MONITORING & DIAGNOSTICS

CONVEY PLANT HEALTH

Koteswara Rao Pothala

Technical Head and PM (Asset Management Services)

Black & Veatch Consulting Pvt. Ltd.

India

Gregory S Tanck
Service Area Leader (Asset Management Services)

Black & Veatch

USA

Copyright Black & Veatch 2016. All Rights Reserved. 1

ABSTRACT

Engineers design and build power plants to operate efficiently and reliably over its designed life.
A robust plant contributes to company’s bottom line. Remote Monitoring & Diagnostics (M&D)
is a step towards understanding and improving power plant health.

Utilities have used Black & Veatch’s analytics platform,ASSET360™, for many years to
monitor plant performance with substantial and sustained results. Black & Veatch demonstrates
that integrating generation data in a unified model-based structure and applying advanced
analytics yields deeper insight regarding both unit performance and equipment health.
ASSET360™ analytics detect anomalies that could indicate impending operational or equipment
problems, which could impact reliability, efficiency and capacity.

Black & Veatch has developed an M&D methodology and process that properly balances the
roles of software tools, processes, and people. Advanced Pattern Recognition leverages the
capability of advanced mathematics and technology to enable automated “mining” of plant data
for meaningful plant equipment and process anomalies. Performance Analysis & Long-term
Trend Analysis is a critical complement to monitoring equipment health data. Issues
Management provides the means to manage issues identified through the M&D program
effectively.

This paper explains how Remote M&D conveys the health of power plants through Case
Studies. These case studies demonstrate the range of issues M&D identifies and the financial
benefit gained.

Copyright Black & Veatch 2016. All Rights Reserved. 2

INTRODUCTION

As power plants have become more complex, so must the tools used to manage their operations.
Analytics enable plant managers to look into the system, understand operational functions and
interdependencies, and manage the complete system. Analytics reduce uncertainty largely if not
completely.

The plant operators have to make decisions in present-time that will have repercussions in the
future. To reduce uncertainty, power plants can observe past trends to forecast the future or use
algorithms and modeling with a variety of inputs to produce probability-based outcomes.
Predictive analytics used in the monitoring & diagnostics (M&D) system are more precise than
trends or models and enable insight for informed and transparent decisions.

TRADITIONAL ANALYTICS SMART ANALYTICS

Figure A: Traditional vs Smart Analytics

What cannot be measured cannot be monitored; what cannot be monitored cannot be controlled.
Monitoring identifies variances between actual parameters and expected parameters and
identifies possible anomalies—system functions that deviate from what the plant considers
standard, normal, or expected. The deviation could be due to external factors (weather, demand,
fuel deliveries); operations (load shape, equipment operations); equipment issues (in-service/out-
of-service, condition of equipment); operator knowledge and skill level; level of O&M best
practices; or Inaccuracies in fuel blend.

Diagnostics strives to identify the cause of variances, monetize the potential impact, and, where
the variance is determined to be within the plant’s control, identify corrective actions. Once
identified, actions are prioritized to determine those of highest value to the plant’s goals,

Copyright Black & Veatch 2016. All Rights Reserved. 3

allowing priority actions to be effectively incorporated into routine maintenance and operations
activities.

The saying “out of sight, out of mind” is not true for remote M&D. A major benefit of a remote
M&D center is the ability to deploy special tools and processes cost effectively across a fleet of
power generation facilities to measure, monitor, diagnose and control. Advanced tools and
processes enable effective participation by remote subject matter experts and specialists in
problem solving. Remote M&D centers are relatively inexpensive to deploy and provide rapid
payback in terms of fuel savings through efficiency improvements and other savings though
reliability enhancements. A collaborative process allows one unit to share lessons learned with
another unit, who can adopt the lessons quickly.

REMOTE M&D INFRASTRUCTURE

The basic remote M&D infrastructure consists of four layers (Figure B).The Data Layer includes
plant instruments, process historians, performance calculations, and other data sources. This
layer enables the remote M&D center to gather information from various plant data sources
through API (Application Programming Interface), OPC (Open Process Control), and other
proprietary communication protocols. Data sources can also include manually recorded data
such as fuel information, outage schedules, and operational logs. This additional information
helps the M&D center place the plant measurements into the proper context and improves the
analysis process.

The Communication Layer securely transmits data to the remote M&D center, while maintaining
data security, integrity and fidelity— the degree of exactness with which something is copied or
reproduced. On-site data buffering and automatic data backfill functionality guard against data
loss from communication interruptions and maintain a continuous archive. A dedicated server at
each plant site will typically handle data collection and data buffering.

