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EPRI Instrumentation, Controls, and Automation Interest Group Meeting June 8, 2011

54th ISA POWID Controls & Instrumentation Conference

Embassy Suites Concord, North Carolina

Meeting Summary

EPRI’s Instrumentation, Controls, and Automation Interest Group Meeting was held on Wednesday, June 8, 2011 from 1:00 PM to 5:00 PM. The meeting was held shortly after the 54th ISA POWID Controls and Instrumentation Conference concluded on Wednesday. The primary purpose of the meeting was to solicit input from the power generation industry on current Instrumentation, Controls, and Automation issues and research needs, and to share with the industry an overview of EPRI research activities in this area. EPRI research program overview presentations were held in the following areas:

• Instrumentation, Controls, and Automation • Monitoring and Diagnostics

A roundtable discussion was held for the majority of the meeting. The following topics were generated and ranked by participants:

Topic Assigned # VotesControls Performance 10Wireless Technology 7Cycling 7Technology Adoption 4Training and Education 3Renewables 3New Technology 3Performance Monitoring 1Environmental Controls 1Cyber Security 1

Participation in this meeting was greatly appreciated and provided valuable industry perspective to EPRI. Roundtable Discussion Notes: Controls Performance: -Plant dynamic performance (controls performance)

o need benchmarking of plant performance first -Using existing functionality of control systems for performance improvements

o can use PID's, cascade, feedforward, etc. in control design within existing computational capabilities of controls

© 2011 Electric Power Research Institute, Inc.

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o Use multivariable design to determine where to place feedforwards in existing control design

-Controls performance: o Determining performance of dynamic performance based on measures of

variability of end devices and effects associated (stresses, heat rate, etc.) o Need a standard set of performance indices and how to tailor for plant based on

what's practical o Would be very useful for cyclic operation to determine good vs. bad controls

performance o Also need to monitor frequency domain (PSD, ESD) to detect problems

-Need to identify tuning problems vs. other controls issues (can improve cycling capabilities)

o First call is to controls technician with request to tune; technician/engineer has to identify the problem (tuning vs. mechanical)

Cycling: -Control systems not designed to handle non-baseload operation -If controls were tuned properly, significant improvements may be possible (before MIMO controllers)

o Vendor experts come in and tune and the necessary evolution of tuning parameters doesn't happen by plant staff

-Poor decisions by design of plants that tuning alone cannot solve o Mechanicals should be taken care of before controls

-Simulation not used enough in basic design of plant, let alone controls design o Need good library of power plant components; would be worth the investment o Available libraries need to be validated and improved (e.g. Dymola, Modelica,

ThermoPower) -Benchmark on how to find root cause of issues (monitoring to determine controls vs. mechanical issues).

o Need for control loop performance monitoring and troubleshooting of causes o Tuning parameter changes needed indicate that equipment/process may have

degraded; opportunity to apply robust control methods -Worth of controls tuning is difficult to quantify, and management is not aware

o Life expenditure is key consideration, but units are often planned to sell within 5 years

o Need ways to communicate results and EPRI message to non-EPRI members

Wireless Technology: -Why cyber security concerns with 802.15.4? Can understand concerns with WiFi.

o Need certification of vendor-provided solutions (e.g. Wireless Compliance Institute)

-Jamming is a bigger threat -Robustness, protocols, etc for control -Applications - many are better suited for wireless (but some wired is more optimal)

o Level, starting/stopping pumps (control app) -Battery life - directly tied to data rate/transmit rate


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o AC power but wireless transmission of data o Power harvesting still being worked on o New battery technologies being developed/are already available

-RFID tagging - can help plant locate equipment Technology Adoption -Always ask vendor to provide on/off switch with new technologies - never fixed after installation

o Must plan in support/maintenance activities o What are the right plant staffing levels? (e.g. performance engineer)

-Adoption of smart devices o How to fix, make talk to each other; takes special skills to keep up-to-date o Also, get more data but noone available to process/use the data

-Simulator-assisted control design engineering o Test logic sheets is an absolute must on simulator prior to commissioning control

changes o Simulators justified for training purpose find a greater value when used for

controls simulations o Will simulators be under change management? Actually helps with this, since the

simulator helps keep control system validation

Training and Education -Basic skills are becoming more demanding due to increasing complexity -I&C techs are sent to DCS training; merger of computer training with controls training -On flipside, it's an interesting/multidisciplinary field


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AGENDA

EPRI Instrumentation, Controls, and Automation Interest Group Meeting June 8, 2011

54th ISA POWID Controls & Instrumentation Conference

Embassy Suites Hotel Concord, NC

Wednesday, June 8, 2011

Time Topic Presenter 1:00 PM Welcome and Introductions A. Hussey 1:15 EPRI Instrumentation, Controls, and Automation Overview A. Hussey 1:45 EPRI Monitoring & Diagnostics Research Overview A. Hussey 2:15 Roundtable Topic Brainstorming & Prioritization

All

2:45 BREAK 3:00 Roundtable Discussion:

-Advanced Control Applications -Best Practices in Control Engineering -Cyber Security

All

5:00 ADJOURN

Welcome and Introductions

Aaron HusseyProject ManagerInstrumentation, Controls, and Automation (ICA) Interest Group MeetingJune 8, 2011

2© 2011 Electric Power Research Institute, Inc. All rights reserved.

