© 2008 OSIsoft, Inc. | Company Confidential Helping People make the right decisions …….. when it matters! John C. Kapron Sr. Technical Specialist DTE Energy,

© 2008 OSIsoft, Inc. | Company Confidential

Helping People make the right decisions …….. when it matters!

John C. KapronSr. Technical SpecialistDTE Energy, Detroit Edison

Process Controls & Technology

[email protected]

2© 2008 OSIsoft, Inc. | Company Confidential

AgendaAgenda

About DTE Energy

OSIsoft a Key Technology Enabler

DTE – OSIsoft Enterprise Agreement (EA)

Control & Technology Framework

Benefits – OSIsoft Enterprise Agreement (EA)

Distributed Control Systems (DCS) Distributed OSIsoft PI Historians

Large Population of Data

Business IntelligenceReliability

Outage & De-rateMaintenance & Market

KPI’s

DashboardsFleet Optimization

WEB VisualizingPlant Alarm, DCS Real-time WEB Graphics

Easy Access to Information

System Dashboards

Fleet Status Assessment

Engineering Applications PMAX, Digital Fuel Tracking, Fuel Cost Framework

Process Discrete to Data

Expert SystemsPredictive Monitoring, Optimization


DTE Energy - Detroit Edison DTE Energy - Detroit Edison

Detroit Edison

• Michigan’s largest electric utility with 2.2 million customers

• Over 11,080 MW of power generation, primarily coal fired

• 54,000 GWh in electric sales

• $4.7 billion in revenue

DTE Energy - Detroit Edison

Detroit


Plants & Performance CenterPlants & Performance Center

Greenwood – 785 mwRiver Rouge - 527 mw Fermi – 1,100 mw

Monroe – 3,135 mw

Trenton Channel - 730 mw

Belle River – 1,260 mw

St Clair – 1,417 mw

Harbor Beach – 103 mw

Performance Center – 11,588 mw


Success!

History of OSI PI in DTE EnergyHistory of OSI PI in DTE Energy

Pilot at Monroe PP in 1998 Fossil Generation Fleet 1999

GenOps – EMS Ranger 2001 SOC SCADA– 2002 Fermi Nuclear– 2003 DTE Subsidiaries – 2007 Enterprise Agreement – 2007 Continuous PI Expansion

– Magnitude – Functionality


OSIsoft a Key Technology EnablerOSIsoft a Key Technology Enabler

Information and Application Integration– Primary data source of process data (current & historic)– Integral part of many Applications (process and business)– Communication Conduit (plant status, fuel cost, control, EMS)– Strategic to DTE Energy’s day to day Operation

Performance Center – Enabling Technology– Equipment Condition Monitoring – SmartSignal– Enables DCS Displays– Process & Market Analysis

DTE – OSIsoft Enterprise Agreement (EA)– Key to the Supply Cabinet– Premium Support


Why – OSIsoft Enterprise Agreement?Why – OSIsoft Enterprise Agreement?

1. OSIsoft is a DTE Energy Core Technology

2. OSI’s Strong Track Record & Future Direction

3. Expand DTE’s Use of OSIsoft Applications

4. Normalize Budget Allocation

5. Premium Software Reliance Program



Business Intelligence

KPI’sDashboards

Fleet Optimization



System Dashboards



Expert SystemsPredictive Monitoring, Optimization5 Key Benefits


1. Core Technology1. Core Technology

Integral Part Technology Framework

Component of Many Applications– Control Processes – Business Processes

Performance Center – Enabling Technology




KPI’sDashboards

Fleet Optimization



System Dashboards





Discrete data Limited value

ActionableInformation – KPI’s



Post Event Analysis DCS, PLC & PI

90%

Business IntelligenceOutage & De-rate (UCF)Maintenance & Market

Relate all Data SourcesProcessNet Framework

(PI, ProcessGuard, Maximo, SAP, UCF, P3M, Predictive Monitoring, NeuCo, LIMS, Plant View ..)25%

% CompleteABB

System DashboardsFleet Status Assessment

Fleet Drill downSubject Matter Experts90%



Standard User InterfaceWEB Visualization

100%


Process Discrete Data

Process Discrete Data Engineering ApplicationsRFID, PMAX, DFTS, eNote,

Fuel Cost Framework,Alarm Management 90%


MBO/PdM/Risk Assessment

Advanced Analysis & Process OptimizationReliability Academy

Equipment, Process, Performance, Reliability ModelsClosed Loop Process Optimization60%

Control & Technology FrameworkControl & Technology Framework

Fossil Generation Business Unit Strategy

People Making right decisions when it matters!

