Page 1 CMDS - Iberdrola Operación y Mantenimiento, S.A. Center for Monitoring, Diagnostic Center for Monitoring, Diagnostic and Simulation of Combined Cycle and Simulation of Combined Cycle Power Plant Power Plant (CMDS) (CMDS) DS - Iberdrola Operación y Mantenimiento, S.A. May 2003 May 2003
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Page 1CMDS - Iberdrola Operación y Mantenimiento, S.A.
Center for Monitoring, Diagnostic Center for Monitoring, Diagnostic
and Simulation of Combined Cycle and Simulation of Combined Cycle
Power PlantPower Plant
(CMDS)(CMDS)
CMDS - Iberdrola Operación y Mantenimiento, S.A.
May 2003May 2003
Page 2CMDS - Iberdrola Operación y Mantenimiento, S.A.
IBERDROLA IBERDROLA
CMDS - Iberdrola Operación y Mantenimiento, S.A.
Page 3CMDS - Iberdrola Operación y Mantenimiento, S.A.
– Iberdrola Group is a listed public joint company with a market capitalisation of more than Euro 13.000 M created in 1992 with the merger of Hidroelectrica Española and Iberduero.
The most cost-effective generation mix among Spanish producers
– Iberdrola Group is one of Europe´s leading electricity companies, providing a full range of power services involving the generation, transmission, distribution and retailing of electricity.
– As of December 31, 2000, Iberdrola had a total installed capacity of 16.062 MW, and an expansive transmission and distribution network offering service to 8.76 million customers in Spain.
– In 2000, Iberdrola generated net revenues in excess of Euro 7.000 M.
– Solid financial profile with a rating of A1/ A+ / AA- (Moody’s / S&P / Fitch IBCA).
– International activity is one of the key factors of the strategy, alongside with growth on our traditional markets, improved efficiency and diversification.
Iberdrola also has specific local partners in its international investments.
– As part of our new strategy, Iberdrola plans to invest Euro 12 bn within the period 2002 - 2006 to double its size, growing in Spain, Europe, Latin America as well as in the USA.
Iberdrola today
Page 4CMDS - Iberdrola Operación y Mantenimiento, S.A.
Fuente: IDAE
Generation
Installed Capacity in 2000 %
Hydro 8.367 MW 50,6%
Nuclear 3.267 MW 41,8%
Fuel/Gas 3.191 MW 38,8%
Coal 1.441 MW 12,8%
TOTAL 16.266 MW 37%
Production 2000: 46.641 GWh
Market share: 28,53%
T&D Assets (2000)
Transmission lines
- 220/380 kV 5.155 km.
- 3/132 kV 94.880 km.
Nº Substations 798
Transf. Capacity 53.880 MVA
Distribution - Commercial (2000)
Sales: 69.912 GWh
Clients: 8,7 Millions
Hydro
Thermal
Nuclear
Distribution Area
FreeMarket29%
Tariff71%
Iberdrola in Spain
Page 5CMDS - Iberdrola Operación y Mantenimiento, S.A.
Page 12CMDS - Iberdrola Operación y Mantenimiento, S.A.
Período Construcción Carbón Importación
Período Construcción CCGTProceso Autorización
ARCOS (*) 400 MW/1.600 MW
CASTEJÓN B 400 MW
ESCOMBRERAS C 600 MW
ESCOMBRERAS B 400 MW
LADA V 600 MW
CASTELLÓN C 800 MW
SANTURCE B 800 MW
ACECA B 400 MW
PASAJES 400 MW
ENERO 2006
ENERO 2007
ENERO 2008
ENERO 2009
ENERO 2010
ENERO 2011
ENERO 2012
ENERO 2013
ENERO 2014
2202
2203
2204
2205
2206
2207
2208
2209
2210
2211
2212
2213
2214
Strategy Plan: 2006 - 2014
Page 13CMDS - Iberdrola Operación y Mantenimiento, S.A.
