Enterprise-Wide Optimization in the Power Industry

Transcription

1 Enterprise-Wide Optimization in the Power Industry Rick Wright Principal Analyst Engineering Support DTE Energy Ann Arbor Brian States - BSEE, MBA Plant Electrical Engineer Shenango Copyright 2012 Rockwell Automation, Inc. All rights reserved.

2 Who is DTE Energy? DTE Energy Co. (NYSE: DTE) is a diversified energy company involved in the development and management of energyrelated businesses and services nationwide. Key Facts 2011 Revenue $8.9 Billion Net Income $711 Million Assets $26 Billion Current Employees 9,800 DTE Energy Company One Energy Plaza Detroit, Michigan 2

3 DTE Energy Our largest operating subsidiaries are Detroit Edison and MichCon. Each have been in operation for over a 100 years. Together, these utility companies provide electric and/or gas services to 2.7 million residential, business and industrial customers in Michigan. Leveraging our utility's wealth of experience and expertise, the Non-Utility platform develops new subsidiaries that provide fully integrated, comprehensive energy solutions for business and industry nationwide. Providing fully integrated, comprehensive energy solutions 3

4 4 DTE Energy s Non-Utility Platform Power and Industrial Businesses Power and Industrial Project Sites This business segment provides services using project assets usually located on or near the customers premises in the steel, automotive, pulp and paper, chemical, airport and other industries. The Power and Industrial business is comprised primarily of projects that deliver energy products and services to industrial, commercial and institutional customers; and sell electricity from biomass-fired energy projects. Providing fully integrated, comprehensive energy solutions

5 Non-Utility Fleet Growth Acquisition Purchased plant assets. Retrofit Update and maintain assets of plant. Operate Customers rely on our expertise to run an efficient operation. Greenfield Design and build from ground up. 5

6 Challenges for Controls Multiple Business Units with different operational needs Sites that are Acquired Specific End Customer Requirements IT and Controls Convergence 6

7 With all these Challenges, How do we Optimize? Standardization Key Partnerships Leverage IT and Control System Mash-ups 7

8 STANDARDIZATION Hardware Control Systems Firewalls Managed Switches Workstation/Server Storage 8

9 Network Fiber Reliable connection to all parts of the plant Stratix Switches Wireless Motorola Canopy - Point to Multi-Point Cisco Bridges Point to Point Zigbee Star, Cluster, or Mesh 9

10 STANDARDIZATION Software Software Versions Antivirus Patching of DMZ servers Qualifying Patches Develop Base Line Vmware Vmotion Windows Terminal Server 10

11 Partnerships Don t Underestimate the Power! Rely on Partnerships Help me so I can help you. Support Patch Qualifications Knowledgebase 11

12 Technology and Control System Mash-ups Introduce VMWare in the PCN NAS - ISCSI Diskless Servers Redundancy/Fail-over Significantly Reduce Foot Print Server Templates 12

13 Technology and Control System Mash-ups Terminal Servers Thin Clients Easy Replacement Diskless Simplify Application Deployment 13

14 Technology and Control System Mash-ups VantagePoint - SharePoint View Real-time and Historical Data Different data for different roles Access to Asset Information Not just display real-time data but drive business processes though work flows 14

15 Enterprise-Wide Optimization Leads to Data Driven Business! Real-time Visibility to Production Performance Truly Measure Business Impact of Continuous Improvement Access to Information Anywhere Through Mobile Devices 15

16 Shenango A Case Study Brian States, Plant Electrical Engineer - Shenango statesb@dteenergy.com 16

17 Plant Optimization Objectives Standardization & reliability Increase data acquisition capabilities Improve operational efficiency Environmental stewardship Safety, safety, & safety 17

18 Shenango Coke Battery Please note: This video was filmed prior to April, 2008 when DTE Energy Services acquired the Shenango Coke Battery. If you notice any actions inconsistent with DTE Safety guidelines, these actions occurred prior to DTE s ownership. DTEES has and will continue to ensure that the Shenango workplace fully meets DTE Energy expectations for a safe working environment. 18

19 Site Overview 19

20 Battery & Materials 20

21 Byproducts, Processing 21

22 Power & Steam 22

23 Plant Operations & Processes: How Does It All Relate? 23

24 Which System Vendor, That s The Question Either solution could provide a fully expandable, capable control and data acquisition system for this process. With this question answered the roadmap could begin to take form, budgeting appropriates take place, and implementation started. 24

25 Develop The Plan Define Your 5-Year Goals Networks Servers PLC/PAC upgrades & implementation HMI s Instrumentation 25

26 Build The Backbone Let The Rollout Begin Standardize on Ethernet I/P, RSLogix 5000 platform Implement fiber ring configurations Wireless in hard to get

27 Server Solutions & Technology IT Management 101 Rockwell/OSIsoft partnership lends itself well for using PI for data acquisition and trending. Powerful real-time trending capabilities Fits well with DTE historian standards Allows simple, effective process windows for managers Virtualization & terminal servers: Reduced hardware costs, energy use, rack space, etc Cheap to deploy and replace = flexibility Increased reliability 27

28 Rockwell Software Suite Many choices, many solutions: Historian Transaction Manager View Server View Client RSLogix 500/

29 Implementing VantagePoint A replacement for custom and proprietary DAS and environmental reporting. Increased flexibility, better support, and no fat fingers. Centralized support. Cost savings. Improved up-time. Unlimited availability. 29

30 VantagePoint, Benefit Analysis Operations 30

31 VantagePoint, Benefit Analysis Environmental Duplication of custom DAS reporting. Can support in-house. Viewable anywhere in the enterprise with browser. 31

32 Optimizing Data Acquisition Efficiency From Circular Charts to Real-time information aids in process improvements and response to process upsets. 32

33 Optimizing Data Acquisition Cont. A day in the life of a Shenango operator 33

34 Optimizing Operations How do we get from that to this? 34

35 Optimizing Operations 35

36 Optimization Goals, Site Specific Examples Standardization & reliability Increase data acquisition capabilities Improve operational efficiency Environmental stewardship Safety, safety, & safety 36

37 Standardization Case-in-point: Wash Oil, Ammonia Still Wash Oil plant and Ammonia Still operations increased yields, etc. First step in standardizing for addressed-based to tag-based. Opportunity to standardize HMI s 37

38 Operations & Data Acquisition Case-in-point: DS Plant Controls Controls Upgrade To control costs, vintage remote PLC was kept in place as a remote I/O rack. Updated controls offer reduced down-time and higher environmental compliance. Removed one more layer of vintage DH485 data acquisition. 38

39 Environmental Case-in-point: Baghouse Controls Controls addition has allowed for better monitoring, targeting of maintenance activities, and optimization of cleaning without installation of costly system updates. Baghouse DP 5.56 inh2o Full Cleaning Sequence Control Band ( inh2o) 4.5 8/25/2012 8:48: PM 8.00 hours 8/26/2012 4:48: AM 39 Copyright 2012 Rockwell Automation, Inc. All rights reserved.

40 Safety Case-in-point: Caustic Tanks Remote displays and instrumentation reduce the need for personnel in the area. New auto TCV s and PCV s placed outside containment area. 40

41 Questions Enterprise-Wide Optimization in the Power Industry Rick Wright Principal Analyst Engineering Support Brian States - BSEE, MBA - Plant Electrical Engineer November 7, 2012 Copyright 2012 Rockwell Automation, Inc. All rights reserved.