Instrumentation, Controls, and Automation - Program 68

Transcription

1 Instrumentation, Controls, and Automation - Program 68 Program Description Program Overview Power generators need to improve their ability to detect damage to plant equipment while preserving the focus of skilled instrumentation and controls (I&C) staff on plant operations and system performance. Additional sensors are needed to improve equipment condition monitoring, enabling optimization of maintenance tasks. Control systems have evolved from analog to digital, with new technologies to improve plant performance and operational effectiveness. The Electric Power Research Institute s (EPRI s) Instrumentation, Controls, and Automation program (Program 68) identifies, develops, and demonstrates state-of-the-art sensing, monitoring, diagnostics, and control system technologies that improve equipment condition assessment and plant performance, and help accurately measure critical plant variables. Research Value Maintaining the availability of existing power generating plants and enhancing the performance of future plants are critical to the future generation portfolio. EPRI s Operations and Maintenance programs address the key issues of operational effectiveness, safety, reduction of maintenance costs, and technical support for the next generation of plant staffs. The program focus is on providing integrated solutions that address the needs for processes, technologies, and skilled workers, allowing program members to: Reduce costs through greater automation in tuning of process controls and operating point transitions. Improve reliability through integrated anomaly detection, diagnostics, and prognostics. Improve reliability through more effective equipment monitoring, made possible through collaborative R&D. Approach Products developed by this program provide guidance through technical reports, guidelines, process specifications, webcasts, seminars, and workshops on research projects. Program activities address the identification, development, and transfer of new technology, and help optimize the use of existing instrumentation and control equipment, which can cost-effectively improve plant performance. Technology development and demonstration projects address critical aspects of fossil plant instrumentation and control systems, including advanced controls, automation, improved loop tuning, and equipment diagnostics. Applied research is conducted in collaboration with host sites at member utilities, expert consultants, universities, laboratories, and equipment vendors. The focus includes cyber security best practices to address industry standards; accurate detection and mitigation of equipment damage; increasing plant operational efficiency through the development and demonstration of control system improvements; and improved tuning processes that save time and improve consistency and staff knowledge capture. Technology Transfer projects provide peer-to-peer information exchange and written guidance on member-selected subjects, including online monitoring, sensors and instrumentation, controls, and automation. Fleet-Wide Monitoring Interest Group (FWMIG) meetings are held twice a year, and I&C interest group meetings are held once annually. Meeting materials including presentations, minutes, and other related files are distributed to all participants. The Instrumentation and Control Guideline addresses a member-selected topic annually. p. 1

2 Accomplishments Successful implementation of online and automated monitoring technology for equipment condition assessment requires applied research conducted in collaboration with universities, laboratories, and equipment vendors. Field demonstrations of technology at operating plants have included combined-cycle plant automation, equipment startup automation, advanced control, and automatic tuning. The R&D in this program has provided: Successful Fleet-Wide Monitoring Interest Group (FWMIG), with more than 20 member organizations; Guidelines on instrument calibration data analysis, control loop tuning, and control loop performance monitoring; reports documenting field demonstrations of new technologies relating to advanced control algorithms, automated controls tuning, multiloop controls tuning, and application of model predictive controls; and reports documenting field demonstrations of sensors, wireless data transmission, and advanced anomaly detection algorithms. Current Year Activities The program R&D for 2012 will focus on using instrumentation and control system capabilities for improving operational flexibility, efficiency of critical control loops, and control system cyber security. Specific efforts will include: report documenting best practices for establishing and operating a cyber security program for control systems; Continuation of the Fleet-Wide Monitoring Interest Group; and report that will serve as a guideline for instrumentation and control processes key to operations and maintenance in power generating plants. Estimated 2012 Program Funding $0.9M Program Manager Aaron Hussey, , ahussey@epri.com Summary of Projects Project Number Project Title Description P Technology Development and Demonstrations This project supports optimization of plant instrumentation and control systems, including cyber security, sensors, wireless technology, equipment diagnostics, advanced controls, automation, and improved loop tuning. P Technology Transfer Successful implementation of online monitoring technology and instrumentation, controls, and automation (ICA) technology requires peer-to-peer interaction among power producers and formal interaction with vendors. Instrumentation, Controls, and Automation - Program 68 p. 2

