Fleet Optimization ………… through Process Information John C. Kapron Sumanth K. Makunur Technological Specialist DTE Energy Senior Engineer DTE Energy
Copyright © 2007 OSIsoft, Inc. All rights reserved. Agenda l About DTE Energy l OSIsoft a Key Technology Enabler l DTE – OSIsoft Enterprise Agreement (EA) l Technology Framework u Current KPI’s Dashboards Fleet Optimization Business Intelligence Reli abilit y Outage & D e­rate Maintenanc e & Mar ket Expert Systems Predictive Monitoring, Optimization
u Future State System Dashboards Fleet Status Assessment WEB Visualizing Pl ant Al arm, DC S R eal­ti me WEB Gr aphics Easy Access to Information Engineering Applications PMAX, Digit al F uel Trac ki ng, Fuel C ost Framewor k Process Discrete to Data Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data 2 Copyright © 2007 OSIsoft, Inc. All rights reserved. DTE Energy ­ Detroit Edison Detroit Edison • Michigan’s largest electric utility with 2.2 million customers • Over 11,080 MW of power generation, primarily coal fired • 54,000 GWh in electric sales • $4.7 billion in revenue DTE Energy ­ Detroit Edison Detroit
3 Copyright © 2007 OSIsoft, Inc. All rights reserved. Plants & Performance Center Monroe – 3,135 mw Belle River – 1,260 mw Harbor Beach – 103 mw Trenton Channel ­ 730 mw Performance Center – 11,588 mw
St Clair – 1,417 mw 4 River Rouge ­ 527 mw Copyright © 2007 OSIsoft, Inc. All rights reserved. Greenwood – 785 mw Fermi – 1,100 mw History of OSI PI in DTE Energy l Pilot at Monroe PP in 1998 Fossil Generation Fleet 1999 l GenOps – EMS Ranger 2001 l l SOC SCADA– 2002 l Fermi Nuclear– 2003 l DTE Subsidiaries – 2007 l Enterprise Agreement – 2007 l Continuous PI Expansion u Magnitude u Functionality
Success! 5 Copyright © 2007 OSIsoft, Inc. All rights reserved. OSIsoft a Key Technology Enabler l Information and Application Integration u u u u l Performance Center – Enabling Technology u u u l Primary data source of process data (current & historic) Integral part of many Applications (process and business) Communication Conduit (plant status, fuel cost, control, EMS) Strategic to DTE Energy’s day to day Operation Equipment Condition Monitoring – SmartSignal Enables DCS Displays Process & Market Analysis DTE – OSIsoft Enterprise Agreement (EA) u Key to the Supply Cabinet
6 Copyright © 2007 OSIsoft, Inc. All rights reserved. Why – OSIsoft Enterprise Agreement? 5 Key Benefits
KPI’s Dashboards Fleet Optimization Business Intelligence Expert Systems Predicti ve M onit oring, Opti miz ati on System Dashboards 1. OSI is a DTE Core Technology WEB Visualizing Easy Access to Information Plant Alarm, DCS Real ­tim e WE B Graphics Engineering Applications Process Discrete to Data PMAX, Digital Fuel Trackin g, Fuel Cost F ra mewo rk Distributed C ontrol Sys tems (DC S) Distributed OSIsoft PI Historians Large Population of Data 2. OSI’s Strong Track Record & Future Direction 3. Expand DTE’s Use of OSIsoft Applications 4. Normalize Budget Allocation 5. Premium Software Reliance Program 7 Copyright © 2007 OSIsoft, Inc. All rights reserved. 1. Core Technology l Integral Part Technology Framework KPI’s Dashboards Fleet Optimization Business Intelligence Expert Systems Predicti ve M onit oring, Opti miz ati on
System Dashboards WEB Visualizing Easy Access to Information Plant Alarm, DCS Real ­tim e WE B Graphics l Component of Many Applications Engineering Applications Process Discrete to Data PMAX, Digital Fuel Trackin g, Fuel Cost F ra mewo rk Distributed C ontrol Sys tems (DC S) Distributed OSIsoft PI Historians Large Population of Data u Control Processes u Business Processes l Performance Center u Enabling Technology 8 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework Drives Performance Excellence Actionable Information – KPI’s KPI’s Process Costs, Asset Health, Dashboards Operational Performance, Market Value, Fleet Optimization Fleet Optimization 15% Relate all Data Sources Analysis Framework Business Intelligence Reliability, 4­Block Outage & De­rate (UCF) Maintenance & Market 25% (PI, ProcessGuard, Maximo, SAP, UCF, P3M, Predictive