Fleet Performance and Reliability in Generation Utilities

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

2. Energy Management Suite Siemens IT-Solutions and Energy

3. Combining Technical and Business Information with Siemens Energy Management Suite Power Plant 1 Power Plant 2 Power Plant n QUALITY Efficiency 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) Shift Management Instrumentation Alarming 1) Available in 2008

4. Power Plant 1 Power Plant 2 Power Plant n Enterprise Wide Decision Support Executive Management Technical Competence Center • User Community • Executive Management • Power Plant Management • Production Management • Technical Management ProductionManager Power PlantManager • Systems • Plant Systems • IT systems . . . Scheduling DCS Internet Process DataArchive Databases EnergyTrading SAP ERP Intranet Multiple Generation Locations

5. 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 visibilityto plant operationsand metrics Energy Management Suiteis the bridge between plant operations and the business

6. 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 2 Power Plant 3 Power Plant 1 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.

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

8. 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

9. Enterprise Information Center– Utilizing the SAP Enterprise Portal and eSOA • Enterprise Information Center • 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

10. 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. MasterData, Maintenance and Materials • Management) integrated with SAP ERP Savings 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

11. Siemens Energy Management Suite - Early Warning System for Diagnostic and Technical Performance Management • PredictiveDiagnostic 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 • 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%

12. Fleet Dash Board Siemens Energy Management Suite- Expert System for Generation Planning and Monitoring • 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

13. 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

14. Energy Management Suite - Customer Value Customer Experience Customer Benefits • 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 • Highly innovative solution package • integrating production, business processes • and metrics. • Faster and improved supportfordecision • 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