Fleet Performance and Reliability in Generation Utilities Rodney Lord, IT Solutions & Services, Siemens Jörn Rassow, Power Plant Engineer, EnBW Kraftwerke AG

Energy Management Suite Siemens IT-Solutions and Energy

Combining Technical and Business Information with Siemens Energy Management Suite Efficiency QUALITY Emissions Availability Fuel costs Flexibility Maintenance costs Performance Operating costs TIME COSTS Business Performance Management Generation Planning & Monitoring Corrective & Preventive Maintenance 1) Technical Performance Management Operations & Maintenance 1) Instrumentation Alarming Shift Management Power Plant 1 Power Plant 2 Power Plant n 1) Available in 2008

Enterprise Wide Decision Support Executive Management Technical Competence Center User Community Executive Management Power Plant Management Production Management Technical Management Power Plant Manager Production Manager Systems Plant Systems IT systems . . . Process Data Archive Internet Databases DCS Scheduling Energy Trading Intranet SAP ERP Multiple Generation Locations Power Plant 1 Power Plant 2 Power Plant n

Integration of SAP Enterprise Asset Management, SAP ERP Systems and Plant Process Information provides visibility to key operational data and information SAP ERP SAP ERP Planning & Execution Energy Management Suite Plant Control and Operational Systems Plant Control and Operational Systems Limited visibility to plant operations and metrics Energy Management Suite is the bridge between plant operations and the business

Enterprise Wide Decision Support Executive Management Technical Competency Center User Community Executive Management Power Plant Management Production Management Technical Management Power Plant Management Production Manager Energy Management Suite Systems Plant Systems IT systems Multiple Generation Locations Power Plant 1 Power Plant 2 Power Plant 3 Kraftwerk 2 EMS connects data from the power generation and business areas with process know how to creating transparency and flexibility. Access to this near real time information enables decision making to increase availability and profitability.

Fleet Wide Monitoring & Decision Support - The Building Blocks SAP Netweaver Enterprise Portal Provides a Single User Interface EMS Operational Data Collection and Processing SAP ERP Plant Management Maintenance and Workforce Plant and IT Systems . . . Process Data Archive Internet Databases DCS Scheduling Energy Trading Intranet SAP ERP

Energy Management Suite - Primary Functional Areas EMS Portal Fleet Generation Monitoring and Planning Fleet Performance Monitoring Fleet-wide Diagnostics & Optimization Business Performance Management Plant Asset Management (PAM) Operational Management SAP Plant Management Enterprise Information Center EMS PAM Extensions Core PAM Alarm Processing Technical Perform. Mgmt. Corrective & Preventive Maintenance PM, WCM PS SAP ERP Generation Planning and Monitoring Shift Management Process Information (OSI PI – Process Book) Maintenance & Workforce SAP Netweaver

Enterprise Information Center – Utilizing the SAP Enterprise Portal and eSOA Integrates information from multiple power plant locations into a common platform Provides easy access to information from other integrated ‘expert’ systems Allows a comprehensive view to company wide information delivered through a single user interface Access to near real-time information from the fleet High degree of integration among plant and business systems The history of Cockpit begun in 1999 where Siemens PG L introduced the vision of a centralized management information system to combine and harmonize information coming from diverse and disparate software systems from the different domains within the enterprise. The aim was to provide a single platform for information distribution and decision support for the individual roles within the company - from the operation floor to business user to traders and the boardroom. In 2000/2001 the first installation was executed in Northern China where the system functionality and philosophy could have been proved in the commercial operation. The Development of more functions & modules and improvements in underlying technologies has been made to adapt to the changing IT environments and conditions. Strategic partnership agreements have been founded and the next steps have been development of web enabled solutions and web portal infrastructure functionality. The concepts have been proven at multiple installations all over the world. Latest project references based on SPPA-M3000 Cockpit solutions you find in the attachment there are given numbers of current and expected users within the respective company and further detail information about the projects. The next steps were to support more system platforms. Strategic partnership with SAP was agreed to announce a Power Portal solution based on the SAP infrastructure. For the future plans and concepts for an energy suite are worked on to combine even more consequently and smoothly technical and business systems and information. 1

