Performance Monitoring and Optimization
The Ultimate Performance Optimization Program
Using Diagnostic Monitoring Centers for Fleet Equipment Condition Monitoring
The Results of the Application of On-Line Monitoring to Power Plant Rotating Equipment
Calculating the Uncertainty of Performance Monitoring Instrumentation at Salt River Project Coronado Generating Station
Evaluation of Steam Path Audits
The Ultimate Performance Optimization Program
2007 Presentation at the EPRI Heat Rate Improvement Conference
Kris Brandt, Performance Consulting Services, Inc.
Steve Williams, AES Corporate Performance
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Using Diagnostic Monitoring Centers for Fleet Equipment Condition Monitoring
2006 Presented at the 8th Annual Electric Power Conference & Exhibition
Elmer Hansen, PhD, Performance Engineer, Performance Consulting Services, Inc.
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Abstract
As generating companies seek to improve plant reliability and increase outage intervals many are turning to on-line condition monitoring to assist in this task. Huge advances have been made in on-line diagnostics in the last five years. These diagnostics have been able to detect the early warning signs of impending failures so that asset managers are able to prevent catastrophic failures. Utilities are also using on-line monitoring in Diagnostic Centers, which cover the entire fleet.
In addition to preventing catastrophic failures, asset managers are able to reduce repair costs and damage to equipment when a repair is made early in the failure cycle. Early warning also allows the planning of outages at economically opportune times.
An on-line monitoring system consisting of selected sensors, equipment models, a modeling engine, a diagnostic engine, a data archive and an actionable list will be described. Each class of equipment has a variety of sensors that can be included in the model. Methods of sensor grouping, the creation of normal models, and the construction of diagnostic rules to identify specific failures will be described.
Several case studies will be presented. These will range from steam turbine performance, to rotating equipment, to feed water heater leaks. Finally the developing culture of centralized diagnostic centers will be discussed.
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The Results of the Application of On-Line Monitoring to Power Plant
Rotating Equipment
2005 Presented at Power-Gen International
Elmer Hansen, PhD, Performance Engineer,
Performance Consulting Services, Inc.
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Abstract
As generating companies seek to improve plant reliability and increase outage intervals many are
turning to on-line monitoring to assist in this task. On-line monitoring has become much more
than traditional high-low control system alarms. It is able to automatically detect the early
warning signs of problems and bring these to the attention of the equipment asset manager.
Using these early warning indications, asset managers are able prevent many catastrophic
failures. A reduction in repair costs and damage to equipment occurs when a repair is made early
in the failure cycle. Early warning also allows the planning of outages at economically
opportunistic times. An on-line monitoring systems consisting of selected sensors, equipment
models, a modeling engine, a diagnostic engine, a data archive and an actionable list will be
described. Each class of equipment has a variety of sensors that can be included in the model.
Methods of sensor grouping and the creation of normal models will be described. The use of a
diagnostic engine is allowing the process identify failures types.
On-line monitoring has been applied to wide variety of rotating equipment. Rotating elements
that will be discussed are fan bearings, pump bearings, motor bearings, turbine bearings and
motor stator temperatures. Each sensor has a limit of delectability and these will be presented for
a various sensors classes. Early warnings have benefited plants and allowed them to avoid loss.
Case studies will be presented. The discussion will close with a vision for the development of a
centralized diagnostic center culture. This center would bring potential problems across power
generation fleets to equipment specialists who would be familiar with various failure modes.
These specialists would then be able to enhance the economic oversight of power plant assets to
provide reliable operation with competitive costs.
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Calculating the Uncertainty
of Performance Monitoring Instrumentation at Salt River Project Coronado Generating
Station
1997 Presented at the Scientech Performance Software User's Group
Meeting
Kevin Coons,
Salt River Project
Marcus Caudill, Vice President,
Performance Consulting Services, Inc.
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Abstract
Performance Consulting Services, Inc. (PCS) was contracted by Salt
River Project (SRP) to supply an instrument survey and calculation uncertainty analysis
for Coronado Generating Station Unit 1. The intent was to determine the bias error
associated with the instruments providing inputs to the PMAX on-line performance monitoring
system and the uncertainty of the resulting performance calculations. SRP intends
to run ASME Code quality performance tests utilizing the PMAX system and station instruments.
The instrument survey was the first step in determining if this is possible.
The industry standard PEPSE (Performance Evaluation of Power System
Efficiencies) computer program was employed in conjunction with the ASME Performance
Test Codes to calculate the impact of each instrument error on the resulting performance
calculation.
In this paper we detail the methodology employed in determining
individual instrument uncertainty and propagating the individual uncertainties to
a combined uncertainty in the calculated performance parameters. In addition, general
recommendations for measurement improvements that can be applied to most power plants
are detailed.
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Evaluation of Steam Path
Audits
1992 Presented at the EPRI Heat Rate Improvement Conference
Marcus Caudill, Vice President, Performance Consulting Services, Inc.
Ron Griebenow, President, Performance Consulting Services, Inc.
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Abstract
Tri-State Generation and Transmission Association is the operating
agent for the 1350 megawatt Craig Generating Station, located in northwestern Colorado.
Tri-State has recently incorporated turbine steam path audits into their aggressive
performance improvement program. The intent of the audits are to quantify and attain
the most cost effective increase in turbine performance as a result of a major outage.
Valuable information about performance losses in the turbine has
been obtained from steam path audits conducted on the three Craig Units. However,
accurate audit results often depend on the quality of measurements and the experience
of the auditor. Without a second method to verify the results of a steam path audit,
repairs might be performed on a non-cost effective basis, or significant performance
degradations might be overlooked. In addition, an inaccurate audit may lead to erroneous
expectations for performance improvements resulting from the outage.
Turbine cycle performance testing and data trending techniques
can be successfully used to check the results of steam path audits. Precision performance
tests can also be used to anticipate areas of the turbine that will require outage
maintenance, even before the turbine is opened. This paper presents the Tri-State
method of combining steam path audits and performance tests in a complementary manner
at Craig Station.
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