Copyright Black & Veatch 2016. All Rights Reserved. 4

 Performance Issues Tracking
Dashboard Portal

Presentation Layer

Monitoring & Diagnostics Layer

Supplemental Issues Anomaly

Historian
Analytics Database Detector

Communications Layer
Data security & integrity Buffering & back-filling

Data Layer

Plant Process Performance Other Data

Instruments Historian Calcs Sources

Figure B: Remote Monitoring Infrastructure

Several data communications options are available, but the most secure and reliable data
transmission occurs over the internet using 128-bit encryption (Secure Sockets Layer -SSL) with
certificate authentication, which is the act of determining that a message has not been changed
since leaving its point of origin. The plants LAN and the remote M&D center LAN remain
safely behind firewalls to protect against outside threats. A few popular data historians on the
market support secure encrypted communications, however custom solutions are also available.
A VPN (virtual private network) gateway is a type of networking device that connects two or
more devices or networks together in a VPN infrastructure. It bridges the communication
between two or more remote sites, networks, or devices and/or to connects multiple VPNs
together. In most cases, a VPN gateway is a physical router device. The VPN gateway is
configured to pass, block or route VPN traffic. Figure C shows a typical M&D network
configuration using the internet for data transmission.

Copyright Black & Veatch 2016. All Rights Reserved. 5

 Formatted Table

Data Communications- from plant to M&D

Center
Figure C Typical M&D network configuration
Typical M&D Network Diagram
Formatted: Font:
Formatted: Font: (Default) Times
New Roman, 12 pt, Not Bold, Font
color: Auto
Formatted: Font: Not Bold, Font
color: Auto
Comment [ZE1]: This seems overly
complicated. Do we need this level of
detail? You can't even read the print. Think
about simplifying or deleting.

Copyright Black & Veatch 2016. All Rights Reserved. 6

TThe M&D Layer is typically located away from the plants being monitored, although hosting a
center on-site is also possible. The key components of the M&D Layer include Supplemental
Analytics, Anomaly Detection, a Data Historian, and an Issues Database.

Supplemental Analytics improve the value of the raw data prior to evaluation by providing
important data transformation capabilities such as averaging, totaling, data validation, and
engineering units. Performance calculation packages can be attached to the Supplemental
Analytics to fill gaps in plant performance data and to ensure uniform performance calculations
across a fleet of plants for benchmarking purposes.

Anomaly Detection software scrutinizes incoming data using predictive analytics in real time to
detect unusual patterns. Alerting module issues alerts on suspicious data. The most common
type of anomaly detection software uses Advanced Pattern Recognition (APR) algorithms with
historical databased reference data sets. Historical data is preferred over design data for anomaly
detection because power plants change over time as equipment degrades and fuels change.
Historical data helps filter noise and reduce false alarms. The very latest anomaly detection
software employs adaptive techniques to ensure the reference data set remains current with little
or no human interaction. This improves the usefulness of the software and helps to reduce false
alarms seen with static reference data sets.
The collected data gains additional value as it passes through the supplemental analytics and
anomaly detection tools. For this reason, it has become necessary to install a data historian in the
M&D center. This gives monitoring personnel quick access to long-term data, which improves
the investigative process by placing emerging issues in proper historical context.

The Issues Management Database stores a history of all identified and diagnosed issues and
prioritizes and categorizes them based on a pre-defined set of criteria. The methodology used to
detect and diagnose is stored along with measurements and calculation results. Issues
Management captures the issue lifecycle from detection and investigation to final resolution.
This is a powerful tool that M&D and plant personnel can reference when similar issues arise.

Copyright Black & Veatch 2016. All Rights Reserved. 7

 Figure D Issues Management

The Presentation Layer consists of a Performance Analyst Dashboard and an Issues Tracking
Portal. The Remote M&D center typically hosts the Dashboard and Portal, which are configured
to provide a common access point for key personnel at any location in the organization. The
Performance Dashboard combines results from the online performance calculations and the
Supplemental Analytics to give a transparent view of the M&D process and performance
improvement process across the entire fleet. Another feature of the Performance Analyst
Dashboard is that it provides a common platform to display contextual data from a multitude of
sources in a single location.

Copyright Black & Veatch 2016. All Rights Reserved. 8

 Figure E Performance Analyst

The Issues Tracking Portal is a collaborative environment where users can track and comment on
emerging issues uncovered by the M&D team. The Portal also serves as the interface for
navigating resolved issues. This tool helps build the team link where key team members can
contribute and view the problem workflow process. Issues management software should also be
able to interface with Computerized Maintenance Management Systems (CMMS) and Enterprise
Asset Management (EAM) systems to ensure that its analysis of priorities and impacts informs
maintenance scheduling.