3 P Technology Development and Demonstrations (069177) Key Research Question Many experienced instrumentation and control system experts in the industry are approaching retirement age, and less-experienced staff members are assuming their duties. At the same time, equipment is aging, plants are operated more aggressively than originally designed, and the industry is preparing for compliance with cyber security standards. Accurate detection and mitigation of damage, using existing control capabilities for flexible operations, and implementing cyber security program best practices are critically important for plant instrumentation and control systems. Approach This project develops and demonstrates plant instrumentation and control system technologies to solve today's critical industry issues. Modern control systems include a suite of technology capabilities that can be used to mitigate equipment damage and improve efficiency of operations. Applied research is conducted in collaboration with host sites at utility members, expert consultants, universities, laboratories, and equipment vendors. Field demonstrations of technologies at operating plants include wireless sensor networks, equipment fault diagnostics, combined-cycle plant automation, equipment startup automation, advanced control, and automatic tuning. The research and development effort in 2012 and future years will focus on: Increasing plant operational flexibility and efficiency through the demonstration and evaluation of control system optimization technology, such as use of model predictive control and automated tuning methods; Improving control system cyber security by collecting and sharing best practices in establishing and operating cyber security programs that address industry standards, and; Improving equipment condition monitoring and diagnostics activities through addition of sensors, wireless networking, use of controls data, and integration of component degradation knowledge in online monitoring systems. Impact Instrumentation, controls, and automation technology R&D can improve plant staff knowledge and provide costeffective evaluations of state-of-the-art technologies prior to full-scale implementation. Some examples of technology developments and demonstrations include: Automation of equipment and processes improves the consistency of startups/shutdowns, helps capture expert knowledge, and reduces equipment damage. Improved control system performance leads to more responsive plant operation, better efficiency, reduced emissions, and reduced likelihood of damaging temperature transients. Multiloop tuning methods result in significantly better control systems performance and lead to better, more robust tuning of boiler control systems. Automation of control system tuning methods improves consistency and enables the expertise of control engineers to be applied on a broad scale. Wireless sensor networking can reduce the cost of installation of additional sensors, enabling more effective detection of critical equipment failure modes. Experience gained through this research will be directly applicable to both existing plants and new plant designs, enabling more effective application of online monitoring technology to create "smarter" components. How to Apply Results End users of this research include system engineers and owners, instrumentation and controls engineers, centralized monitoring staff, and technicians at fossil power plants. Some technology results will be published in the form of technical reports, guidelines, and process specifications that specify the proper approach for implementation of instrumentation, controls, and automation technology. Other technology results will be delivered as spreadsheets, databases, and presentation materials for quick review capability and ease of use. Instrumentation, Controls, and Automation - Program 68 p. 3

4 Without this documented guidance, benefits of applying instrumentation, controls, and automation technology may not be realized to the full potential. In addition, key research results will be communicated periodically through webcasts, teleconferences, and face-to-face meetings Products Product Title & Description Cyber Security Best Practices for Instrumentation and Control Systems: This project will begin a study on cyber security programs that utilities are implementing to meet industry standards. The focus is to identify and document industry best practices in mitigating security risks to I&C systems. Monitoring and Test Methods to Identify Pulverizer Response Problems: This project will complete the second year of study of the impact of pulverizer performance on load response and identify a mechanism to easily test a pulverizer online to determine its responsiveness (or change in responsiveness). Results will be used to determine if the pulverizer needs maintenance or if the control system needs tuning. Using Control Methods to Accommodate Changing Coal Quality: Coal quality variation from coal blending and other mechanisms causes process variations for which the boiler controls were not originally tuned. Advanced control technology, including adaptive control, might help to consistently control boiler systems within given constraints when changes to fuel heating value, moisture, and other characteristics occur. This study will investigate controls solutions for this problem and collaborate with other related research programs. Planned Completion Date Product Type 12/31/12 Report 12/31/12 Report 12/31/12 Future Year Products Product Title & Description Optimizing Sensor Placement to Infer Spatial Patterns: Optimal placement of heat flux and oxygen sensors in boilers is a key determination, often based on access and cost considerations. However, the most optimal placement could be determined through proper modeling for spatial patterns that can be measured through an optimized number of sensors. Using Control Methods to Accommodate Changing Coal Quality: Coal quality variation from coal blending and other mechanisms causes process variations for which the boiler controls were not originally tuned. Advanced control technology, including adaptive control, might help to consistently control boiler systems within given constraints when changes to fuel heating value, moisture, and other characteristics occur. This study will investigate controls solutions for this problem and collaborate with other related research programs. Drum Level Control Solution for Combined-Cycle Startups: During startup, closing the feedwater valves is not always sufficient to prevent high levels in the drum. As a result, operators anticipate this problem and lower the level setpoint with the hope of preventing water carryover. This project would investigate a control or automation solution to this problem. Drum Level Control Solution for Combined-Cycle Startups: During startup, closing the feedwater valves is not always sufficient to prevent high levels in the drum. As a result, operators anticipate this problem and lower the level setpoint with the hope of preventing water carryover. This project would investigate a control or automation solution to this problem. Planned Completion Date 12/31/13 Product Type 12/31/13 Report 12/31/13 12/31/14 Report Instrumentation, Controls, and Automation - Program 68 p. 4