RM&D RM&D ScopeScope
MonterreyMonterrey III III 1000 MW
Abr’02
TermopernambucoTermopernambuco 500 MW
Dic’03
TermoaçúTermoaçú350 MW
Dic’03
EscombrerasEscombreras800 MW
Dic’04
CastellónCastellón800 MW
Sep’02
Tarragona PowerTarragona Power400 MW
Jun’03
CastejónCastejón 400 MW
Abr’03
SanturceSanturce 400 MW
Mar’04
AltamiraAltamira III y IV III y IV 1036 MW
Oct’03
AcecaAceca400 MW
Jun’04
Arcos AArcos A800 MW
Oct’04Arcos BArcos B800 MW
Jul’05
Castellón BCastellón B800 MW
Dic’05
BBEBBE (25%) (25%) 800 MW
Mar’03
Remote Monitoring & Diagnostic Center – CMDS
Page 14CMDS - Iberdrola Operación y Mantenimiento, S.A.
CMDSCMDS
CMDS - Iberdrola Operación y Mantenimiento, S.A.
Page 15CMDS - Iberdrola Operación y Mantenimiento, S.A.
DEFINITION Goals Functions Mission Training Simulator Forum
HOW TO ACHIEVE THE GOALS??
IMPLEMENTATION
Diagnostic Instrumentation
Lay-out of CMDS Systems
Telecommunication System
PI System
PI ICE
Other Applications (R-Link; IT Monitoring)
SUMMARY
Page 16CMDS - Iberdrola Operación y Mantenimiento, S.A.
DEFINITION
Goals
Functions
Mission
Training Simulator
Forum
Page 17CMDS - Iberdrola Operación y Mantenimiento, S.A.
Controlling the load
is not the main goal
of the CMDS
Its main goal is to carry out
O&M recommendations based
on the cumulative operational
experiences of all the CCPP
CMDS
IS NOT A REMOTE CONTROL CENTER
Remote Monitoring & Diagnostic Center – Definition
1. CMDS1. CMDS
Page 18CMDS - Iberdrola Operación y Mantenimiento, S.A.
SIMULATION, MONITORING & DIAGNOSTIC CENTER (CMDS):
CMDS is a Technology Center which will act as a core technological competencies, that is, where IBERDROLA POWER GENERATION knowledge, skills and facilities are concentrated to optimize Combined Cycle Power Plant operation and maintenance.
Remote Monitoring & Diagnostic Center – Definition
1. CMDS1. CMDS
Page 19CMDS - Iberdrola Operación y Mantenimiento, S.A.
GOALS OF RM&D CENTER:
Maximize the efficiency, reliability and availability of CCPP, and in this way lengthen the intervals between planned plant maintenance shut down (reducing plant outages).
All the above based on more reliable and precise information on plant equipment condition and whole plant thermodynamic condition.
2. Goals2. Goals
Remote Monitoring & Diagnostic Center – Definition
Page 20CMDS - Iberdrola Operación y Mantenimiento, S.A.
FUNCTIONS OF RM&D CENTER:
Operation & Maintenance monitoring and reliability tracking of CCGT
Diagnosis of the key plant parameters (performance and condition monitoring of CCGT)
Detection of malfunctions before they lead to trips and serious faults in the plant (avoiding catastrophic failure)
Archive and retrieval of M&D and O&M data
Generation of reports on performance and incidents
Carrying out of O&M recommendations
3. Functions3. Functions
Remote Monitoring & Diagnostic Center – Definition
Page 21CMDS - Iberdrola Operación y Mantenimiento, S.A.
THE MISSION IS TO DEVELOP AN ANALYSIS PROCEDURE WHICH ALLOWS US TO:
Identify the degradation and malfunctions in the performance of Combined Cycle Power Plants (CCPP) by means of symptoms and indicators of initial stage problems that by providing solutions and operational and maintenance recommendations in time allow the optimization of CCPP performance.
REMOTE MONITORING & DIAGNOSTIC SYSTEM
4. Mission 4. Mission
Remote Monitoring & Diagnostic Center – Definition
Page 22CMDS - Iberdrola Operación y Mantenimiento, S.A.