REMOTE MONITORING & DIAGNOSTICS PROCESS

An effective process helps build a performance improvement culture across an organization and
establishes accountability among the team members by focusing on root cause analysis and
corrective action plans. The correct process will allow for collaboration with experts during the
diagnostic process and will integrate experts into the performance and maintenance decisions.
Effective communication is a vital function of the M&D process, and plant O&M personnel are
critical to the M&D process.

Copyright Black & Veatch 2016. All Rights Reserved. 9

An ideal M&D solution should be audited for compliance with utility cyber security rules. Black
& Veatch’s ASSET360™ solution can comply with NERC-CIP (Critical Infrastructure
Protection) strategy. An effective M&D process will require access to the plant’s IT systems.
Figure F outlines the steps required to transition from reactive to proactive issue management.

Figure F Remote M&D Issue Identification Process

Anomaly or Deficiency Detection: The first step in the process is to detect anomalies or
changes in plant or equipment performance. Software tools generate an alert when
further action is required.

Rule Out False Indication (Plausibility check): Once an alert is triggered, a Monitoring
& Diagnostics expert steps in to review the supporting information related to the alert.
Instrumentation issues, changes in fuel, and changes in ambient conditions can all
contribute to false alarms and must be ruled out as possible causes. The M&D expert
determines the validity of the alert before continuing.

Impact & Risk Quantification: After an alert has been validated, the cost of the
deviation is determined though engineering analysis and estimation. Assigning a cost of
the alert is an important step because it enables the plant to make insightful maintenance
decisions.

Copyright Black & Veatch 2016. All Rights Reserved. 10

 Diagnosis Validation: The problem diagnosis is then validated to ensure the plant is
acting on accurate information. This usually involves reviewing historical data, but
targeted equipment testing is sometimes required.

Issue a Recommendation: After a problem has been verified and a cost assigned, the
M&D center can recommend a corrective course of action.

Documentation & Prioritization: Prioritizing issues is important to understand how to

best allocate maintenance resources and to manage the time available for repairs. Finally,
documenting issue life cycle preserves the knowledge acquired during the M&D process.

Figure G Typical Illustration of a Remote M&D Setup

Black & Veatch has been providing power plant M&D solutions to clients since 2001 with only
minimal up-front cost. Plant owners that use Black & Veatch’s remote M&D report that they
quickly recover up-front costs through rapid issue resolution. Presently, Black & Veatch’s two
M&D centers located in Kansas City, USA and Pune, India provide around-the-clock monitoring
of around 22.5 GW of capacity.

Copyright Black & Veatch 2016. All Rights Reserved. 11

 Kansas City Center - since 2001 Pune Center - since 2012

Figure H: Black & Veatch Remote M&D Centers

CASE STUDIES
Some of the noteworthy gains realized through M&D capabilities are highlighted below (all
quantities are in US dollars).

Case No. 1: Failing Internal Low-Pressure Feedwater Heater Extraction Line

Early Detection: Subtle deviation in feedwater heater extraction line pressure.
What was Found? Extraction line failure suggested.
Quantify the Loss: $15,000 per month heat rate.
What was the Cost and Risk of forced outage.
Risk?
Action: Repair scheduled, parts ordered.
What was Done? Replacements made during outage.

Case No. 2: Failing Reheat Stop Valve

Early Detection: Drop in intermediate-pressure turbine efficiency along with
What was Found? reheat bowl and exhaust pressure. Valve issue suggested.
Quantify the Loss: $65,000 per month heat rate.
What was the Cost and 3-5 MW lost capacity.
Risk?
Action: Valve test confirmed which valve was the problem.
What was Done? Outage scheduled and made offline repair.

Copyright Black & Veatch 2016. All Rights Reserved. 12

Case No. 3: Failing High-Pressure Feedwater Heater Partition Plate
Early Detection: Slowly increasing terminal temperature difference.
What was Found?
Quantify the Loss: $12,000 per month heat rate.
What was the Cost and 0.4 MW capacity loss.
Risk?
Action: Noncritical issue repaired during scheduled maintenance
What should be Done? outage.

Case No. 4: Condenser Air In-Leakage

Early Detection: Condenser air in-leakage had been an ongoing problem at the
What was Found? plant. Upon returning from a brief outage, the M&D Center
detected a 0.5 in Hga increase in condenser 4A backpressure
accompanied by an increase in condenser vacuum pump
amps, signifying an increase in air in-leakage to the 4A
condenser.
Quantify the Loss: The heat rate impact of the increase in backpressure
What was the Cost and associated with the air in-leakage was 82 Btu/kWh.
Risk?
Action: After a discussion with the plant, it was determined that air
What was Done? in-leakage was a result of a known leak that apparently was
worsening. The M&D center provided context information,
including heat rate and economic figures, to better prioritize
repair of the problem.