5 Product Title & Description Optimizing Sensor Placement to Infer Spatial Patterns: Optimal placement of heat flux and oxygen sensors in boilers is a key determination, often based on access and cost considerations. However, the most optimal placement could be determined through proper modeling for spatial patterns that can be measured through an optimized number of sensors. Planned Completion Date Product Type 12/31/14 Report P Technology Transfer (065777) Key Research Question Plant owners demand more efficient operation and effective maintenance to reduce production costs and improve availability. Successful implementation of online monitoring technology and instrumentation, controls, and automation (ICA) technology requires peer-to-peer interaction among power producers and formal interaction with vendors. Technology gaps must be identified by end users to guide development and demonstration efforts. Approach Held twice a year, Fleet-Wide Monitoring Interest Group (FWMIG) meetings offer open peer-to-peer information exchanges and formal presentations by vendors on member-selected subjects. Meeting materials including presentations, minutes, and other related files are distributed to all participants. The FWMIG will guide EPRI projects on centralized online monitoring and diagnostics technology. A technical update, Instrumentation and Controls Guideline, is issued annually on member-selected topics. These topics may include instrumentation, calibration, controls, automation, sensors, online monitoring, and wireless technology. The focus of these reports is on best practices in the electric utility and other industries. As funding permits, assessments of emerging technologies and their early adoption in power-producing facilities is conducted through webcasts and documentation in the form of technical updates. Additional peer-to-peer exchange of ICA topics takes place during interest group meetings held in conjunction with industry conferences, or at host sites/epri facilities as funding permits. Newsletters are published, and webcasts are presented as necessary to communicate key technology transfer activities and progress on projects. Impact Peer-to-peer information sharing improves technology implementation in emerging areas, such as online monitoring and ICA technology. Collaboration among utility members, vendors, and researchers results in more effective technology development. Sharing experiences from early technology adoption in other industries benefits power producers. How to Apply Results End users of this research include system engineers and managers, control systems engineers, and technicians at fossil power plants. Interest group meetings are held periodically to enable open information exchange among members in key strategic areas affecting utilities. ICA technology guidelines are published in the form of technical update reports and are used as guidance when reviewing or improving key plant ICA processes. Key research results are communicated periodically through webcasts. Instrumentation, Controls, and Automation - Program 68 p. 5