Fleet Optimization

Process CostsAsset Health,Market Value

Drives Performance Excellence Fleet Optimization

Process Costs, Asset Health,Reliability

Operational Performance, Market Value

15%


Fleet Performance CenterFleet Performance Center

• Located in Ann Arbor Michigan

• 7x24 hour operation (February 2006).

• Plant interface with Merchant Operation Center.

• Oversight of Outage and de-rate coordination.

Performance Center – Mission Equipment Performance Optimization of the Fossil Generation Portfolio through continuous “real time and predictive asset condition monitoring” to maximize the asset market value.

Performance Center – Vision Fossil Generation’s Fleet-wide “Mission Control Center” for continuous monitoring and optimization of plant equipment performance


2. Track Record & Future Direction2. Track Record & Future Direction

Exceptional Track Record– Worldwide and Multi Industry – Exceptional System Availability– Open and Fast Data Access for Analysis– Unlimited Interfaces (PLC, DCS, Corporate Systems)

Future Direction– Multi Industry Leverage– Managed PI– High Availability (HA) PI System – Analysis Framework

OSIsoft


3. Expand Use of PI Applications3. Expand Use of PI Applications

Currently Application in Use– PI Data Historian – Fleet Wide 300,000 tags– ProcessBook, DataLink, Active View, PI ManualLogger, PI Alarm, PI SMT– Multiple PI interfaces, Data Access Pack, API and SDK

Planned Expansion– Expand PI tag count (Process Data, Operator Rounds, Application data ...)– IT Monitor– Analysis Framework– Advanced Computing Engine (PI ACE) – PI Module Database– RtPortal (WEB Visualization)

Required Expansion– NERC Critical Infrastructure Protection– Market Interface– Environmental Reporting Regulations


4. Normalize / Reduce Budget4. Normalize / Reduce Budget

Capital Budget – Application Expansion

– Strategic Technology Approval

– Facilitates stable budget forecast

O&M Budget – Support

– Fixed Budget

– Known Future Budget Impact

Product Cost

– Significant Discounts

– Unlimited Usage


5. Premium SRP (Software Reliance Program)5. Premium SRP (Software Reliance Program)

Enterprise Project Manager and Enterprise Account Manager

Remote Monitoring

Proactive Problem Resolution

Specialized Performance Reports

Access to Center of Excellence

Unlimited Tags & Standard Interfaces

Software Update System

Quarterly Reviews

Access to all CBT’s and Webinars, Training and Event vouchers


Why – OSIsoft Enterprise Agreement?Why – OSIsoft Enterprise Agreement?

1. A DTE Core Technology

2. OSI’s Strong Track Record & Future Direction

3. Expand DTE Use of OSIsoft Applications

4. Normalize Budget Allocation

5. Premium Software Reliance Program




KPI’sDashboards

Fleet Optimization



System Dashboards





How Did We Get Here?How Did We Get Here?

Lets take a closer look under the hood.


Control & Technology Framework Control & Technology Framework




Large Population of DataABB



Plant Process ControlsPlant Process Controls

ABB Distributed Control Systems– All Unit with exceptions of:

• Belle River Unit 1 – 2008

• Greenwood – 2009

– Installed investment $150 – $200 Million Dollars

– Critical to

• Plant Operation

• Personnel Safety

• Equipment Protection

Many stand alone control systems.

Process Information Historian (PI) & Interfaces


Raw PI Data AnalysisRaw PI Data Analysis

PI Yields BenefitsPost trip analysisProcess monitoringOptimizationEarly warningAlarming


DCS installations on nearly every unit Nearly 300,000 process data tags

– PI Systems at each plant– PI Interfaces to DCS & many PLC’s

What is that data screaming at us?

How do you effectively utilize the data?

How do you turn data into information?

Challenge - Process Data Everywhere!









90%

90%

ABB



Fleet Performance Analysis (PMAX)Fleet Performance Analysis (PMAX)

Thermal Performance Calculation Engine


Digital Fuel Tracking SystemDigital Fuel Tracking System

On-line Fuel Analyzer


NOx Emissions StrategyNOx Emissions Strategy

NOx Reduction with Improved Heatrate

Before

Implementation After

Implementation

Primary focus is NOx

reduction only

Focus on operating near NOx

budget curve


Electronic Operator RoundsElectronic Operator Rounds

RFID Tags

Industrial PDA (Symbol MC9060S) IntelaTrac Software


PI to PI Process Data ConduitPI to PI Process Data Conduit

Performance CenterESO - DetroitPI

PI

Belle River

PI

St Clair

PI

GreenwoodPI

Harbor Beach

PI

River Rouge

PI

Trenton Channel

PI

Monroe

PI

PIEMS Ranger

Ann Arbor


Energy Management System (EMS)Energy Management System (EMS)

The Plant Energy Management System is used to automatically control unit dispatch

Implements data validation on all fields

Performs several calculations based on PI data to determine validity of inputs.

