1. Chevron’s Power Performance Monitoring Solution
Presented by:
Ken Yoss
Roy Blanco

2. Agenda Power Support Center Overview
PSC Performance Monitoring Solution
PSC Workflow Process
El Segundo Refinery CHP Overview
Case Studies
Q&A

3. Power Support Center Capabilities
Monitoring & Diagnostics Center
Power Solutions Network
Business planning support
Operations philosophy and tools
Maintenance philosophy and tools
Engineering and technical solutions
Performance monitoring/trip analysis
Training/OC development
Equipment modifications and upgrades

4. Power Support Center Organization
Central PSC Office
Turbine
Parts
QA/QC
Management: Turbine Metallurgist Expertise
Equipment Assessment & Upgrades
Major
Inspection
Management
O&M Philosophy & Tools: OE Compatible
Refineries
Performance
Monitoring & Diagnostics
Engineering
Analysis
Oil & Gas Operations
Project
Management PI
Administration
YOSS:
Upstream and downstream power facilities are STAFFED AS POWER IS NOT AN INHERENT SKILL SET CORE TO UPSTREAM AND DOWNSTREAM BU’S. Generally with SHORT ROTATIONS, new hires and LITTLE POWER EXPERIENCE
PSC:
ME’S
EE/I&C’S
METALLURGISTS
ENG ASSIST
CGP SITE EXPERTISE IN DEVELOPMENT AND TROUBLESHOOTING EMERGENCIES AND SPECIAL PROJECTS
ETC/CES
SITE STAFF AND OPERATORS/TECHNICIANS
The PSC SUPPORT MODEL is designed TO FILL GAPS, and provide an EXTRA SET OF EYES for site staff supporting sustained power reliability performance.
The PSC provides all the skill sets found at the most reliable power utility power plants which would make no sense to develop at each upstream or downstream facility. PSC will spread these skill sets as shared resources to all upstream and downstream power facilities.
There will be one designated PSC Operations Engineer working out of Houston responsible as the primary contact point continuously analyzing and supporting his/her site while also connecting the variety of PSC power skill sets on appropriate projects and initiatives at there upstream or downstream site.
KPI
Tracking
Business
Plan
Development

5. PSC Performance Monitoring Solution
OSIsoft EA for data infrastructure
ProcessBook
Datalink
To come: MD
RT Webparts via SharePoint
AF2.0 & Notifications
Etc.
SmartSignal for predictive analytics
SmartSignal EPI*Center
SmartSignal participates in the performance monitoring portion of the weekly PSC/ES teleconference.
Transition to Chevron hosted, monitored and maintained instance of EPI*Center.
Develop process displays to represent operational data.
The purpose of the displays is two-fold;
to provide the engineer a means of tracking plant operation and performance,
to provide a means of presenting data to users with other disciplines in an efficient and constructive format.
The initial displays are standard presentations of the following power or steam plant;
Combustion turbine
Steam turbine
Heat recovery boiler
Boiler systems
Cooling tower and condenser systems
Switchyard status
Fuel systems
Boiler feed water systems
Wind turbine data
The displays will provide links to subsystem displays based on level of detail required.
Inlet and exhaust data
Steam data
Etc
in sub-displays, statistical representation of key process variables.
Alarm values for process variables with graphical display elements
Ad-hoc trending at every display level
The RTWebparts applications carry over to a hyper threaded interface (internet style) the features of processbook and datalink.
Web based application does not require user to install PI applications on machine
Provide a robust development environment with potential for numerous third party applications with features and applications
Ease of linking data on network cloud to portable devices without requiring an specific OS on device
Generally an easier to support, but harder to develop, modular database
The modular data is used to provide data that is not provided by typical tag database
Modular data can be used in displays that appear data source independent
Modular data can be used with alias tag names to provide generically named process variables such as HP Steam Pressure, as opposed to a specific point name field and separate tag description field
Modular database lends itself to a modular design of graphic displays and data analysis
Unit display can link to multiple units’ process values
Process tuning parameters, set point values, alarm ranges etc. can be graphically represented dynamically
Engineering drawing, process control sheets, P&ID’s references and other static data can be made available within displays as requested by user’s selection of a menu brought up by a right hand mouse click. As a result, documents and other knowledge based links that may be required for troubleshooting are listed in context.
ProcessBook can use P&ID’s and other drawings to graphically display contextual operational data.

6. El Segundo Refinery CHP Overview
Located on the Pacific coast in El Segundo, CA just south of LAX.
3 - Cogeneration Trains (GE Frame 6Bs, dual pressure HRSGs), ,000 hrs.
1 - Steam Turbine Generator
1 - Auxiliary Boiler
2 - Sets of BFWPs
(weather data)

7. Case Study: High Steam Drum Conductivity

8. Case Study: High Steam Drum Conductivity

9. Case Study: High Steam Drum Conductivity

10. Case Study: High Steam Drum Conductivity

11. Case Study: High Steam Drum Conductivity

12. Case Study: High Steam Drum Conductivity
Value delivered:
Long term reliability
Confirmation of equipment issues

13. PSC Performance Monitoring Workflow
Weekly Calls
Direct Calls
APC
Plant
Engineer
Chevron Power Facilities
PSC Ops Engineer
PSC Ops Engineer
SmartTracking
Portal & Log
Summary Reports
OSIsoft EA

14. Case Study: NH3 Over Injection
11/7/2008: PSC received phone call from SmartSignal APC informing of a NH3/air ratio High Rule posting on the WatchList.

15. Case Study: NH3 Over Injection

16. Case Study: NH3 Over Injection16
Note: Identified in SmartSignal – Trended in PI for visual aid. 16

17. Case Study: NH3 Over Injection
Value delivered:
Decrease in NH3 release to atmosphere
$ decrease in NH3 purchases
Operational procedures/training modified 17
Note: Identified in SmartSignal – Trended in PI for visual aid. 17

18. PSC Performance Monitoring Workflow
Weekly Calls
Direct Calls
APC
Plant
Engineer
Chevron Power Facilities
PSC Ops Engineer
PSC Ops Engineer
SmartTracking
Portal & Log
Summary Reports
OSIsoft EA

19. Case Study: NH3 Control Valve

20. Case Study: NH3 Control Valve

21. Case Study: NH3 Control Valve

22. Case Study: NH3 Control Valve

23. Case Study: NH3 Control Valve
Path forward:
Find optimal NOx ppm setpoint for SCR
efficiency and operability
Upgrade the SCR system

24. PSC Performance Monitoring Workflow
Weekly Calls
Direct Calls
APC
Plant
Engineer
Chevron Power Facilities
PSC Ops Engineer
PSC Ops Engineer
SmartTracking
Portal & Log
Summary Reports
OSIsoft EA

25. Performance Monitoring Value
PI (1 year)
Confirmed – 3 trip avoidances
Potential – 6 trip avoidances
Equipment Abnormalities – Over 70 abnormalities monitored > long term reliability
SmartSignal (3 months)
Equipment Abnormalities - 14 identified that either returned to normal or communications to plant lead to corrective actions > long term reliability
Instrumentation Issues – Over 35 identified resulting in a potential increase of plant reliability > long term reliability
Efficiency - 2 efficiency catches resulting in the scheduling of a water wash and NH3 injection reduction.
Culture Change
PSC has noticed plant personnel are more cognizant of equipment abnormalities that are not yet urgent.
Operational procedures have been modified to prevent less than optimal operational conditions.
The PI implementation is off the shelf and only consists of trending, no advanced calculations or alerts currently exists.
The SmartSignal implementation was performed by the APC

26. & Q A