6 2012 Products Product Title & Description Instrumentation, Controls, and Automation Interest Group Meeting: This meeting is held annually in response to I&C staff needs. The group will follow a similar format to other interest groups with a focus on technology discussions, peer sharing of best practices, and discussion of industry issues that can be addressed through I&C research. Fleet-Wide Monitoring Interest Group Meetings: The group meets twice annually (typically in May and October) to discuss challenges and solutions related to the implementation of on-line monitoring technology. Topics discussed include thermal performance monitoring, equipment condition assessment, data integration, and technology gaps. Planned Completion Date 12/31/12 12/31/12 Product Type Instrumentation and Controls Guideline: 2012 Topical : This guideline is updated annually with at least one new topic as voted on by the program advisory committee. The topic will be reviewed, and potential and proven industrial applications will be identified and documented. 12/31/12 Future Year Products Product Title & Description Instrumentation and Controls Guideline: 2013 Topical : This guideline is updated annually with at least one new topic as voted on by the program advisory committee. The topic will be reviewed, and potential and proven industrial applications will be identified and documented. Fleet-Wide Monitoring Interest Group Meetings: The group meets twice annually (typically in May and October) to discuss challenges and solutions related to the implementation of on-line monitoring technology. Topics include thermal performance monitoring, equipment condition assessment, data integration, and technology gaps. Instrumentation, Controls, and Automation Interest Group Meeting: This meeting will be held once annually in response to I&C staff needs. The group will follow a similar format to other interest groups with a focus on technology discussions, peer sharing of best practices, and discussion of industry issues that can be addressed through I&C research. Instrumentation and Controls Guideline: 2014 Topical : This guideline is updated annually with at least one new topic as voted on by the program advisory committee. The topic will be reviewed, and potential and proven industrial applications will be identified and documented. Fleet-Wide Monitoring Interest Group Meetings: The group meets twice annually (typically in May and October) to discuss challenges and solutions related to the implementation of on-line monitoring technology. Topics discussed include thermal performance monitoring, equipment condition assessment, data integration, and technology gaps. Instrumentation, Controls, and Automation Interest Group Meeting: This meeting will be held once annually in response to I&C staff needs. The group will follow a similar format to other interest groups with a focus on technology discussions, peer sharing of best practices, and discussion of industry issues that can be addressed through I&C research. Planned Completion Date 12/31/13 12/31/13 12/31/13 12/31/14 12/31/14 12/31/14 Product Type Instrumentation, Controls, and Automation - Program 68 p. 6

7 Fleetwide Monitoring Interest Group (063807) Supplemental Projects Background, Objectives, and New Learnings The Fleet-Wide Monitoring Interest Group (FWMIG) was formed to enable open information exchange between utility members, vendors, and researchers on all aspects of fleet-wide monitoring. Topics covered by this interest group include equipment condition monitoring, thermal performance monitoring, operations and maintenance (O&M) effects of a fleet-wide approach, cost-benefit analysis, and ongoing discussions on R&D and technology gaps. Project Approach and Summary The FWMIG meets twice per year, with participants representing utilities, vendors, universities, and EPRI. Meeting topics include updates on activities in other industries as well as monitoring applications within the power industry. Participants present the latest progress made in fleet-wide monitoring implementations. The meeting agenda also includes a member roundtable to discuss open issues in the application of fleet-wide monitoring tools. As part of the roundtable, gaps that can be addressed by research projects are discussed. These gaps will be formulated into additional supplemental projects with specific scopes and approaches, which will be carried out separately from the interest group. A website bulletin board will provide a forum for correspondence among members as well as an archive of meeting materials and links to related projects. Benefits Unplanned and/or corrective maintenance of power industry equipment remains one of the most significant O&M expenses, sometimes resulting in unplanned outages and reduced financial margins due to increased replacement electricity costs. Online equipment condition monitoring can provide early warning of potential failure by detecting incipient leading indicators of equipment degradation via powerful signal processing applied to existing instrumentation. EPRI's role in fleet-wide monitoring is to bring its knowledge of equipment reliability and understanding of equipment failure modes and effects to participants of this interest group. The objective is for equipment condition monitoring software to be applied on a fleet-wide basis to move it closer to a "plug and play" mode of operation. This advancement should measurably reduce maintenance efforts and costs, improve reliability, and increase customer and investor confidence. Instrumentation, Controls, and Automation - Program 68 p. 7