Alstom SimulatorAlstom
SimulatorGE
Simulator GE
Simulator
Training Simulator
Gain operating experience,
confidence and accuracy when
operating the plant in normal/abnormal
conditions Gain confidence to handle the controls system and plant
equipment in normal and abnormal
conditions
Follow operating procedures for given normal and critical
situations and therefore practice the response and
recovery actions to manage various
malfunctions
Reduce the outages time cost
by operational errors and improve the productivity of the unit through
optimize operation for all load conditions
5. Training Simulator5. Training Simulator
Remote Monitoring & Diagnostic Center – Definition
Page 23CMDS - Iberdrola Operación y Mantenimiento, S.A.
CMDS
6. Forum 6. Forum
Meeting point for
Alstom and GE
Users to exchange
knowledge, best
practices and
experiences
Technological forum
within the area and a
place to exchange
information with
different
Universities of Spain
The international
exchange is reflected
by the staff itself of
the CMDS: personnel
of Mexico and Brazil
Meeting point and
front-office with the
Monitoring Center of
GE in Atlanta (USA).
IBERDROLA is one of
the “key customer” of
General Electric.
Remote Monitoring & Diagnostic Center – Definition
Page 24CMDS - Iberdrola Operación y Mantenimiento, S.A.
HOW TO ACHIEVE THE GOALS??
Page 25CMDS - Iberdrola Operación y Mantenimiento, S.A.
CONCEPT OF REMOTE MONITORING & DIAGNOSTIC (RM&D) IMPLIES:
Access to and collection of operation and maintenance data of the CCPP,
its transmission to the RM&D Center,
the analysis and diagnosis by means of a combination of automatic analysis and the M&D specialists,
the editing of condition and performance reports,
and provision of operational and maintenance recommendations.
How to achieve the goals??
Page 26CMDS - Iberdrola Operación y Mantenimiento, S.A.
Network Plant
TELECONTROLGATEWAY
VibrationTransaducers
Gas TurbineControlSystem
Steam Turbine Control System
………Control System
MachineProtec.Syst.
Transducers
………..
Client Applications
DataAcquisition
Devices
PLANT INFORMATION
SYSTEM
M&D application client
Performance application
client
ROUTER
SIMULATION MONITORING & DIAGNOSTIC
CENTRE
How to achieve the goals??
Page 27CMDS - Iberdrola Operación y Mantenimiento, S.A.
IMPLEMENTATION
Diagnostic Instrumentation
Lay-out of CMDS Systems
Telecommunication System
Plant Information System
PI ICE
Other Applications (R-Link; IT)
Page 28CMDS - Iberdrola Operación y Mantenimiento, S.A.
IMPLEMENTATION OF THE MONITORING & DIAGNOSTIC SYSTEM OF COMBINED CYCLE POWER PLANTS:
I.- Diagnostic Instrumentation (special+standard)
II.- Lay-out of CMDS Systems
III.- Telecommunication System
IV.- Plant Information System
V.- PI ICE
VI.- Other applications (R-Link; IT Monitoring)
Implementation
Implementation Implementation
Page 29CMDS - Iberdrola Operación y Mantenimiento, S.A.
Page 32CMDS - Iberdrola Operación y Mantenimiento, S.A.
II. Lay-out II. Lay-out
Implementation
M&D LAN - Ethernet
S D
Professional Workstation 6000
PRO
VIBRATIONSERVER
S D
Professional Workstation 6000
PRO
PDADATABASE
PDA SERVER
VIBRATIONDATABASE
SD
Professional Workstation 6000
PRO
IT MONITORDATABASE
IT MONITORSERVER
SD
Professional Workstation 6000
PRO
PIDATABASE
PI SERVER(HISTORIAN)
BN 3500PDA DATA
ADQUISITIONUNIT
VIBRATIONSENSORS
PDASENSORS
DCS(ENGINEERINGWORKSATION)
MARK VICONTROLLERS
SENSORS SENSORS
IBERDROLAWAN
FRAME RELAY2 Mbps
Redundant
CENTRALVIBRATION
SERVER
S D
S D
ESC
DLT
PROLIANT 8000
CENTRALPDA
SERVER
S D
S D
ESC
DLT
PROLIANT 8000
CENTRALIT MONITOR
SERVER
S D
S D
ESC
DLT
PROLIANT 8000
CENTRALPI SERVER
SD
SD
ESC
DLT
PROLIANT 8000
APPLICATIONSSERVERS
EXPERT SYSTEM
OTHERS SYSTEMS
S D
H E W L E T T
P A C K A R D
S D
H E W L E T T
P A C K A R D
Lay-Out"on-site"
Lay-Out"on-CMDS"
Page 33CMDS - Iberdrola Operación y Mantenimiento, S.A.
