Mitsubishi Heavy Industries Technical Review Vol. 56 No. 3 (September 2019)
1

MHPS-TOMONI®: Sophisticated Power Plant Operation
through Digital Solutions

DAIJIRO HIRASAKI*1

AKIHISA ENDO*2ITARU ENDO*3

Mitsubishi Hitachi Power Systems, Ltd. (MHPS) has offered remote monitoring services forthermal power plants as digital solutions since 1999. As the efficient operation of power plants is
becoming ever more important, in 2007 MHPS achieved advanced plant operation by improving
availability using an anomaly detection system.
As another milestone in the digital solutions journey, in March 2017 “MHPS-TOMONI®”
was launched, and the operational data of operating power plants around the world is being
analyzed to promote the development of applications that can address customer businesschallenges. This paper gives an insightful introduction of MHPS-TOMONI®, a digital solution
developed by MHPS that is being applied to actual power plants in the field.

|1. Introduction
MHPS-TOMONI® is a comprehensive digital solution including an analytical platform
developed for the optimization of power plant operation. “TOMONI” is the Japanese word for“together with” and reflects our "customer first principle" to solve problems together withcustomers. This paper presents MHPS-TOMONI®, which we have been researching, designing,
implementing, and enhancing to meet the diversifying needs of customers in changing businessenvironments, such as the increasing use of renewable energy, saving manpower, and expanding
the need for technology transmission.
We operate customer portal sites that provide service information to customers with service
contracts, and provide a wide range of information such as technical bulletins, monthly operational
reports, mounted parts information, etc. In addition to such information, customers who haveintroduced MHPS-TOMONI® are able to obtain information on analysis and diagnosis results, etc.,
in a more timely manner. Through MHPS-TOMONI®, MHPS offers the three values of O&M
optimization, performance improvement and flexible operation to customers (Figure 1).

Figure 1 Three advantages of MHPS-TOMONI®

*1Group Manager, Project Engineering Department, Power & Energy Solution Business Headquarters, Mitsubishi Hitachi Power*2Engineering Manager, Power & Energy Solution Business Headquarters, Mitsubishi Hitachi Power Systems,Ltd.

*3

Power & Energy Solution Business Headquarters, Mitsubishi Hitachi Power Systems,Ltd.

Systems,Ltd.

Mitsubishi Heavy Industries Technical Review Vol. 56 No. 3 (September 2019)2We are promoting application development for gas turbines, boilers, steam turbines,generators, air quality control systems (AQCS) and other plant auxiliary equipment to enable
information analysis and to provide solutions throughout the plant.
As a comprehensive manufacturer that has been involved in the field of thermal power
generation for many years, MHPS used its expertise to provide solutions that meet the businesschallenges of customers based not only on the latest AI technology and statistical processing, butalso on our accumulated EPC expertise.

|2. Digital platform
MHPS-TOMONI® is a cloud- and edge-based system. The cloud offers the built-inapplications, which can be accessed via the Internet, and that provide services such as data analysis
and visualization. On the other hand, the edge-based part of the system carries out datatransmission from the power plant to our company cloud with high data security through theinstallation of the "Netmation Secure Gateway (NSGW)" edge device developed by our company.
In addition, we are developing equipment that is to be installed on the edge side and has function totransmit sampling data more frequently and to link information with the cloud with high affinity.
The above analysis platform consists of three layers: ICT foundation, high-precision AI
application and service application. (Figure 2)

Figure 2 MHPS-TOMONI® platform

2.1

ICT foundation

MHPS concluded a partnership agreement with Microsoft and OSIsoft to establish an ICT
platform for storing power plant operational data safely and developing value-added applications
thereon. Microsoft Azure Cloud is used by a wide range of users irrespective of industry, andfeatures highly-reliable security. OSIsoft PI System has been the de facto standard in the plantindustry including power generation as a data historian (software for data accumulation andvisualization), and is used by many power producers. By using software that is highly compatible
with our customers, we built an environment in which information can be linked more quickly.

2.2

High-precision AI application

Anomaly detection using statistical methods works at this layer. In addition, asset models
used for thermal efficiency calculation and product life analysis of power plants are also
implemented in this layer.
Furthermore, a mechanism that links structured data and unstructured data and automaticallydetermines how a power plant nonconforming event is caused using sensor data and the fault tree
analysis (FTA) database is also implemented in this layer.