8 HRSG Damage Reduction through Improved Controls (072046) Background, Objectives, and New Learnings Many combined-cycle units are cycling much more than anticipated in the original design basis. Problems resulting from increased cycling include accelerated component failure rates and additional incremental fuel cost. In combined-cycle units, as with coal-fired units, superheat and reheat spray attemperation introduces the potential for serious component degradation and failures in piping, headers, and tubes. On many combinedcycle units, the superheater (SH) and reheater (RH) controls strategies are based on designs long used in coalfired plants. Due to the faster response time of combustion turbines, these control design philosophies are not necessarily adequate, in particular in those that do frequent cycling. As a result, a significant number of heat recovery steam generator (HRSG) failures have been experienced worldwide that have at least been attributed partly to inadequate attemperation control. The primary objective of this project is to investigate and implement advanced instrumentation and control (I&C) strategies to mitigate the adverse impacts of inadequate steam temperature control. This research will include thorough investigations of control strategies and instrumentation and control hardware and their overall effects on steam temperature control performance, followed by implementation and evaluation. Project Approach and Summary To meet the overall objective of this project, the following approach is envisioned: 1. Document existing controls and their performance 2. Identify candidate I&C improvements 3. Perform detailed design of identified improvements 4. Implement identified improvements 5. Test and evaluate benefits 6. Document the entire effort in an industry report Potential I&C improvements include advanced control algorithms such as automatic proportional-integralderivative (PID) tuning, model predictive control (MPC), additional traditional and novel instrumentation, and primary control element modifications. Benefits Using the results of this research, steam temperature control optimization could better reduce damage to equipment (valves and piping.) and help improve the reliability, costs, and environmental impact of power generation through: Performance and heat rate improvements and fuel cost reductions Reduced fuel consumption through improved thermodynamic efficiency Increased availability of power generation through reduced unplanned outages due to equipment failure Instrumentation, Controls, and Automation - Program 68 p. 8

9 Cyber Security Solutions for Instrumentation and Control Systems (071911) Background, Objectives, and New Learnings Information technology (IT) practices for personal and business networks require continual updates to mitigate threats from cyber attacks. Antivirus programs, firewalls, passwords, and encryption are familiar technologies protecting our personal and business networks. But even with all of these mitigation technologies, cyber attackers continue to find ways to penetrate computer systems. Such attacks pose significant risks when directed at power plant control systems, particularly those at generating units that are critical to production. IT security policies and practices are well-established, with professionals working to secure business networks while constantly increasing workplace productivity. Although industrial control systems (ICS) share much of the same type of computing technologies as business networks, security policies and practices must consider a different type of productivity requirement safety and efficiency of process control. Control engineers are required to maintain, upgrade, and secure control systems while also optimizing their end use by plant operators. Cyber security standards have been produced as a result of continual threats to business and process control networks. Many standards have been drafted, undergone revision, and are being enforced for compliance. In recent years, electric utilities have established cyber security programs to ensure compliance with critical infrastructure protection (CIP) standards requirements of the North American Electric Reliability Corporation (NERC) and related requirements in the international community. Compliance with these standards is not easy, and requires IT staff and control engineers to work together to implement and maintain a cyber security program for control systems. As part of establishing and maintaining a cyber security program, a variety of security strategies and technologies are needed to mitigate risk and react to new vulnerabilities while improving program efficiency. The objective of this project is to investigate and document solutions for control system security. This work will enable effective application and foster new technology developments. Project Approach and Summary This project will explore and document a variety of solutions for securing instrumentation and control systems. The focus will be on solutions implemented in the fossil power industry, and solutions from other industries also will be considered. For each solution topic, the project team will study how the technology works, implementation options and best practices, field installations, and capabilities/limitations. EPRI will work with participants to establish and prioritize solution topics to study, and will address the top three. A preliminary list includes: Data diodes Automated change management Remote access White listing of applications Wireless sensor network security Active control network scanning Hardening cyber assets Patch management Ports and service management Security status monitoring USB memory stick protection Use of active directory Virus/malware protection Instrumentation, Controls, and Automation - Program 68 p. 9

10 EPRI will research and summarize all existing industry documentation for the topics selected with a focus on implementation best practices, technology gaps, and new developments. Benefits Cyber security strategies and technologies will reduce vulnerabilities of power plant control systems to malicious attacks that could cause disruption to electricity generation and damage to equipment. Technology-assisted early detection and prevention of cyber attacks can ensure reliable, safe, environmentally sound, and economic operation of critical generating units. Participants in this project will gain new knowledge and receive practical implementation guidance for a variety of options for establishing required control system security. This guidance can improve participants abilities to address elements of cyber security standards through improved understanding of strategies and technology options. The project will include an assessment of actual field application of specific strategies for achieving control system security. Instrumentation, Controls, and Automation - Program 68 p. 10