Energy Business Solutions A Real-Time Enterprise Solution for Guohua Electric Power Corporation

Power Generation l Power IT Solutions 2 Burkhard Frese / April 2004 Cockpit for GHEPC Abstract OSISoft and Siemens team-up to deliver Real-Time Enterprise solution for Chinese Guohua Electric Power Corporation (GEPC) The Chinese energy market is on the threshold of deregulation. To optimally prepare for the future, Guohua Electric Power Corporation (GEPC) has implemented an integrated real-time IT solution in its Inner Mongolia Power Plant, and is installing the same solution in its Taishan and Dingzhou power plants. The enterprise solution brings together the domains of plant management, process information, production cost forecasting, and energy market information across multiple power generation units across the company. This paper describes the business needs and the technology solution provided by Siemens and OSI Soft. The OSI Soft foundation technology forms the basis for the Cockpit by Siemens, the unifying command center for fleet generation management. In addition, the Siemens plant asset management system and process optimization systems have been implemented. The paper will highlight the substantial customer benefits, including increased efficiency and reduced generation costs, which make these among the most modern power plant operations in China today.

Power Generation l Power IT Solutions 3 Burkhard Frese / April 2004 Cockpit for GHEPC Introduction: Guohua Electric Power Corporation Business Requirements The Business Solution: Cockpit by Siemens: supporting Fleet Generation Management Solution Modules Cost Forecasting Capability Forecasting Extensions based on OSIsoft‘s PI system A Closer Look Achievements Agenda

Power Generation l Power IT Solutions 4 Burkhard Frese / April 2004 Cockpit for GHEPC Guohua Electric Power Corporation Power Plant Locations Zhunge’er Taishan Dingzhou Headquarter Power Plant Location Current IT Solution Projects

Power Generation l Power IT Solutions 5 Burkhard Frese / April 2004 Cockpit for GHEPC Xuejiawan Town, Erdos, Inner Mongolia, China 2 x 330 MW, coal-fired in operation since April 2002 Guohua Electric Power Corporation Current Power IT Solution Projects Tongluowan, Taishan City Guangdong Province 8 x 600MW, coal-fired planned First units in operation since Feb Kaiyuan Town, Dingzhou City Hebei Province 2 x 660MW, coal-fired First units in operation planned for June 2004 Location : Plant: Schedule:

Power Generation l Power IT Solutions 6 Burkhard Frese / April 2004 Cockpit for GHEPC Guohua Electric Power Corporation Requirements for Enterprise Solutions Business Targets: Preparation for competitive Chinese power market Optimal quality of the product “electricity” for usage in strategic marketing Business Targets: Preparation for competitive Chinese power market Optimal quality of the product “electricity” for usage in strategic marketing Optimized technical, operative and strategic functions Transparency of technical and business processes Requirements

Power Generation l Power IT Solutions 7 Burkhard Frese / April 2004 Cockpit for GHEPC Zhunge‘er Thermal Power Plant Installed systems IT Solutions in Zhunge‘er Process Automation Process Solutions Operations Solutions Business Solutions Cockpit Advanced Management Information Automated Data Exchange Production Cost Prognosis Plant Information Management. Maintenance Management & Strategy Shift Management Safety Management Spare Parts Management Project & Outage Planning Performance Monitoring/Optimization Advanced Unit Control Condensate Throttling Temperature Control

Power Generation l Power IT Solutions 8 Burkhard Frese / April 2004 Cockpit for GHEPC A Real-Time Enterprise Solution for Fleet Generation Management based on the Cockpit system by Siemens Cockpit is the integrating component of the Siemens Fleet and Plant Management solution for the power generation industry. Fleet Generation Management A Real-Time Enterprise Solution

Power Generation l Power IT Solutions 9 Burkhard Frese / April 2004 Cockpit for GHEPC business and job functions Historical Information Forecasts & Plans Load Capability Production Costs Energy Prices Energy Commit- ments Reserve Capacity Process data Maintenance Management Trading Operations Fuels Management In Market Availability Plant Diagnostics Environmental Management Plant Utilization key business information Dispatching Information Real Time Power Plant Operator(s) Load Dispatcher Trader Exchange Manager Maintenance Manager Fleet Management Risk Mgmt data sources Calculation engine Fleet Generation Management Central Information Desk for Management