Case No. 5: Main Steam Leak Into Boiler Feed Pump Turbine
Early Detection: The remote M&D center reviewed the past 12 months of data
What was Found? as part of the setup and initialization process. Historical data
revealed a possible main steam leak to the boiler feed pump

Copyright Black & Veatch 2016. All Rights Reserved. 13

 turbine during steady-state operation.
Quantify the Loss: The impact of the leak was estimated at 29 Btu/kWh.
What was the Cost and
Risk?
Action: It was corrected at the next unit outage.
What was Done?

Case No. 6: Economizer Bypass Dampers Actuation/Control Mismatch

Early Detection: The M&D center detected a 20°F increase in flue gas
What was Found? temperature before the emissions equipment inlet. In addition
to the change in inlet temperature, a loss of bypass damper
indication also occurred around the same time. Upon further
inspection, the plant found a bound bypass damper, resulting
in a faulty indication.
Quantify the Loss: The impact of the leak was 150 Btu/kWh.
What was the Cost and
Risk?
Action: The damaged damper was allowing flue gas to bypass the
What was Done? economizer and caused an increase in the flue gas
temperature. The damper was repaired at the next
opportunity, and the issue was resolved.

Case No. 7: Boiler Feed pump Recirculation Valve Leak

Early Detection: Upon return from an outage, the M&D center noticed a 50
What was Found? ampere increase in boiler feed pump motor power. Flow
across the boiler feed pumps also increased, suggesting a
possible recirculation valve issue. After a call to the control
room, it was found that the recirculation valve was sticking
and allowing a leak flow of approximately 5.5 klb/h.
Quantify the Loss: Loss of $6,600 per month. The increase in motor power due

Copyright Black & Veatch 2016. All Rights Reserved. 14

What was the Cost and to increased flow also contributed to a 350 kilowatt (kW) loss
Risk? in capacity margin.
Action: The recirculation valve was closed immediately and
What was Done? scheduled for repair.

Case No. 8: Turbine Inner Casing Leak

Early Detection: Through routine statistical monitoring and diagnostics, the
What was Found? process identified a 2.5 to 3% drop in low-pressure turbine
efficiency. With further data investigation, turbine damage
was ruled out, except possibly in the last stage of the low-
pressure turbine. An inspection was performed, and a leak
was identified.
Quantify the Loss: This leak totaled approximately $36,000 per month in fuel
What was the Cost and costs and 2.6 MW in capacity margin.
Risk?
Action: The inner casing inspection port gasket was failing and was
What was Done? immediately corrected.

Case No. 9: Turbine Deposits

Early Detection:
What was Found?
Quantify the Loss:
What was the Cost and
The unit received a high-efficiency high-pressure/
intermediate-pressure turbine upgrade. Within the first 6
months following the upgrade, capacity dropped
approximately 17 MW. High-pressure turbine efficiency also
dropped 4.8%, while intermediate pressure turbine efficiency
decreased 3.5%. There was also an 8%loss in steam flow.
Diagnostic efforts ruled out stop/governing valve issues.
Further investigation revealed that turbine deposits were the
cause of the unit derate .
The turbine deposits cost about $37,500 per month in added
fuel cost.

Copyright Black & Veatch 2016. All Rights Reserved. 15

Risk?
Action: Suggested a chemical wash to restore capacity and determine
What was Done? fouling agents. Turbine steam/chemical washing done.

CONCLUSION
The remote M&D processes use follow DMAIC (Define-Measure-Analyze-Improve-Control).
The key objectives of the M&D process are defined. Metrics are established and relevant
parameters are measured. The parameters are analyzed and anomalies are identified. Suggested
improvements achieve control over reliability, availability, maintainability, and efficiency. As
seen in the case studies, numerous issues can be resolved by Black & Veatch’s M&D solution.
Clients realize substantial savings, and their return-on-investment comes in months, not years.
The remote M&D process offers many numerous client benefits, some of which are summarized
below.

Client Benefits
Provides a proactive issue management Sidelines typical reactive approaches
approach
Helps increase reliability and availability Trend analysis and reconciliation
Creates “Team Link” between Operations and Communication on criticality of issues
Maintenance.
Improves heat rate Reduces fuel burn cost
Captures knowledge Minimizes aging workforce concerns
Provides outage assessment Proactive planning of spares, resources
Real time geographically diverse operation Provides 24-hour monitoring & analysis

Copyright Black & Veatch 2016. All Rights Reserved. 16