Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. CCGT Plant Optimisation using Real Time Data Regional Seminar Series Mark Bate Efficiency Team Leader EON – Connah’s Quay Power Station

2 Value now. Value over time. © Copyright 2009, OSIsoft Inc. All rights Reserved. EON: Efficiency Targets Surpassed “We beat our Efficiency target in 2007 by 2.6%. The 2008 result was >1% against target. This equates to annual CO 2 savings of over 135,000 Tonnes, saving enough gas to supply the annual needs of over 50,000 homes!.” Mark Bate, EON Efficiency Team Leader Business Challenge SolutionResults / Benefits Reduce Shaftline Trips Improve Unit Efficiencies Reduce CO2 emissions Performance Watchdog Displays optimise Plant Proates models with data stored in PI Performance Equations, ProcessBook and DataLink ‘d4e’ Improvement project Reduced CO 2 emissions by 135k Tonnes Efficiency increased by 0.5%. Saving £20k in lost generation! Saving over £4m per year

Click to edit Master title style 3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Connah's Quay... taking power generation forward Hamilton North Douglas Hamilton Lennox Deeside Connah's Quay Point of Ayr Burton Point Rhyl River Dee Liverpool Chester

Click to edit Master title style 4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Contents of Presentation Introduction to PI and PROATES Early development of Plant Monitoring Introduction of a Performance Watchdog Display Benefits of ‘d4e’ Efficiency Improvement Projects More recent developments Summary

Click to edit Master title style 5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Introduction to PI and PROATES PI, ProcessBook and DataLink allow Plant data to be interrogated post event or displayed as live values in a ProcessBook Display or Excel spreadsheet PROATES(PROcess Analysis for Thermal Energy Systems) reads actual Plant data from PI performs a series of thermal calculations based on the Plant writes the results back to PI calculations can also be referenced to Standard Conditions. areas of poor performance are then identified and can be rectified.

Click to edit Master title style 6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Project History Installed in 2001 as part of Powertech Trial Used by a few engineers By 2003 extensive use by Operations Team Shaftline trips, troubleshooting Trend analysis

Click to edit Master title style 7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Trend Analysis

Click to edit Master title style 8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Development of Plant Monitoring As the use of PI flourished… Development of ‘real time’ displays for comparing Unit Performance Use of ‘Multistate’ symbols on displays to act as visual alarms Use of Datalink to create reports for various Plant performance issues (Condenser Tube Pick Report)

Click to edit Master title style 9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Unit Comparisons

Click to edit Master title style 10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Unit Comparisons

Click to edit Master title style 11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. U2 Tube Pick Report

Click to edit Master title style 12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Problem with ‘GT Inlet Bleed Heating Valve’ Performance Watchdog Display

Click to edit Master title style 13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. GT Air Inlet Bleed Heating Valve found open at around 8%, bleeding off warm air to the GT Air Inlet. Found out using PI Trends that this had been the case for almost 3 Days Cycle Output increased by 7MW Efficiency increased by 0.5% This incident alone was estimated to have cost over £20k in lost generation! Surely we could make use of PI Performance Equations to minimise these events and give us early warning? Performance Watchdog Display

Click to edit Master title style 14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Digital State Performance Watchdog Display

Click to edit Master title style 15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Performance Watchdog Display These PI screens helps us maintain a 0.5% efficiency improvement on each unit, through optimising output and performance saving of over £4m per year across the site.

Click to edit Master title style 16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Performance Watchdog Display

Click to edit Master title style 17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Performance Watchdog Display

Click to edit Master title style 18 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Performance Watchdog Display

Click to edit Master title style 19 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Performance Watchdog Display

Click to edit Master title style 20 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Performance Watchdog Display

Click to edit Master title style 21 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Benefits of ‘d4e’ Efficiency Improvement Projects Cooling Water Systems+0.7% Gas Turbine / Compressor Improvements+0.6% Filter upgrades and new offline wash strategy Compressor Core Plugs fitted HRSG Pre Heater clean+0.2% Many others….

Click to edit Master title style 22 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. In 2007 we beat our Efficiency target by 2.6% in 2008 result was >1% against target This equates to annual CO2 savings of over 135,000 Tonnes, saving enough gas to supply the annual needs of over 50,000 homes! Benefits of ‘d4e’ Efficiency Improvement Projects

Click to edit Master title style 23 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. More Recent Developments

Click to edit Master title style 24 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Live Imbalance Monitoring

Click to edit Master title style 25 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. Imbalance Monitoring – Daily Reports

Click to edit Master title style 26 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved. In Summary Continually evolving process The PI Watchdog screens ensure we are getting the most out of the current state of the Plant at all times We have been able to develop and enhance our monitoring PI has given us the confidence to address areas of: poor plant performance carry out effective cost / benefit analysis to obtain the necessary funding Our PI system has become an integral part of the way we operate at Connah’s Quay.

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