Power Generation l Power IT Solutions 10 Burkhard Frese / April 2004 Cockpit for GHEPC   Future Systems Technical Systems I&C Systems ERP Systems Presentation of data user friendly on one screen Aggregation of data to information Collection of data from all connected sources Fleet Generation Management Cockpit – Information Integration

Power Generation l Power IT Solutions 11 Burkhard Frese / April 2004 Cockpit for GHEPC Templates Web Reports Future Systems Technical Systems I&C Systems ERP Systems Navigation center as single entry point for all information Navigation to all information on your fingertips Fleet Generation Management Cockpit – Navigation

Power Generation l Power IT Solutions 12 Burkhard Frese / April 2004 Cockpit for GHEPC Synchronization of all data elements to given point in time Pick the time and find your answers Fleet Generation Management Cockpit – Time Synchronization

Power Generation l Power IT Solutions 13 Burkhard Frese / April 2004 Cockpit for GHEPC Fleet Generation Management Cockpit - Architecture Principles Engineering Cockpit Kernel Comm- unication Data storage Data calculation Risk Management Production Costs DCS PCS7 TXP DCS TXP+ Siemens Energy Business Solutions Business Visualization Level Managing Board Executive Director Power Station Management Operations Process Plant A Plant B Plant C Plant D

Power Generation l Power IT Solutions 14 Burkhard Frese / April 2004 Cockpit for GHEPC Calculation Modules Basic mathematical functions Accumulation functions Load capability forecast Production cost forecast Load allocation Data Exchange Functions Mail in / out File read from / save to Copy to databases Embedded Calculation Engine Fleet Generation Management Cockpit – Function Modules

Power Generation l Power IT Solutions 15 Burkhard Frese / April 2004 Cockpit for GHEPC Archive Data (from Process Control) Metering, Temperatures, Sunshine Hours Archive Data (from Process Control) Metering, Temperatures, Sunshine Hours Forecasts Temperature, Sunshine Hours Forecasts Temperature, Sunshine Hours Demand Prognosis Heat, Power Demand Prognosis Heat, Power Contract Data Periods, Accounts, Cost Contract Data Periods, Accounts, Cost Tech. Risk Forecast Periods, Accounts, Cost, Probabilities Tech. Risk Forecast Periods, Accounts, Cost, Probabilities Production Cost Forecasting Losses, Thermodynamics, Fuels, Temperature Production Cost Forecasting Losses, Thermodynamics, Fuels, Temperature Plant Data Restrictions, Characteristics Plant Data Restrictions, Characteristics Load Capability Prognosis Gradients, Fuels, planned Availability Load Capability Prognosis Gradients, Fuels, planned Availability Dispatch Periods, Accounts, Cost, Availability Dispatch Periods, Accounts, Cost, Availability Fleet Generation Management Module: Production Cost Forecasting

Power Generation l Power IT Solutions 16 Burkhard Frese / April 2004 Cockpit for GHEPC Thermodynamic calculation Turbine Characteristics Extractions Description of water & steam process Boiler Characteristics Condenser Characteristics Thermodynamic model: Calculation based on detailed technical data of the plant, Production cost calculation Number of preheaters Number of pumps Fleet Generation Management Module: Production Cost Forecasting with Thermodynamic Models

Power Generation l Power IT Solutions 17 Burkhard Frese / April 2004 Cockpit for GHEPC Legend: CRC = Capability Relevant Component Legend: CRC = Capability Relevant Component Fleet Generation Management Module: Load Capability Forecasting

Power Generation l Power IT Solutions 18 Burkhard Frese / April 2004 Cockpit for GHEPC WHAT DOES THIS HAVE TO DO WITH OSIsoft PI?

Power Generation l Power IT Solutions 19 Burkhard Frese / April 2004 Cockpit for GHEPC Main Extensions by Siemens: Cockpit is based on PI Interfaces Graphical editor Object-oriented modeling with Module Database (MDB) Scheduled function calls with Advanced Computing Engine (ACE) OSIsoft PI as basic platform mainly using: 1 Time-Series Management incl. Quality Tag 2 Future data for planning scenarios 3 Plant model templates in MDB 4 Object structure for recursive processing of functions 5 Drill down information with new display features 6 Navigation into correct position in connected application 7 Integration with plant maintenance data

Power Generation l Power IT Solutions 20 Burkhard Frese / April 2004 Cockpit for GHEPC Extension for Time Series Management Calculation of time series data – needs Time series properties First data point (yesterday 2:00 pm) Time range (2 days) Interval between individual points (15 min) Calculation of time series data – needs Time series properties First data point (yesterday 2:00 pm) Time range (2 days) Interval between individual points (15 min) Mainly needed for scheduled data Showing load schedules or forecasted loads / emissions / production costs

Power Generation l Power IT Solutions 21 Burkhard Frese / April 2004 Cockpit for GHEPC Log Tag Information for Time Series Calculations Time series calculations need result quality check 0 = Good 1 = Bad 2 = Subst.