Transported to EMS Ranger via PI


Before Fuel Cost FrameworkBefore Fuel Cost Framework

EMSRanger

PI

PI to PI

MarketTrades

Gas__________

Oil__________

Coal__________

Emissions

Fuel Supply

Fuel Cost

GasOil

CoalEmissions

EmailFax’sPhone

Manual Process

Email To19

UnitsOps

PlantPI

Type, Type, Oops

Manual Process

Manual Process

No sys error checking

CalculatesFuel

BlendScenarios

&Business

Logic

Gen. Ops.

Fuel Cost

GasOil

CoalEmissions

Email

Manual Process

Manual Process


Fuel Cost FrameworkFuel Cost Framework

RangerPI

Ann Arbor

5

ps-mon-pi

ps-tch-pi

ps-rrg-pi

ps-blr-pi

ps_hbh_pi

ps-grw-pi

ps-stc-pi

4

Blend Calculations

Blend Calculations

Blend Calculations

Blend Calculations

Blend Calculations

Blend Calculations

Blend Calculations

Default ModeAuto calculate & update Ranger

Hourly & DailyAuto update

Market Data

Gas -- Dawn & Michcon City Gate

Gas & Oil Price at Hubs

Oil

ESO PI ps-eso-pi

1

Current &

Historic Data 2

Fuel Supply

Analysisand

Acquisition

Current Fuel Cost

3

Improvements… • 30 to 3 people• Timely data entry• Zero errors


PI to PI (AGC)PI to PI (AGC)

AGC – Automatic Generation Control6 largest Fossil units & Peaking Units are ramped through PI Set Point control









90%

90%

Drive Performance ExcellenceFleet Optimization

DrivePerformanceExcellence


Easy Access to Information 100%

ABB

Fleet Perspective• Methods• Applications

Involves• Operation• Performance• MISO Market• Reliability• Maintenance• Reporting• Budget



Fleet Status – PI WEB enabledFleet Status – PI WEB enabled


Real-Time DCS Operator Displays Real-Time DCS Operator Displays

6000 real time dynamic actively linked WEB DCS graphics

Click & Trend


PI enabled - Event Re-playPI enabled - Event Re-play

Re-play events using historical PI data


Mobile Work ForceMobile Work Force

Mobile Work ForcePI WEB reports availableon your BlackBerry


Reporting – 4 BlocksReporting – 4 Blocks






Large Population of Data 90%

System DashboardsFleet Status Assessment 90%




Process Discrete Data 90%

ABB



System Dashboards – PI EnabledSystem Dashboards – PI Enabled

2000 real time dynamic actively linked WEB System graphics

Click & Drill













MBO/PdM/Risk Assessment 60%

ABB



Equipment Condition MonitoringEquipment Condition Monitoring


Equipment Condition MonitoringEquipment Condition Monitoring

Similarity Based Modeling


SmartSignal – ECM 2006SmartSignal – ECM 2006

SmartSignal Installations(26 Units)

Monroe Unit 1Monroe Unit 2Monroe Unit 3Monroe Unit 4

Trenton Channel 7Trenton Channel 8Trenton Channel 9

River Rouge 2River Rouge 3Belle River 1Belle River 2

St Clair 1St Clair 2St Clair 3St Clair 4St Clair 5St Clair 6St Clair 7

Greenwood 1Harbor Beach 1

10 Combustion Turbines

EquipmentAir HeatersCondenser

BoilerTurbineID FansFD FansPA Fans

Boiler Feed PumpsGeneratorPulverizes

Feed water Heaters


EPI Center Live – October 2008EPI Center Live – October 2008

SmartSignal EPI Center- 1200 Models- 74 Assets- 140,000,000 data points reviewed

ECM - EPI CENTER MIGRATION PROCESS

INVENTORYASSETS

&STANDARDIZE

STD CLASSES

(DEFINITION)

STANDARDIZENAMINGASSETS

DESCRIPTORS

VALIDATETEMPLATES

&CLASSES

APPLYCLASSES

TEMPLATESPI -ALIASES

CONSULTSME,GPA,

SO

MAKECHANGES TO

PI TAGS

MODELEXIST?