III.- TELECOMMUNICATION SYSTEM:
by means of a warning from plant itself when the malfunction is automatically detected
In a continuous mode “in real time”
In a periodical transmission of information according to the selected frequency rate
Monitored by the IT Monitoring
III. Telecommunication System III. Telecommunication System
Implementation
Page 34CMDS - Iberdrola Operación y Mantenimiento, S.A.
IV.- PLANT INFORMATION SYSTEM:
The Plant Information System is a set of Server and Client based software programs designed to fully automate the collection, storage and presentation real-time plant data.
The Plant Information serves plant information to end users and software applications, quickly and efficiently, working as a real time platform.
Implementation
IV. PI SystemIV. PI System
What do we do with the PI System???
Acquire Data Store Data Process Data Display Data
Page 35CMDS - Iberdrola Operación y Mantenimiento, S.A.
ACTIONABLE DATA
M&D EXPERTS
MAINTENANCE PERSONNEL
PLANT MANAGEMENT
OPERATORS
Information tailoredto the specific customer needs
Process data
RAW DATA
IV. PI SystemIV. PI System
Implementation
Page 36CMDS - Iberdrola Operación y Mantenimiento, S.A.
PI-to-PI configuration
Implementation
IV. PI SystemIV. PI System
Generator Monitoring
Generator Monitoring
Generator Monitoring
PDH
UDH
PIHistorian
M&D LAN
GT1 GT2 ST1
DCS
HMI1 HMI2 HMI3
Ethernet Card #1(HW Redundant)
Ethernet Card #2(HW Redundant)
Ethernet Card #3 (HW Redundant)
B.O.P. Points
Mark VI Points
Page 37CMDS - Iberdrola Operación y Mantenimiento, S.A.
ON-LINE DATA ACQUISITION:
The data acquisition system is the link between the monitoring system and CCPP itself, providing the necessary data for its diagnosis.
Thermodynamic and Functional Analysis
Generator Partial Discharge Analysis
Vibration and Rotor Dynamics Analysis
RAM Analysis
DATA PROCESSING AND VALIDATION:
The collected data is validated on-line and can be calculated as a mathematical function of the recorded data.
Implementation
IV. PI SystemIV. PI System
Page 38CMDS - Iberdrola Operación y Mantenimiento, S.A.
PI - DL
EXCEL
VBA
PI - PBVBA
PE, PI-ACE, SQC
ODBC
RDBMS
PI SERVER
SAP
DATA ARCHIVE
RLINK
RDBMS2PI
CONTROL SYSTEM
RELATIONAL DATA BASE
Implementation
IV. PI SystemIV. PI System
Page 39CMDS - Iberdrola Operación y Mantenimiento, S.A.
DATA ANALYSIS AND DIAGNOSTIC INFERENCE:
There are two levels of malfunction detection: The detection of malfunction at an initial stage by means of an immediate
flagging system which is carried out by the PI- Alarm View to acknowledge and view the alarms in real time/historical.
The detection of malfunction over a longer timescale is carried out by M&D experts in the RM&D Center trough an Expert System which is 100% compatible with the PI System
Implementation
IV. PI SystemIV. PI System
Dependability Server
Performance Monitoring in two levels: Monitoring raw data (PI-PB)
Through processed data running on a thermodynamical model 100% compatible with the PI System (PI-Advanced Computing Engine)
Performance Server
Page 40CMDS - Iberdrola Operación y Mantenimiento, S.A.
