1

PI : Information on hand for

Operational Analytics

Presented by: Ranjith Ramachandran

Chandra Prakash Dewangan

AGENDA

3

• Information Enhancement • ABT System. • Auto Reports. • Enhancement of data.

• Performance Monitoring, Analysis & Improvement • Plant Performance Monitoring. • Plant Performance Improvement.

Trombay Haldia Jojobera Hydro

Central PI

Enterprise Systems

Wind

PI System Integration

Mundra T&D Maithon

- Existing

- Proposed

Legend

TROMBAY SERVER

JOJOBERA SERVER

BHVP U1 U2 U3 U4 PH#6

HALDIA SERVER

U1 U3 U4 U5 U6 U7 U8

MIS / HYPERION

LD KHP

HYDRO SERVER

MAITHON SERVER

MUNDRA SERVER

BHIRA

CENTRAL PI SERVER

BELGAUM LODHIVLI ABT

T&D SERVER (DHARAVI)

SCADA DAS AMR

U2

WIND SERVER

RDBMS INTERFACE

PI System - Network

MULSHI 3MW

ENERCON SUZLON REGEN U1 U2

U5 EMS

PI-PI INTERFACE

TATA POWER WAN

U1 U2 U3 U4 U5

PI System Monitoring

PI System Monitoring

PI System Monitoring

ABT SYSTEM

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∗Acquisition of data from ABT System deployed for Mumbai Operations.

∗Accurate, reliable and wide acceptance. ∗My SQL database in the backend. ∗Web client with limited features available for

monitoring. No tools for analysis purposes. ∗Not possible to import data into excel. ∗ Report creation facility is not available.

ABT System

∗ RDBMS Interface connectivity with PI server ∗ Immediate and time triggered data collection. ∗ Easier to import into excel sheet for analysis. ∗Displays and trend making with ProcessBook. ∗ Report creation became error free and less

time consuming ∗ Reports from PI being utilized by Load Control

Centre for planning and forecasting.

Integration of ABT System with PI

AUTOMATED REPORTS

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Daily operational and maintenance report on E-mail Created Visual Basic application which utilizes PI DataLink to generate reports.

Reports are in MS Excel format. The values are available as static. Hence, no need of PI DataLink on the recipients computer. Reports saved on a network drive.

E-mail the report using PI notifications to a list of recipients by setting time based triggers.

Automated Reports

Automated Reports

ENHANCEMENT OF DATA QUALITY

2

Solution to Energy Meter commn. error

Energy meter communication problems during shutdown which results in error of the source data affecting calculations .

Before

TR U7 SATE 8.9014E+07KWH

15/12/2010 5:21:55 AM15/12/2010 12:00:00 AM 5.37 hours8.882E+07

8.884E+07

8.886E+07

8.888E+07

8.89E+07

8.892E+07

8.894E+07

8.896E+07

8.898E+07

8.9E+07

8.902E+07

Created a performance equation for storing the last reading of the energy meter and the same tag used for energy calculations.

After

Solution to Energy Meter commn. error

TR U7 SATE 8.9014E+07KWH

15/12/2010 5:21:55 AM15/12/2010 12:00:00 AM 5.37 hours8.88E+07

8.885E+07

8.89E+07

8.895E+07

8.9E+07

8.9029E+07

Energy Meter reset

Energy meter resets to zero after reaching the maximum of cumulative reading which affects energy calculations.

Before

Result : Negative

Added a condition in performance equations to check for a meter reset for the entire day and provided two methods of calculation using an IF clause.

After

IF (TAGVAL('TR U7 SATEC STG KWH NO ERROR','T')-TAGVAL('TR U7 SATEC STG KWH NO ERROR','Y'))<0 THEN (TAGMAX('TR U7 SATEC STG KWH NO ERROR','Y','T')-TAGVAL('TR U7 SATEC STG KWH NO ERROR','Y')+TAGVAL('TR U7 SATEC STG KWH NO ERROR','T'))/1000000 ELSE (TAGVAL('TR U7 SATEC STG KWH NO ERROR','T')-TAGVAL('TR U7 SATEC STG KWH NO ERROR','Y'))/1000000

Modified PE

Result : Accurate

Energy Meter reset

Single tag for OPC interface status based on a particular watchdog. No direct monitoring over the data received from various functional areas.

Before

OPC Server PI ICU

PI Server PI Interface

Watchdog tag OPC tag Interface status

Multiple interface status

Multiple interface status

Introduced the concept of multiple interface status tags using multiple watchdog from different functional areas.

Better monitoring over the plant. Improved the availability of plant data. Helps the plant engineers for immediate identification of the

affected area.

After

OPC Server PI ICU

PI Server PI Interface

Watchdog tag OPC tag Interface status

Watchdog tag OPC tag

Watchdog tag OPC tag

Watchdog tag OPC tag

OR

Trigger based PE

Performance equations was clock scheduled and it was consuming more computing power and memory.

It was not possible to output results at a pre defined time.

Created Triggers for the desired time.

Used triggers for event triggering of the calculated tags.

Calculations are performed only onetime in a day which greatly reduced the system load and made the results accurate.

Before After

THERMAL POWER PLANT PERFORMANCE MONITORING

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PI Data used for Monitoring Plant Performance “Before & After” Performance Analysis Boiler & Turbine Efficiency Monitoring Monitoring of Design vs. Actual Performance Performance Analysis at different operating conditions Dashboard / Report having Last Hour, Today, Last Day &

Monthly data.

Performance Monitoring

Performance Monitoring - “Before & After” Analysis

Performance Monitoring - Boiler & Turbine Efficiency

Performance Monitoring - Design vs. Actual

Performance Monitoring – Diff. operating conditions

Performance Monitoring - Dashboard

PERFORMANCE IMPROVEMENT INITIATIVE -

SANKALP

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SANKALP

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• Structured, Time bound, Team based program with top management support & bottom up approach to impact the company’s bottom line with minimal investment in shortest possible time.

• Uses the creativity and energy of the people of Tata Power and all its stakeholders

• Utilizes Online Data from PI System to take informed decisions.

Online Data for 500 MW Coal Fired Unit

History Data for analysis

MS Temp

520.0

525.0

530.0

535.0

540.0

545.0

550.0

555.0

4:25 PM6:25 PM

8:25 PM

10:25 PM

12:25 AM2:25 AM

4:24 AM6:24 AM

8:24 AM

10:24 AM

12:24 PM2:23 PM

4:23 PM6:23 PM

8:23 PM

10:23 PM

12:22 AM2:22 AM

4:22 AM6:22 AM

8:22 AM

10:21 AM

12:21 PM2:21 PM

Date & time

Temp

0.0

2.0

4.0

6.0

8.0

10.0

12.0

SH Temp SH Temp SH Spr

Trend format for analysis

Unit 8

70.0

90.0

110.0

130.0

150.0

170.0

190.0

210.0

230.0

250.0

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95

-400.0

-350.0

-300.0

-250.0

-200.0

-150.0

-100.0

-50.0

0.0

Load Cur Avg Suc Pr Avg

Last 100 Data only captured in Graph

Trend format for analysis

Predictive Analysis

Questions