Asset Monitoring in Power

Generation
Lodovico Menozzi
National Instruments
Outline
Introduction to National Instruments
Industry Trends and Challenges in Power
Generation
Case Study in Power Generation (Duke Energy)

10/29/2014 www.ni.com
National Instruments
We equip engineers and scientists with tools that accelerate productivity, innovation, and discovery
Non-GAAP Revenue: $1.2 Billion in 2013
Global Operations: Approximately 7100
employees; operations in more than 45
countries
Broad industrial customer base: More than
35,000 companies served annually
Invest for the future: adoption in more
than 6,000 universities worldwide
Diversity: No industry >15% of revenue
Culture: FORTUNEs 100 Best Companies to
Work For list for 14 consecutive years.
Ranked among top 25 companies to work
for worldwide by the Great Places to Work
Institute
R&D Commitment: 16% investment in R&D

Long-term track record of growth and profitability
*A reconciliation of GAAP to non-GAAP results is available at investor.ni.com
Graphical System Design what we do
We equip engineers and scientists with tools that accelerate productivity, innovation, and discovery
A Platform-Based Approach for Measurement and Control
Real-Time
Measurement&Control
Desktops and
PC-Based DAQ
RIO and Custom Designs
Test Monitor Embedded Control Cyber Physical
Open Connectivity
with 3
rd
Party I/O
INDUSTRY TRENDS IN POWER GENERATION
WHY ASSET MONITORING
The power generation industry is
undergoing a transition from traditional
power using Nuclear and Coal to more
efficient Combined Cycle technologies
Power Generation Industry Trend #1
Risk and Cost of Failures Increasing
Aging units with critical equipment at end-of-life
Transformers, generator stators/rotors, etc

New technologies adoption (Flue Gas Desulfurization (FGD),
Zero Liquid Discharge (ZLD), CT/CC) that might have
catastrophic failures high cost

Existing Predictive Programs 80% data collection, 20%
analytics


Predictive
Vibration
Oil
IR Therm
Motor

Engineering
Inspections &
Assessments

Operator Logs
Maintenance
PMs

Plot-0
10/7/2007 9:17:30.977 AM 10/10/2007 9:17:30.977 AM 3.00 day s
80
85
90
95
75
100
108
126
100
125
114
123
101
111
55
90
0
160
100
400
72
92
0
90
On-Line
Process Data
Work History & Events

Performance
Testing &
Monitoring

Need: Better integration
and visualization of
equipment information.

Existing Equipment Condition
Information is Manual
Power Generation Industry Trend #2
Use of Technology as a Solution
Scarcity of specialists (i.e. vibration analyst)
Operations- replace rounds with higher value tasks

Decreasing cost of sensors & acquisition hardware
Predictive maintenance through automation of data collection, analysis

Big Data technology trend spurring emergence of fleet-wide,
enterprise solutions for asset condition monitoring
Cost of Data Storage is Decreasing
$-
$50
$100
$150
$200
$250
$228/GB
$3.88/GB
$0.88/GB
1.2 Petabyte hard drive expected on the
market in 2012-2013 at the price of $500
$.0006/GB
20 Petabytes: Total hard drive space
manufactured in 1995
20 Petabytes: the amount of data processed
by Google Per Day
Can Too Much Data Be a Bad Thing?
We can create and collect complex data at tremendous rates,
but unless we can manage and analyze that data, it's useless.
Ron Musick, former lead researcher
at Lawrence Livermore National
Laboratory
The real opportunity for change is still ahead of us, surpassing the magnitude of the
development and adoption of the consumer internet. It is what we call the Industrial
Internet, an open, global network that connects people, data and machines. The
Industrial Internet is aimed at advancing the critical industries that power, move and
treat the world.

-
Images courtesy:
Big Data Trend



Images courtesy:
Big Data Trend
Big Analog Data
TM
Sources
Sources of Big Data:
T.M.S. Bradicich, PhD
Managing Big Analog Data
Condition Monitoring Challenges
1. Standardization in equipment evaluation technologies, terminology of equipment and
sensing types, and company maintenance procedures

2. cost justification that can be used to obtain management buy-in, or formal acceptance to
invest in fleetwide monitoring.

3. build visibility across the organization and to promote best practices, centralization of
management and monitoring. Centralization fosters collaborative efforts across company
organizations and identification of best practices and technologies.

4. alarm management, find a mechanism to validate alarms prior to planning a response is
critical in building confidence in the program.

5. integration of multiple monitoring technologies, to obtain the benefits of each and to create
a holistic view of monitored equipment.
DUKE ENERGY CASE STUDY
POWER PLANT SMART M&D
Key Corporate Facts
Largest power generation holding company in US
Diversified energy portfolio mix with 58GW in US, more overseas
58 GW of electricity generation in US
41 GW of non-nuclear power (largest in US)
~80 Plants in US
Overseas holdings

.
Smarter Monitoring & Diagnostics
VP CHALLENGE:
Better leverage new technologies
to address increasing reliability demands
and workforce optimization.
Asset Monitoring - Equipment
Transmission
& Distribution
Energy Usage
& Efficiency
Industrial Gas Turbines
Aero Gas Turbines
Steam Turbines
Hydro Turbines
Wind Turbines
Boilers
Generators
Compressors
Blower / Fans
Pumps
Electric Motors
Reciprocating Comp
Crushers / Pulverizers
Pelletizers / Extruders
Gears
Expanders
Heat Exchangers
Vessels
Valves
Piping
Instruments
HVAC
Transformers
Pulp Refiners
Rotary Kilns
Centrifuges
Cooling Towers
Turbochargers
Etc.
Assets that require maintenance:





Power
Generation
Asset Monitoring - Equipment
Transmission
& Distribution
Energy Usage
& Efficiency
Duke Energy prioritized:
1. Balance of Plant monitoring,

2. Turbine monitoring
(vibration-based measurements)
3. Advanced sensors

Power
Generation
SmartGen Project
Expanded Instrumentation
More equipment monitoring using wireless
technology and low cost sensors at a fraction of
the cost of conventional instrumentation.