Siemens Energy Management Suite - Shift Log for Asset Performance Management Shift Management Planning of shifts and shift crews Manual or automatic logging of events and DCS signals Replaces paper based Operator Logs Shift Tasks e.g. operator rounds Maintenance Strategy Multiple maintenance strategies to select from Plant Management Core Plant Management (e.g. Master Data, Maintenance and Materials Management) integrated with SAP ERP Predictive Diagnostic System asset status reporting As part of the RDC roll-out Siemens will manage the schedule for creation and tuning of the models, review and comment on the site acceptance test plans, and participate in the site acceptance process. Vibration data collected by using MHM equipment will be integrated into the Siemens M3000 system and classic alarm monitored by M3000 EWS review of selected thermal cycle calculation system. -> recommendations regarding the monitored components and the precision of the calculated actual and target performance values. a fleet-wide plant condition monitoring / alarming system based on Siemens SPPA-M3000 Early Warning System. Integrate Alarming into Shift Log and / or CMMS System Availability: Maintenance and Plant Data Management Minimizing the risk of unplanned outages  900,000 €/y Maintenance: Spare Parts and Maintenance Management Reduced lead time for planned outages  115.00 €/y Reduction in spare parts inventory  1.600.000,-€/y Savings

Siemens Energy Management Suite - Early Warning System for Diagnostic and Technical Performance Management Predictive Diagnostic System Fleet-wide plant condition monitoring and alarming system Asset status reporting integration of the local Vibration system with EWS Creation and tuning of the plant operational models Review of selected thermal cycle calculation system Integrated Alarming into Shift Log component Predictive Diagnostic System asset status reporting As part of the RDC roll-out Siemens will manage the schedule for creation and tuning of the models, review and comment on the site acceptance test plans, and participate in the site acceptance process. Vibration data collected by using MHM equipment will be integrated into the Siemens M3000 system and classic alarm monitored by M3000 EWS review of selected thermal cycle calculation system. -> recommendations regarding the monitored components and the precision of the calculated actual and target performance values. a fleet-wide plant condition monitoring / alarming system based on Siemens SPPA-M3000 Early Warning System. Integrate Alarming into Shift Log and / or CMMS System Savings of more than $8 M/Yr. Additional 50 MW capacity Improved efficiency for: Additional output of nuclear power plants: - Lignite-fired units: 2% + 2MW - Gas-fired units: 1.5% Fleet availability increased by 0.5%

Siemens Energy Management Suite - Expert System for Generation Planning and Monitoring Fleet Dash Board Availability/Capability Event Logging - Visualization of past capability and projections for the future Economic Dispatch Economic dispatch of a fleet taking into account the current circumstances. (e.g. head water pressure, thermal heat rates, costs) Generation Monitoring Manage schedules and control production. Early reaction to emerging issues Fuel Supply - and Emissions Management Monitoring (calculation) of actual emissions and reporting 5000 MW installed generation capacity Average fuel reduction of 0.5% [0.3-1.0%] Average fuel costs of 25 €/MWh Plant Utilization 60% -> 3 000 000 €/year

Siemens Energy Management Suite - Business Performance Monitoring 15.10.2008 Key Performance Indicators Calculation and reporting of KPIs on each unit in the fleet and component MTBF, MTBR IEEE, VGB, … Technical & Maintenance Reporting Comprehensive business reporting Fleet wide YTD actuals Production forecasts Maintenance order status and costs …. Business Advisor ‘What if‘ planning scenarios for the fleet based on generation supply contracts and fuel targets Early Detection of Performance Deviations Benefits for a typical Generation Fleet 5000 MW installed generation capacity Increase of In-Market Availability by 0.5 %; equals 25 MW of additional generation Invest of 1.000.000 €/MW installed capacity Depreciation 10 %/year -> 2.500.000 €/year

Energy Management Suite - Customer Value Customer Benefits Customer Experience Highly innovative solution package integrating production, business processes and metrics. Faster and improved support for decision making to meet the short and long term market needs. Early detection of potential plant and unit issues lead to; reduced maintenance costs increased availability and efficiency economic and technical optimization of plant and fleet performance consistent management reporting Efficienct Technical Performance: Early Detection of deviations 500.000 €/y (800MW, coal-fired steam power plant) Generation Monitorong.&Planning: Optimized Generation Schedule Planning  3.000.000 €/y (5000 MW installed capacity) Availability Monitoring and Alarming: Avoidance of unplanned outages, and avoided asset damage  720.000 €/y (300 MW Combined Cycle Unit) Early Detection of Performance Deviations: Increased Asset Utilization  2.500.000 €/y (5000 MW installed capacity) * Actual savings achieved by an existing EWS Customer