Introductions


Quote…

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Agenda

Time Topic Presenter 1:00 PM Welcome and Introductions A. Hussey1:15 EPRI Instrumentation, Controls, and Automation Overview A. Hussey 1:45 EPRI Monitoring & Diagnostics Research Overview A. Hussey 2:15 Roundtable Topic Brainstorming & Prioritization

All

2:45 BREAK 3:00 Roundtable Discussion:

-Advanced Control Applications -Best Practices in Control Engineering -Cyber Security

All

5:00 ADJOURN


Together…Shaping the Future of Electricity

2011 Program Overview

Aaron HusseyProject ManagerICA Interest Group MeetingJune 8, 2011


Outline

• 2011 Project Overview• 2011 Calendar• Open Discussion


2011 Program Structure – Program 68Instrumentation, Controls, and Automation

• P68.001: Technology Development & Demonstrations

– Boiler temperature matching for steam turbine stress reduction

– I&C solutions for steam temperature control optimization

– Impact of pulverizer performance on load response

• P68.002: Technology Transfer

– Fleet-Wide Monitoring Interest Group Meetings

– I&C Guideline: 2011 Topical Update

– Survey I&C training materials


Boiler Temperature Matching for Steam Turbine Stress Reduction (Joint with P65)

• Project Manager: Merrill Quintrell• Product Type/ Deliverable Date:

Technical Report (Dec. 2011)• Deliverable Title: Boiler

Temperature Matching for Steam Turbine Stress Reduction

• Project Description:

•This study will focus on reducing turbine and boiler stresses by developing new boiler and turbine operating strategies for low-load and cyclic operations for drum type plants.

•EPRI will leverage new technology by utilizing a high-fidelity replica simulator of a suitable coal-fired plant for the development and testing of new operational philosophies and control strategies.


I&C Solutions for Steam Temperature Control Optimization

• Project Manager: Aaron Hussey• Product Type/ Deliverable Date: Technical

Update (Dec. 2011)• Deliverable Title: I&C Solutions for Steam

Temperature Control Optimization• Project Description:

– Task 1: Document hardware modifications and control system optimization from the coal-fired plant study

– Task 2: Utilize automatic tuning methods, advanced regulatory controls, and model predictive control to optimize steam temperature control

FTTT

PID

Drum PressureFinal Superheat

Outlet Temp

f(t)

f(x)

PI

TA A

TT

Desuperheater Outlet Temp

Superheat Spray Valve #1

f(x)

f(x)

Superheat Spray Valve #2

f(x)


Impact of Pulverizer Performance on Load Response

• Project Manager: Aaron Hussey

• Product Type/ Deliverable Date: Technical Update (Dec. 2011)

• Deliverable Title: Impact of pulverizer performance on load response


– This project will study the impact of pulverizer performance on load response and identify a mechanism to easily test a pulverizeronline to determine its responsiveness (or change in responsiveness).

– Results will be used to determine if the pulverizer needs maintenance or if the control system needs tuning.


Fleet-Wide Monitoring Interest Group


• Product Type/ Deliverable Date: Technical Resource (Dec. 2011)

• Deliverable Title: Fleet-Wide Monitoring Interest Group


– EPRI’s Fleet-Wide Monitoring Interest Group (FWMIG) provides a forum where utilities can share monitoring and diagnostic center experiences in a peer-to-peer setting, without commercialism in the meetings.

– Meetings will be held twice per year.


I&C Guideline: 2011 Topical Update



• Deliverable Title: Fossil Plant Instrumentation and Controls Guideline: Volume 4: Best Practices in Controls Engineering


– The guideline will provide I&C engineers, and in some cases technicians, with guidance for performing infrequent I&C tasks that may require engineering practices combined with best practices within the industry.


Survey I&C Training Materials



• Deliverable Title: Survey of Fossil Plant Instrumentation and Controls Training Materials


– This project will survey available I&C training materials to identify available options, and will assemble a list of gaps that should be addressed by the program. In some cases, generic training materials may be available but specific industry guidance should be developed.


P71.004: Heat Rate and Cost OptimizationEvaluation of Remote Monitoring for Heat Rate Improvement

• Determine the effectiveness of improving plant performance through the practice of remote monitoring - conducted jointly with Program 68.

