.
More Info:Clinton E. CarterDirector, Advanced Monitoring & Diagnostic [email protected]