Monitoring, NeuCo, LIMS, Plant View ..) Advanced Analysis & Process Optimization Expert Systems Equipment and Process Monitoring Closed Loop Process Optimization Predictive Monitoring, Optimization 60% System Dashboards Fleet Status Assessment Fleet Drill down 50% Subject Matter Experts WEB Visualizing Standard User Interface Plant Alarm, DCS Real­time WEB Graphics WEB Visualization Easy Access to Information 100% Process Discrete Data Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework Discrete data Limited value Copyright © 2007 OSIsoft, Inc. All rights reserved. Process Discrete to Data 90% Post Event Analysis Distributed Control Systems (DCS) Distributed OSIsoft PI Historians Large Population of Data PMAX, DFTS, eNote, Fuel Cost Framework, Alarm Management DCS, PLC & PI 90% % Complete
9 How Does Technology Enable You? Mobile Work Force PI WEB reports available on your BlackBerry
10 Copyright © 2007 OSIsoft, Inc. All rights reserved. Fleet Performance Center Performance Center – Mission Equipment Performance Optimization of the Fossil Generation Portfolio through continuous “real time and predictive asset condition monitoring” to maximize the asset market value. Performance Center – Vision Fossil Generation’s Fleet­wide “Mission Control Center” for continuous monitoring and optimization of plant equipment performance
• Located in Ann Arbor Michigan • 7x24 hour operation (February 2006). • Plant interface with Merchant Operation Center. • Oversight of Outage and de­rate coordination. 11 Copyright © 2007 OSIsoft, Inc. All rights reserved. 2. Track Record & Future Direction OSIsoft
l Exceptional Track Record u Worldwide and Multi Industry u Exceptional System Availability u Open and Fast Data Access for Analysis u Unlimited Interfaces (PLC, DCS, Corporate Systems) l Future Direction u Multi Industry Leverage u Managed PI u High Availability (HA) PI System u Analysis Framework 12 Copyright © 2007 OSIsoft, Inc. All rights reserved. 3. Expand Use of PI Applications l Currently Application in Use u u u l Planned Expansion u u u u u u l PI Data Historian – Fleet Wide 300,000 tags ProcessBook, DataLink, Active View, PI ManualLogger, PI Alarm, PI SMT Multiple PI interfaces, Data Access Pack, API and SDK Expand PI tag count (Process Data, Operator Rounds, Application data ...) IT Monitor Analysis Framework Advanced Computing Engine (PI ACE) PI Module Database RtPortal (WEB Visualization) Required Expansion u u u NERC Critical Infrastructure Protection Market Interface Environmental Reporting Regulations
13 Copyright © 2007 OSIsoft, Inc. All rights reserved. 4. Normalize / Reduce Budget l Capital Budget – Application Expansion u Strategic Technology Approval u Facilitates stable budget forecast l O&M Budget – Support u Fixed Budget u Known Future Budget Impact l Product Cost u Significant Discounts u Unlimited Usage
14 Copyright © 2007 OSIsoft, Inc. All rights reserved. 5. Premium SRP (Software Reliance Program) l l l l l l l l l Enterprise Project Manager and Enterprise Account Manager Remote Monitoring Proactive Problem Resolution Specialized Performance Reports Access to Center of Excellence Unlimited Tags & Standard Interfaces Software Update System Quarterly Reviews Access to all CBT’s and Webinars, Training and Event vouchers
15 Copyright © 2007 OSIsoft, Inc. All rights reserved. Why – OSIsoft Enterprise Agreement? KPI’s Dashboards Fleet Optimization Business Intelligence Expert Systems Predicti ve M onit oring, Opti miz ati on
1. A DTE Core Technology System Dashboards WEB Visualizing Easy Access to Information Plant Alarm, DCS Real ­tim e WE B Graphics Engineering Applications Process Discrete to Data PMAX, Digital Fuel Trackin g, Fuel Cost F ra mewo rk Distributed C ontrol Sys tems (DC S) Distributed OSIsoft PI Historians Large Population of Data 2. OSI’s Strong Track Record & Future Direction 3. Expand DTE Use of OSIsoft Applications 4. Normalize Budget Allocation 5. Premium Software Reliance Program 16 Copyright © 2007 OSIsoft, Inc. All rights reserved. How Did We Get Here? Lets take a closer look under the hood.