– Site specific examples will be evaluated to determine the effectiveness of remote monitoring for heat rate improvement.

• Interest Group Comments

– Heat rate more complicated than equipment condition monitoring.

– Include combustion turbines and combined cycle units, working jointly with P79.

– Assess effectiveness of outsourcing to a third party.


2011 Meeting Schedule

Event Name Location Date(s)

Instrumentation, Controls, and Automation Interest Group Meeting

Charlotte, NC June 8, 2011

Fall Fleet-Wide Monitoring Interest Group Meeting

Orlando, FL October 10-12, 2011

Fall Program 68 Advisory Meeting Boston, MA September 13, 2011


2012 - 2014 Project Ideas

• Next two slides list potential projects for future years.

• Zoomerang ranking to be completed to prioritize, and add new ideas.

• If 2011 has sufficient funding, the top ranked project will be started.


List of potential projects – I&C(program that deliverable/costs might be shared with)

• Reheat Temperature Control for the Mitigation of Pipe Cracking during Combined-Cycle Startups (P88)

• Using Control Methods for Accommodating Changing Coal Quality (P71)

• Optimizing Sensor Placement to Infer Spatial Patterns (P71)

• Cyber Security Best Practices for I&C Systems

• Preventive Maintenance of Digital Control Systems (Nuclear I&C)


List of potential projects – Monitoring & Diagnostics(program that deliverable/costs might be shared with)

• M&D projects will be a part of supplemental offering

– Generator M&D Guideline (P65)

– Steam Turbine M&D Guideline (P65)

– Combustion Turbine M&D Guideline (P79)

– Fossil-Fueled Boiler M&D Guideline (6P3)

– HRSG M&D Guideline (P88)

– Wind Turbine M&D Guideline (P84)

– Guidelines for Implementation of NERC-CIP Standards for FWM Centers

Monitoring & Diagnostics of Power Plant Equipment

Aaron HusseyProject ManagerICA Interest Group MeetingJune 8, 2011


Contents

• Industry Challenges

• Recent Equipment Failure

• Fleet-Wide Monitoring Centers

• Online Monitoring Basics

• Diagnostic Approaches

• Conclusion


Industry Overview


Existing Generation Plants Value Soaring . . .

• Plant Capacity

– 20GW cancelled or withdrawn

– 27GW proceeding

• Reliability may be at risk by mid-decade (NERC)

• Natural gas – is it the answer?

• Wind capacity

– Difficult to launch new coal

– Coal plants to cycle?

Availability of existing fossil plants is a top industry strategic priorityAvailability of existing fossil plants is a top industry strategic priority


Aging of Generation Assets

BernsteinResearch, U.S. Utilities: Which utilities are most at risk from pending plant retirements? April 23, 2008


Recent Equipment Failure


Forced Draft (FD) Fan Bearing Failure

An oil sample was taken, but never submitted (too many visible pieces).

A quick vibration analysis was done and indicated a wiped bearing.

Parts were gathered, manpower scheduled, and the fan was scheduled out over for the weekend.

The bearing was replaced.


Bearing Damage

If not for the Condition-Based Maintenance (CBM) Vibration technologist, this would not have been acted on.

He believed there was a potential for a problem based on what was presented, and then confirmed the problem.


Fleet-Wide Monitoring Centers


Centralized Monitoring andDiagnostics (M&D) Strategy

• Main thrust is leveraging staff expertise, using technology for efficiency of monitoring, to detect and mitigate potential equipment failures

• Multi-disciplinary staffing with experienced operators, maintenance technicians, and engineers

• Information integration, including connection of plant data historians and enterprise asset management tools to central facility

• Brick-and-mortar facilities in a location central to monitored units

• Executive support for establishing an implementation plan and for communicating the need and benefit across the fleet


Carolina’s

Fleet Wide Pattern recognition monitoring for Fossil, Combustion Turbine (CT), & Combined-Cycle (CC)

Nuclear & Transmission interested

Florida

Fleet Wide Thermal Performance monitoring for Fossil, CT, & CC

Progress Energy M&D Centers

11


Online Monitoring Basics


Limit Checking

• Normal behavior has normal range

• Abnormal behavior not in normal range

• Limits detect unreasonable changes in data values or trends

• Limits mightnot be sensitiveenough for many applications


Prediction Models

• Predictors provide a dynamic reference

• Predictors use observed values to infer expected values for normal behavior

Predictor


Using Predictors

• Train predictors using normal data

• Pass corrupted data to predictor to get estimate of un-corrupted values

PredictorPredictor

Predictor


Using Predictors

• Predictor estimates follow the expected trend

• The difference between actual and estimated values identifies the fault


Prediction Model Examples

• Univariate Methods– Auto Regression (AR)