Mitsubishi Heavy Industries Technical Review Vol. 56 No. 3 (September 2019)
32.3

Service application

We defined three values for power producers, O&M optimization, performance improvement
and flexible operation, and planned applications based on these categories. For example, for aservice application for thermal power generation, monitor not only gas turbine hot gas path parts
that require life management, but also about 60 items including consumables and replacements
parts of the major equipment. It also calculates the stress developed in the parts based on theoperation mode to calculate the optimal timing for part replacement. In addition, for thedevelopment of the GUI (Graphic User Interface), we collaborated with the Advanced Design
Center of Mitsubishi Heavy Industries, Ltd. and external design companies to study user
friendliness based on ergonomics and analyzed when, by whom and in what situation is theapplication used.

|3. Cyber security
Thermal power plants are important pieces of infrastructure that provide electricity, anessential utility and lifeline, so ensuring the cyber security needs to be considered as a top priority.
MHPS-TOMONI® ensures security as follows.
The cloud foundation of MHPS-TOMONI® complies with ISO/IEC27017 and NIST800-53.
The security measures (i.e., firewall, encryption, vulnerability management, security patch update,and log monitoring) of the National Institute of Standards and Technology (NIST))
characteristically require two-factor authentication for access.
On the other hand, the communication between the thermal power plant and the cloud isencrypted. By restricting access to both sides by using authentication with digital certificates, allcommunication connections – especially to the power plant – are blocked. Furthermore, to ensure
the security measures of the plant side control network, NSGW is installed. Its data diode (one-waycommunication) function permits data transmission only from the power plant side to the outside,and access from outside the power plant is physically blocked. In addition to the one-way
communication function, NSGW permits limited communication from the outside to the insidewith a serial cable, realizing flexible operation while maintaining high-level security (Figure 3).

Figure 3 Cyber security of MHPS-TOMONI®

|4. ICT services and applications for thermal power plants
4.1

Remote monitoring service

MHPS established remote monitoring centers at Takasago Works in 1999 and in Orlando,
USA in 2001, and our specialized staff provide remote monitoring services for GTCC (gas turbinecombined cycle) power plants on a 24-hour basis. We established remote monitoring centers in thePhilippines in 2016 and at Nagasaki Works in 2019 as new monitoring bases, and also launchedremote monitoring services using MHPS-TOMONI® mainly for steam power plants (Figure 4).
Currently, these remote monitoring centers monitor about 150 power generation facilities aroundthe world, mainly including large gas turbines, to provide customer operational support. The
infrastructure of the remote monitoring centers in the Philippines and Nagasaki Works is based on
the MHPS-TOMONI® cloud, and other centers are also gradually transitioning to its use orinterconnecting one after another aiming at global deployment.

Mitsubishi Heavy Industries Technical Review Vol. 56 No. 3 (September 2019)
4Figure 4

4.2

Remote monitoring centers of MHPS-TOMONI®

ICT applications

MHPS-TOMONI® provides the solutions using ICT and covers the entire thermal power
generation field. Figure 5 gives examples of these solutions. These solutions were developed basedon operational data, information on nonconformities and countermeasures obtained from all over
the world, and were prepared to realize the optimum operational pattern for the fleet compatible
with each product model.
Each solution will not only provide value through ICT software, but also provide optimal
solutions based on the customer's business goals, such as the proposal of the modification of themajor equipment through optimization.
MHPS has prepared customer portal sites that provide service information to customers witha service contract, and MHPS-TOMONI® provides functions via these customer portal sites.