Generator
COMBINED
CYCLE
POWER
PLANT
MONITORING
&
DIAGNOSTIC
CENTRE
FUNCTIONAL DIAGRAM OF REMOTE MONITORING & DIAGNOSTIC SYSTEM
on-line data acquisition system
on-line data processing and validation M&DData Base
Thermodynamic Analysis
Hot Gas sectionMonitoring
VibrationAnalysis
GeneratorMonitoring
Base-line Deviation RulesInference
Engine
ANALYSIS
Condition evaluatión/malfunction detection
Telecommunicationsystem/remote
warning
Remote accessand retrieval of Plant Data
Configuration M&D system
(local/remote)
Detailed Analysis and Diagnosis
Operational follow-up
Incidents Analysis
O&M Monitoring/ reliability
tracking
M&DData Base
O&MData Base
Generation of O&M Reports
O&M Recommendations
IncidentsReports
Communication system INTRANETNETWORK
Page 41CMDS - Iberdrola Operación y Mantenimiento, S.A.
IV.- PI Interactive Configurable Environmental:
CMDS uses PI ICE to build up its intranet web: CMDS on-line.
What for?? To keep our clients informed
To keep the Managers informed
To know the real status of all the CCPP wherever you are
Implementation
V. PI ICEV. PI ICE
Page 42CMDS - Iberdrola Operación y Mantenimiento, S.A.
Implementation
V. PI ICEV. PI ICE
CMDS
Cisco.7500Cisco Systems
PI-CENTRALCluster w2000
Node 1 Node 2 Dependab.Server
Cisco.7500Cisco Systems
Perform.Server
Cisco.7500Cisco Systems
VibrationServer
WAN IBERDROLA
MonitoringServer
WEB SERVER-IIS-SQL
PI-ICE
Combined Cycle Power Plant
Combined Cycle Power Plant
MANAGEMENT
INTERNET
Page 43CMDS - Iberdrola Operación y Mantenimiento, S.A.
Implementation
Page 44CMDS - Iberdrola Operación y Mantenimiento, S.A.
R-LINK Real time performance management:
The R-Link is the link between the Plant Information System and SAP R/3 using the interface RDBMS-to-PI. What for??
Generates the work orders of the operators of the plants automatically
Calculates de operation hours of the different plant equipment
IT MONITORING:
Tool based on IT Monitor for monitoring critical applications, communications devices, security and hardware performance of CMDS infrastructure to improve the availability, performance and security of the System
Implementation
IV. Other ApplicationsIV. Other Applications
Page 45CMDS - Iberdrola Operación y Mantenimiento, S.A.
Implementation
IV. Other ApplicationsIV. Other Applications
PDH
Servidor IT
SISTEMA M&D"ON-SITE"
HMI1 HMI2 HMI3
Ethernet Card #1(HW Redundant)
Ethernet Card #2 (HW Redundant)
Servidor PI
Servidor Vibraciones
Servidor PDA Otros
Switch
Router
Est.Ingeniería
Est.Operación #1
Est.Operación #2
DCS
SCADA TURBINAS
Bajo Demanda
IT configuration
Page 46CMDS - Iberdrola Operación y Mantenimiento, S.A.
SUMMARY
Diagnostic Instrumentation
Lay-out of CMDS Systems
Telecommunication System
Plant Information System
PI ICE
Other Applications (R-Link; IT)
Page 47CMDS - Iberdrola Operación y Mantenimiento, S.A.
SUMMARY:
With all the aforementioned a communication network is set up between plant staff ( plant management, operators, maintenance personnel,.…) and RM&D Center (diagnostic engineers, M&D experts,.....) which will enable on-line technical assistance and support on-line technical assistance and support in the operation and maintenance of Combined Cycle Power Plant.in the operation and maintenance of Combined Cycle Power Plant.
Summary
Page 48CMDS - Iberdrola Operación y Mantenimiento, S.A.