Power Generation l Power IT Solutions 22 Burkhard Frese / April 2004 Cockpit for GHEPC Object structure The structure for a plant will be delivered as template - embedded in the MDB basic structure - to be copied, completed and parameterized while project engineering Hierarchical object structure

Power Generation l Power IT Solutions 23 Burkhard Frese / April 2004 Cockpit for GHEPC Object structure The structure for a plant will be delivered as template - embedded in the MDB basic structure - to be copied, completed and parameterized while project engineering Hierarchical object structure

Power Generation l Power IT Solutions 24 Burkhard Frese / April 2004 Cockpit for GHEPC Visualization Extension Combing process and maintenance Color Coding for Availability of Components: With combination of a plant maintenance system a visual observation of maintenance tasks is possible

Power Generation l Power IT Solutions 25 Burkhard Frese / April 2004 Cockpit for GHEPC Visualization Extension Combing process and maintenance Color Coding for Availability of Components: With combination of a plant maintenance system a visual observation of maintenance tasks is possible Drill Down Navigation: Right click on the object starts the information and navigation menu. In the static part are linked documents like drawings, characteristic curves, manuals or queries to an external system In the dynamic part true query results are shown for the selected time After Drill Down Navigation – Detail information file is opened

Power Generation l Power IT Solutions 26 Burkhard Frese / April 2004 Cockpit for GHEPC Visualization Extension Context-related detail information (drill-down) After selecting Work order in the Drill Down Navigation menu the program navigates into the maintenance program directly to the concerned input/information mask

Power Generation l Power IT Solutions 27 Burkhard Frese / April 2004 Cockpit for GHEPC POTENTIAL EXTENSIONS: (Already implemented by Siemens for North American generators)

Power Generation l Power IT Solutions 28 Burkhard Frese / April 2004 Cockpit for GHEPC Key Performance Indicators for In-Market Availability

Power Generation l Power IT Solutions 29 Burkhard Frese / April 2004 Cockpit for GHEPC Key Performance Indicators for In-Market Availability Plant In Market Availability: Market prices, average, incremental costs, risk of de-rate, committed and left over capacity define the in market availability of the plant. Plant In Market Availability: Market prices, average, incremental costs, risk of de-rate, committed and left over capacity define the in market availability of the plant.

Power Generation l Power IT Solutions 30 Burkhard Frese / April 2004 Cockpit for GHEPC Key Performance Indicators for In-Market Availability Plant Operation Overview: Commercial and technical performance - in market availability - unit operation status - inadvertent energy - unit emission values Plant Operation Overview: Commercial and technical performance - in market availability - unit operation status - inadvertent energy - unit emission values

Power Generation l Power IT Solutions 31 Burkhard Frese / April 2004 Cockpit for GHEPC CUSTOMER BENEFITS AND OPINIONS

Power Generation l Power IT Solutions 32 Burkhard Frese / April 2004 Cockpit for GHEPC Guohua Electric Power Corporation Benefits Modern Plant Maintenance Management Automatic generation of work orders Adequate maintenance strategy Control over stock of spare parts Fit for Future Market Conditions Flexible reaction to market changes Rapid decision making Business Improved Plant Operation High flexibility Dynamic optimization using online models Process Plant

Power Generation l Power IT Solutions 33 Burkhard Frese / April 2004 Cockpit for GHEPC Achievements WHAT HAS THE CUSTOMER ACHIEVED? "All requirements for competitive markets fulfilled" "Best starting position for future market liberalization" "Optimized production and maintenance"

Power Generation l Power IT Solutions 34 Burkhard Frese / April 2004 Cockpit for GHEPC Contacts Siemens AG Power Generation Germany Burkhard Frese Tel – 6746