17 Copyright © 2007 OSIsoft, Inc. All rights reserved. Challenge ­ Process Data Everywhere!
l l DCS installations on nearly every unit Nearly 300,000 process data tags u u PI Systems at each plant PI Interfaces to DCS & many PLC’s l What is that data screaming at us? l How do you effectively utilize the data? l How do you turn data into information? 18 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework ­ Benefits Annual Savings
Actionable Information – KPI’s Discrete data Limited value Copyright © 2007 OSIsoft, Inc. All rights reserved. Distributed OSIsoft PI Historians Data Analysis Large Population of Data $3,000,000 19 Raw Data Analysis l Post trip analysis l Process monitoring l Optimization l Early warning l Alarming $ 1,890,000 One Plant 1st year savings!
20 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework ­ Benefits Annual Savings
Actionable Information – KPI’s Engineering Applications Process Analysis $4,500,000 PMAX, Digital Fuel Tracking, Fuel Cost Framework Discrete data Limited value Process Discrete to Data 90% 21 Distributed OSIsoft PI Historians Copyright © 2007 OSIsoft, Inc. All rights reserved. Large Population of Data 90% $3,000,000 Fleet Performance Analysis (PMAX) Thermal Performance Calculation Engine $500,000 Annual Savings!
22 Copyright © 2007 OSIsoft, Inc. All rights reserved. Digital Fuel Tracking System $1,200,000 Annual Savings!
On­line Fuel Analyzer 23 Copyright © 2007 OSIsoft, Inc. All rights reserved. NOx Emissions Strategy $2,200,000 Annual Savings!
NOx Reduction with Improved Heatrate Primary focus is NOx reduction only Copyright © 2007 OSIsoft, Inc. All rights reserved. Before After Implementation Implementation Focus on operating near NOx budget curve 24 PI to PI Process Data Conduit PI PI Belle River St Clair PI Greenwood EMS Ranger Harbor Beach PI PI Ann Arbor
ESO ­ Detroit PI Monroe PI PI PI Trenton Channel Performance Center PI River Rouge 25 Copyright © 2007 OSIsoft, Inc. All rights reserved. Energy Management System (EMS) The Plant Energy Management System is used to automatically control unit dispatch l Implements data validation on all fields l Performs several calculations based on PI data to determine validity of inputs. l Transported to EMS Ranger via PI l $120,000 Savings!
26 Copyright © 2007 OSIsoft, Inc. All rights reserved. Before Fuel Cost Framework Fuel Supply Manual Process Manual Process
Gen. Ops. Manual Process Manual Process Gas __________ Market Trades Email Fax’s Phone Fuel Cost Oil __________ Gas Email Oil Coal Coal __________ Emissions Calculates Fuel Blend Scenarios & Business Logic Emissions Fuel Cost Gas Oil Coal Emissions Email To 19 Units Ops Manual Process EMS Ranger PI PI to PI Plant PI Type, Type, Oops No sys error checking 27 Copyright © 2007 OSIsoft, Inc. All rights reserved. $530,000 Annual Savings! Fuel Cost Framework Fuel Supply Default Mode Auto calculate & update Ranger Analysis and Acquisition ps­mon­pi Improvements… • 30 to 3 people • Timely data entry • Zero errors
Blend Calculations Current & Historic Data Oil 3 Current Fuel Cost 2 ps­tch­pi Blend Calculations ps­rrg­pi Blend Calculations Gas & Oil Price at Hubs 1 Gas ­­ Dawn & Michcon City Gate Market Data Hourly & Daily Auto update ESO PI ps­eso­pi ps­blr­pi 4 Blend Calculations 5 Ranger PI Ann Arbor ps_hbh_pi Blend Calculations ps­grw­pi Blend Calculations ps­stc­pi Blend Calculations Copyright © 2007 OSIsoft, Inc. All rights reserved. 28 PI to PI (AGC) $200,000 Savings!