REQUESTEXIST?

GIVEPRIORIT # 1

CHECKTHE

MODEL

NEEDCHANGE

CREATEMODEL

SETPRIORITIES

CONSULTSME,GPA,

SO

CONSULTSME,GPA,

SO

APPLYSTATISTICAL

TOOLS

PLACE ONDEV

ACCEPTPERF

PUT INTOPRODN

ECM

EPICENTER

YES

NO

YES

YES

NO

NO

NO

YES

Migration Process

U1_CPC01 CONDENSER_MU_WATERBOX_A_INLET_TEMP_1

CONDENSER_1COMPARTMENTTAG NAME (ALIAS)

GROSS_LOADAMBIENT_AIR_TEMPERATURE_1AMBIENT_AIR_TEMPERATURE_2AMBIENT_AIR_TEMPERATURE_3AMBIENT_AIR_TEMPERATURE_4AMBIENT_AIR_TEMPERATURE_5BAROMETRIC_PRESSCONDENSER_MU_BACK_PRESSURE_1CONDENSER_MU_BACK_PRESSURE_2CONDENSER_MU_A_SAT_TEMPCONDENSER_MU_B_SAT_TEMPCONDENSER_MU_TERMINAL_TEMP_DIFF_1CONDENSER_MU_TERMINAL_TEMP_DIFF_2CONDENSER_MU_HOTWELL_CONDENSATE_TEMP_1CONDENSER_MU_HOTWELL_CONDENSATE_TEMP_2CONDENSER_MU_HOTWELL_LEVEL_1CONDENSER_MU_HOTWELL_LEVEL_2CONDENSER_MU_LP_TURB_EXHAUST_TEMP_1CONDENSER_MU_LP_TURB_EXHAUST_TEMP_2CONDENSER_MU_HOTWELL_DISSOLVED_O2CONDENSER_MU_CONDENSATE_DISSOLVED_O2CONDENSER_MU_HOTWELL_CATION_CONDUCTIVITYCONDENSER_MU_CONDENSATE_SODIUM_CONCCONDENSER_MU_CONDENSATE_PHCONDENSER_MU_CONDENSATE_FLOW_ACONDENSER_MU_CONDENSATE_FLOW_BCONDENSER_MU_MAKE_UP_FLOWCONDENSER_MU_EMERGENCY_MAKE_UP_FLOWCONDENSER_MU_FWH_DRAIN_VALVE_POSITION

Module Database (PI ModuleDB)PI Module Database sorts PI System contents into useful groups;

helps organize real-time data, stores parameters or specifications,

and makes them ready for use in programs and displays.


Combustion Optimization – NeuCo Combustion Optimization – NeuCo

Objective – Coal pile to stack Optimization– Closed loop Neural Net Optimization– In Service St Clair Unit 7 (Neural Mode July 2008)

– Installation in progress on Belle River 2 (September 2008)

– Planned for Monroe Units 1-4 (High PRB Utilization Project)


Process Alarm Analysis Fleet wide Process Alarm Analysis Fleet wide














Business IntelligenceOutage & De-rate (UCF)Maintenance & Market 25%

ABB



RealTime

MarketStrategy

Day Ahead

Unit Capacity Framework (UCF)Unit Capacity Framework (UCF)

Power Plants Market

Process Flow

Market Feedback

MerchantCenter

Performance Center


Unit Capacity Framework (UCF)Unit Capacity Framework (UCF)

• Manages all Unit Capacity and De-rates - Interfaces to MISO, P3M & EMS• Automatically Generated Status Report (Availability on BlackBerry)• Dynamically linked with Outage and de-rate process


Enterprise Business Systems (EBS)Enterprise Business Systems (EBS)

SAP– Financial Information– Human Resources– Supply Chain

Maximo– Work Management System














Business IntelligenceOutage & De-rate (UCF)Maintenance & Market 25%

Fleet Optimization

Process CostsAsset Health,Market Value 15%

ABB


People Making right decisions when it matters!


No Shortage of Information!No Shortage of Information!

Work Management

SAP

De-rateManagement

PI Data Historian

Fuel Cost

Ancillary Services

MISOReal Time

MISODay Ahead

EmissionsMonitoring

CombustionOptimization

EmissionsMonitoring

LaboratoryInformation

PerformanceAnalysis

AlarmsOutage

Planning

Unit Capacity

ProjectManagement

DocumentManagement

OperatorLogs

EPRIPlant View


Common MethodologyCommon Methodology

Application Framework: Integrated applications environment:

Consistent framework for data, analysis, reporting and consistent

user graphical interface.