• Multivariate Methods– Multivariate State Estimation Technique (MSET)– Inductive Monitoring System (IMS)– Principal Component Analysis (PCA)

• Redundant Sensor Methods– Instrument Calibration Monitoring Program (ICMP)


Principal Component Analysis

• Transforms data into a new coordinate system

• The principal components provide the new axes

• Good data will fall within a statistically determined distance from the principal component axes

OK

Not OK


Instrument Calibration Monitoring Program

• Estimate is the consistency weighted average of threeor more redundant signals

• Consistency parameters are derived from training data

• Inconsistent signals are removed from the average


Fault Detection Examples

• Threshold Methods

– Residual Value Limit

• Hypothesis Test Methods

– Sequential Probability Ratio Test (SPRT)

• Statistical Process Control (SPC) Methods

– Mean Test

– Standard Deviation Test

– Range Test


Statistical Process Control

• Used to maintain processes within specific control limits• Compares sample mean, standard deviation and range

to the control limits to determine abnormal behavior


Diagnostic Approaches


Example Use Case Scenario

OLM/FWMUser Query

Alert

Pattern

Tech ExamDatabase

Diagnostic Reasoner

DetermineFault Indication

Pattern

MatchFault Signature

Pattern

AFSDatabase

Fault

Pattern

Provide Diagnostic

Advice

Fault

Diagnosis

CorrectiveAction Advice

PerformTroubleshooting

RemedyProblem

• Online Monitoring/Fleet-Wide Monitoring (OLM/FWM) system alert pattern is observed

• Related data for asset are retrieved and a fault feature pattern is created

• Possible matching signatures are retrieved from the Asset Fault Signature (AFS) database and the best match is determined

• Diagnosis is presented, with optional troubleshooting and corrective action information


Diagnostic Advisor Function

Fault SignaturesFeature Detection

Roundtable Discussion TopicsJune 8 ICA Interest Group Meeting

Brainstorming Notes Topic AssignedPlant dynamic performance (controls performance) Controls PerformanceUsing existing functionality of control systems for performance improvements (e.g. advanced controls, robust/feedforward design, etc.) Controls PerformanceBenchmarking of plant control system performance Controls PerformanceCyber security challenges Cyber SecurityGraceful degradation of control system Cyber SecurityCycling issues and remedies CyclingNew multi-core computational capabilities and future capabilities for controls CyclingMaximum achievable control technology (MACT) effects on industry Environmental ControlsLaser-based measurement systems for multiple purposes, tied in with visualization systems New TechnologyVirtual plant technologies for locating equipment, optimizing use of staff New TechnologyCare and feeding of performance monitoring Performance MonitoringControls for renewables - wind turbines, solar, etc. RenewablesAdoption of smart devices Technology AdoptionSite maintenance needs for advanced control technologies post-implementation Technology AdoptionSimulator-assisted control design engineering Technology AdoptionSmart instrumentation training needed for I&C techs Training and Education

Roundtable Discussion TopicsJune 8 ICA Interest Group Meeting

Brainstorming Notes Topic AssignedDetermining role of I&C technician and training needs in face of new technologies Training and EducationLosing experience and need for knowledge retention Training and EducationInaccurate mental models of plants Training and EducationDumbing down of control systems because of limited process understanding Training and EducationWireless sensor technology opportunities and challenges (e.g. cyber security) Wireless TechnologyCan we utilize wireless sensors in the face of cyber security standards compliance Wireless TechnologyEarly target applications for wireless sensors Wireless TechnologyWireless sensors - battery life considerations vs. monitoring frequency needs Wireless TechnologyRFID tagging of equipment Wireless Technology

EPRI ICA Interest Group Meeting Attendance ListJune 8, 2011

First Name Last Name Company Email AddressJoseph Bentsman University of Illinois [email protected] Dodds Rockwell Automation [email protected]

James GoosbySouthern Company Services, Inc. [email protected]

Russell Hedge Luminant [email protected]

Aaron Hussey

Electric Power Research Institute (EPRI) [email protected]

Donald Labbe Invensys [email protected] Lee ABB Automation [email protected] Lekich GSES [email protected] Logan Southern Company [email protected] Lowery Progress Energy [email protected] Olson Chevron Corporation [email protected]

Mukesh PandyaSouthern Company Services, Inc. [email protected]

Prayag Parikh

Electric Power Research Institute (EPRI) [email protected]

John PlengeGE Energy (USA), LLC [email protected]

Hubby Robert Retired [email protected] Roney URS [email protected]

Jeremy Shook AREVA NP Inc. (USA) [email protected] Sorge Southern Company [email protected] Taft Taft Engineering, Inc. [email protected] Zadiraka Consultant [email protected]

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