AGC – Automatic Generation Control 5 largest Fossil units & Peaking Units are ramped through PI Set Point control 29 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework Annual Savings
Actionable Information – KPI’s WEB Visualizing Easy Access to Information Easy Visualization $5,500,000 100% Engineering Applications $4,500,000 PMAX, Digital Fuel Tracking, Fuel Cost Framework Discrete data Limited value Process Discrete to Data 90% Distributed OSIsoft PI Historians Copyright © 2007 OSIsoft, Inc. All rights reserved. Large Population of Data $3,000,000 90% 30 Fleet Status – PI WEB enabled
31 Copyright © 2007 OSIsoft, Inc. All rights reserved. Real­Time DCS Operator Displays 6000 real time dynamic actively linked WEB DCS graphics Click & Trend
32 Copyright © 2007 OSIsoft, Inc. All rights reserved. PI enabled ­ Event Re­play Re­play events using historical PI data
33 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework Annual Savings
Actionable Information – KPI’s Organized Drill Down $1,000,000 System Dashboards Fleet Status Assessment 50% WEB Visualizing Easy Access to Information $5,500,000 100% Engineering Applications $4,500,000 PMAX, Digital Fuel Tracking, Fuel Cost Framework Discrete data Limited value Process Discrete to Data 90% Distributed OSIsoft PI Historians Copyright © 2007 OSIsoft, Inc. All rights reserved. Large Population of Data $3,000,000 90% 34 System Dashboards – PI Enabled 2000 real time dynamic actively linked WEB System graphics Click & Drill
35 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework Annual Savings Actionable Information – KPI’s Predictive – Optimize $8,000,000 Expert Systems Predictive Monitoring, Optimization 60%
System Dashboards Fleet Status Assessment $1,000,000 50% WEB Visualizing Easy Access to Information $5,500,000 100% Engineering Applications $4,500,000 PMAX, Digital Fuel Tracking, Fuel Cost Framework Discrete data Limited value Process Discrete to Data 90% Distributed OSIsoft PI Historians Copyright © 2007 OSIsoft, Inc. All rights reserved. Large Population of Data $3,000,000 90% 36 PI Dependant Expert Systems l Equipment & Process Monitoring – SmartSignal u Fleet wide implementation 2006 u A Primary Performance Center Application $7,769,680 Annual Savings!
l Combustion Optimization – NeuCo u Startup on St Clair Unit 7 u Installation in progress on Belle River 2 u Planned for Monroe Units 1­4 $330,000/unit Annual Savings! 37 Copyright © 2007 OSIsoft, Inc. All rights reserved. Technology Framework Actionable Information – KPI’s Annual Savings KPI’s Dashboards Fleet Optimization Fleet Optimization $20,000,000 (Projected Savings)
15% Business Intelligence Reliability, 4­Block Outage & De­rate (UCF) Maintenance & Market 25% Expert Systems $11,000,000 Predictive Monitoring, Optimization 60% System Dashboards Fleet Status Assessment $1,000,000 50% WEB Visualizing Easy Access to Information $5,500,000 100% Engineering Applications $4,500,000 PMAX, Digital Fuel Tracking, Fuel Cost Framework Discrete data Limited value Process Discrete to Data 90% Distributed OSIsoft PI Historians Copyright © 2007 OSIsoft, Inc. All rights reserved. Large Population of Data $3,000,000 90% 38 Unit Capacity Framework (UCF) Process Flow Power Plants Day Ahead Performance Center
Real Time Market Merchant Center Market Strategy Market Feedback 39 Copyright © 2007 OSIsoft, Inc. All rights reserved. Unit Capacity Framework (UCF) • Manages all Unit Capacity and De­rates ­ Interfaces to MISO, P3M & EMS • Automatically Generated Status Report (Availability on BlackBerry) $3,200,000 • Dynamically linked with Outage and de­rate process 7 months 2007!
40 Copyright © 2007 OSIsoft, Inc. All rights reserved. No Shortage of Information! Project Management Laboratory Information Operator Logs SAP Work Management Document Management PI Data Historian Emissions Monitoring De­rate Management Unit Capacity EPRI Plant View
Alarms MISO Real Time Combustion Optimization Performance Analysis Copyright © 2007 OSIsoft, Inc. All rights reserved. Emissions Monitoring Outage Planning MISO Day Ahead Fuel Cost Ancillary Services 41 Analysis Framework Analysis Framework: Standard GUI Single Method
Integrated applications environment: Consistent framework for data, analysis, reporting and consistent user graphical interface. PI Data Historian EPRI Plant View Alarms Operator Logs Performance Analysis Combustion Optimization MISO Real Time Emissions Monitoring Laboratory Information Emissions Monitoring De­rate Management Work Management Project Document Management Management SAP Unit Capacity Outage Planning Fuel Cost MISO Day Ahead Ancillary Services 42 Copyright © 2007 OSIsoft, Inc. All rights reserved. Process Cost Drill Down Plant Summary EAF y
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Dispatch Costs Production Costs Milling Costs Heat Rate 43 Copyright © 2007 OSIsoft, Inc. All rights reserved. Expanded System Dashboard
44 Copyright © 2007 OSIsoft, Inc. All rights reserved. Total Fleet Management Drives Performance Excellence Process Costs Asset Health Operational Performance Market Value Fleet Optimization
Financials Work Management Market SAP Maximo MISO, Fuel Coat Framework Unit Capacity Framework Real­time Process Applications Expert Systems SME Status Displays WEB Portal Applications Distributed Control Systems (DCS) Distributed PI Historians Copyright © 2007 OSIsoft, Inc. All rights reserved. 45 Copyright © 2007 OSIsoft, Inc. All rights reserved.