Standard GUISingle Method

PI Data Historian

EmissionsMonitoring

CombustionOptimization

ECGAccuTrack

LaboratoryInformation

PerformanceAnalysis

Alarms OperatorLogs

EPRIPlant View

Process Information

Work Management

SAP

ProjectManagement

DocumentManagement

Business Systems

De-rateManagement

Fuel Cost

AncillaryServices

MISOReal Time

MISODay Ahead

OutagePlanning

Unit Capacity

Market Data


Common StructureCommon Structure

Process Information Market DataBusiness Systems


Fleet Performance Fleet Performance

Pulverizer DashboardProcess Information

More information is need for Analysis


What information is needed?What information is needed?Pulverizer

– Milling Costs

– Process Costs

– Production Costs

– EAF

– SmartSignal Watch List

– Work Performed & Work Pending

– Alarms

Pulverizer AssessmentPulverizer Assessment


Pulverizer Multiple Data SourcesPulverizer Multiple Data Sources

Consistent Reporting• Common Methodology• Common Structure

PI

Alarms

P3MSAP

SmartSignal

Maximo

Documentum

EPRI PlantView

Unit Capacity


Common Thread - Equipment HierarchyCommon Thread - Equipment Hierarchy

Equipment Hierarchy Hierarchical System Index (HSI) Work Breakdown Structure (WBS)

Primary System

Secondary System

Sub SystemEquipment

Sub Equipment


Pulverizer - Multiple Data SourcesPulverizer - Multiple Data Sources

Consistent Reporting• Common Methodology• Common Structure

PI

Alarms

P3MSAP

SmartSignal

Maximo

Documentum

EPRI PlantView

Unit Capacity


Expanded System DashboardExpanded System Dashboard

PI

DCS

SmartSignal Watch List Alarms

Trends

KPI’s

Health

Health Assessment


Plant Summary

Heat Rate

Production Costs

Dispatch Costs

EAF

Process Cost Drill DownProcess Cost Drill Down

Milling Costs

Unit Summary


Expanded System DashboardExpanded System Dashboard

PI

DCS

SmartSignal Watch List Alarms

Trends

KPI’s

Health

Health Assessment


Logical Display FlowLogical Display Flow


Fleet OverviewFleet Overview


Plant OverviewPlant Overview


Unit OverviewUnit Overview


Coal MillCoal Mill


Coal Mill Health StatusCoal Mill Health Status


Total Fleet ManagementTotal Fleet Management

Real-timeProcess Applications

Distributed Control Systems (DCS) Distributed PI Historians

WEB Portal

SME Status Displays

Applications

Expert Systems

FinancialsWork Management

SAP Maximo

Market

MISO, Fuel Coat Framework

Unit Capacity Framework

Drives Performance Excellence Process CostsAsset Health

Operational Performance Market Value

Fleet Optimization


DTE Energy - A Technology LeaderDTE Energy - A Technology Leader

Contributed to DTE’s recognition as a technology leader in North America.

Performance Center Tours -- Global visitors

Conference Presentation (past 12 Months)

– User Conferences -- SmartSignal, NeuCo, Matrikon, Coal-Gen, OSIsoft,

– Gartner, Inc. (NYSE: IT) is the world’s leading information technology research and advisory company.

– Vattenfall Workshop Copenhagen Denmark November 2007

– Marcus Evans Asset Management February 2008

– Electric Power 2008 Conference May 2008

Awards & Recognitions

– M2M Gold Award (Manufacturing Category)

– Matrikon (Most Visionary Initiative)

Articles

– Power Engineering October 2006

– Control December 2007


DTE Energy - A Technology Leader

Presentations, Articles & Awards


Benefits - OSIsoft Enterprise AgreementBenefits - OSIsoft Enterprise Agreement

Product usage– Expansion (SmartSignal, Modual DB, IT Monitor)

– Regularity requirements (NERC CIP)

Premium Software Reliance Program– Manage PI (Continuous Health Assessment)

– Easy Access to “Experts”– Upgrades, revisions– Standardization

Engineering Support– Migration Path– NERC CIP

Budget


ProcessNet DemonstrationProcessNet Demonstration

People Making the right decisions when it matters!

Fleet Optimization is about ……

74© 2008 OSIsoft, Inc. | Company Confidential74

QUESTIONS?QUESTIONS?


Documents

© 2008 OSIsoft, Inc. | Company Confidential Helping People make the right decisions …….. when it matters! John C. Kapron Sr. Technical Specialist DTE Energy,