Sensors
Vibration
Temp
Oil
Motor
Ultrasound
IR
Leak Detection
Press
DGA
EMI
Partial Discharge

Operator Rounds
Cameras
Smell Sensors
Microphones

New Plant M&D Network:
Wired/wireless network to
key remote Plant locations, like
equipment areas,
Information
Automation
National
Instruments
CRIO
Enhanced M&D Center Capabilities
-Implement EPRI Diagnostic & Risk Advisors
-M&D Centers more info & diagnostic advise
- PdM - more analytical less data collection
- Operations reduce rounds w/ new sensors
- Engineering enhanced Risk Analysis
M&D Center
10,000+
Equipment
30,000+ Sensors
Other Machinery

Turbine
Other Machinery
Systems Architecture for Enterprise-Level Asset
Monitoring
Database
Historian
NI
SW
Plant Servers
Plant Communication
Data collection-interface
Signal Analysis
User Interface
Remote Clients
(Configuration)
Remote Clients
(Visualization&Post
Processing)
Fault
Database
Enterprise M&D Servers
Pattern
Recognition
Software/
Prognostics
Computerized
Maintenance
Management
Software (CMMS)
Fleet Communication
Fleet Data Analysis
Data Fusion Visualization
Integration CBM Process
Database
Historian
Fleet-Wide
Asset Health
Visualization
Sensor
Sensor
Sensor
D
e
v
i
c
e

Leak
Smell
Camera
D
e
v
i
c
e

Handheld
Device
Instrument
Online Monitoring
Manual Rounds
Other Machinery

Turbine
Sensor
Sensor
Sensor
D
e
v
i
c
e

Other Machinery
Leak
Smell
Camera
D
e
v
i
c
e

Fault
Database
Handheld
Device
Instrument
Online Monitoring
Manual Rounds
Remote Clients
(Configuration)
Systems Architecture for Enterprise-Level Asset
Monitoring
Fleet M&D Servers
Database
Historian
Pattern
Recognition
Software
NI
SW
Computerized
Maintenance
Management
Software (CMMS)
Plant Servers
Remote Clients
(Visualization)
Plant Communication
Data collection-interface
Signal Analysis
User Interface
Fleet Communication
Fleet Data Analysis
Data Fusion Visualization
Integration CBM Process
Database
Historian
Fleet-Wide
Asset Health
Visualization
PI Server
PI Server
NI CompactRIO
NI CompactRIO
PlantView NI
InsightCM
Motor / Pump with Accelerometers
Accelerometers
Corporate Monitoring, Control,
and Diagnostics
Database Historian
Fault Signature
Database
Accelerometers
Electrical Power
Proximity Probes
Sensors
Miscellaneous
Temperature Sensors
Thermal Cameras
Plant Servers Monitoring Systems
System Nodes Sensors IT Infrastructure (Big Analog Data Analytics/Mining)
Online Monitoring
& Analysis
Software
Database
Historian
Data Acquisition &
Analysis System









Fleet-wide Online Monitoring
Duke Energy End-To-End Solution Architecture
3
rd
Party Devices








12, 000 Sensors
1,200 Acquisition
Nodes
~7,000-30,000 Models
Advanced Sensors
CVS-1457RT
Thermography
1 ,200 MW Generator with severe arcing
of shaft grounding braids
0.1 0.01 1 100 10
0.1
1
10
100
1000
10000
With Arcing
Shaft Grounding Braid
Power
Line
Carriers
W/O Arcing
EMSA
MCSA

Sensors
Data
Acquisition
Feature
Extraction
Performance
Assessment
Change
?
Fault Signature
Database
Performance
Prediction
Acquisition and Signal
Processing
Speed and Order Analysis (1X,
2X)
Change in Speed or RMS
Performance
Assessment
Logistic Regression
Gaussian Mixture
Model
Feature Map Pattern
Matching
Performance
Prediction
ARMA
Bayesian Belief
Network
Support Vector
Machine
Autonomously extracted dynamic forces
leading to roller bearing degradation.
Current Level of
performance
degradation
Predicted
performance
over time
Plant Computing
Infrastructure
Smart Data Logging Field Device
No
Yes
Prognostic Systems Architecture
Past




20% Analytics
Inconsistent Diagnostics
Limited Risk Assesment
Capabilities
Poor Integration & visuals
M&D Center process data
Workforce low value tasks
Current




80% analytics
Diagnostic Advisors - fault dB
Risk Management - failure predictions
Data Fusion & Visualization
M&D Center integrating all info
Workforce high value analytics
80% data collection
20% data analysis
Automated data
collection & analysis
Fleet-wide Asset Condition Monitoring - ROI


THANK YOU!