Figure 5

Solution examples of MHPS-TOMONI®

Figure 6 shows the ICT solution examples for GTCC. We make the best mix of solutions
based on customer value.
(1) Anomaly detection
Early detection of abnormalities using various APR (Advanced Pattern Recognition)technologies. Detects signs of abnormalities before protective operation of the controller andprovides preventive measures.
(2) Operational support for abnormalities
Supports and guides operators in the central control room by providing
countermeasure instructions when alarms are initiated. The latest countermeasures from theMitsubishi Heavy Industries Technical Review Vol. 56 No. 3 (September 2019)5

cloud database are provided, making it unnecessary to look them up in a paper manual.
(3) Performance degradation analysis
Analysis of the cause of deterioration of major equipment (GT/ST/HRSG/generator)
and performance of the entire GTCC. Performance analysis of the GTCC is possible throughthe use of the latest heat balance calculation technology.
(4) KPI (Key Performance Indicators) Monitoring
Through the use of web technology, the key performance indicators of the power plant
are monitored and displayed on mobile terminal devices, etc. In addition to real-time
information on a specific power plant, the availability rate and deterioration status comparedwith other fleets are monitored.
(5) Enhancement of inspection work
Monitoring the abnormalities of plant auxiliary equipment and motors using electricalcurrent analysis technology. Abnormal trends can be determined by measuring the electricalcurrent of on-site motors (motors for pumps, motors for small compressors, etc.).
(6) Optimization of periodic inspection timing
The timing of periodic inspections is optimized based on the operational pattern anddeterioration state of the main equipment, as well as the load applied to individual parts.
(7) Optimization of water quality management
The system automatically presents current issues and improvement plans bymonitoring and analyzing the water quality of the raw water, waste water, circulating waterand boiler feedwater, which results in optimized water and chemical consumption.
(8) Enhancement of control equipment (MHPS-TOMONI® Edge Enabler)
A solution package that utilizes MHPS-TOMONI® Edge Enabler, which wasdeveloped as an enhancement for OT (Operational Technology). The customer can select theuse of the optimization program arbitrarily.
(9) AI-CPFM (Combustion Pressure Fluctuation Monitoring system)
A new combustion vibration avoidance system equipped with AI (machine learning).
Further advanced combustion optimization technology is provided.

Figure 6

MHPS-TOMONI® service package examples

An example of an application using the aforementioned anomaly detection function ispresented hereinafter. The anomaly detection system (Pre-ACT) provided by MHPS was originallydeveloped independently and applied based on the proprietary MT method (Mahalanobis Taguchimethod) used for remote monitoring services. It consists of two functions: anomaly detection andMitsubishi Heavy Industries Technical Review Vol. 56 No. 3 (September 2019)
6failure point prediction. The MT method manages the correlation of multiple signals with one index(MD: Mahalanobis Distance). The system predicts anomalies before the threshold value of thealarm or protective function provided in the device for each sensor signal is exceeded, andcontributes to preventive measures based on early detection and the improvement of the monitoringefficiency. The failure point prediction program has a mechanism for automatically predicting
nonconforming points based on pattern matching between the behavior of sensor signals (SN ratio)
and nonconformity events in the nonconformity database (learning database), as well as one formaking notification of inspection items for the predicted nonconformity via email and the web.

Figure 7

Functional overview of Pre-ACT|5. Conclusion
MHPS-TOMONI® was launched in March 2017 as a digital solution for power plants.
Value-added applications implemented in the cloud, such as technology to derive optimal
operational control based on an analysis of operating conditions, anomaly detection technology
using artificial intelligence (AI) and statistical methods, and technology to derive deterioration
trends and countermeasures based on advanced heat balance calculation, have grown rapidly inrecent years. Simultaneously, a device (NSGW) that transmits information issued by the mainequipment of a power plant while ensuring high-level security was developed, and we have started
providing digital solutions that stand out from our competitors to our customers around the world.
Aiming at autonomous operation of thermal power generation facilities, we will further
expand digital solutions, and develop and provide solutions that respond to the fast-changing
electric power business in the aspects of hardware and software to contribute to the sustainablegrowth of society.
MHPS-TOMONI is a registered trademark or trademark of Mitsubishi Hitachi Power Systems, Ltd. inthe United States and other countries.

References(1)(2)

H Aiki, et.al., Boiler Digital Twin Applying Machine Learning, Mitsubishi Heavy Industries Technical
Review Vol. 55 No. 4 (2018)
H Ishigaki, et.al., MHPS-TOMONI: Thermal Power Generation Digitalization
Platform Cloud/Edge Service and System Architecture，Mitsubishi Heavy Industries Technical Review
Vol. 55 No. 4 (2018)