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IntroductionHeat RateFuel TrackingFrequency Analysis PI Applications at First Energy with PlantView...
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Introduction Heat Rate Fuel Tracking Frequency Analysis PI Applications at First Energy with PlantView 2000 TM Ron Carson, First Energy Corp. Jim Scavuzzo, Engineering Consultants Group Inc. Introduction
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Transcript of IntroductionHeat RateFuel TrackingFrequency Analysis PI Applications at First Energy with PlantView...
Introduction Heat Rate Fuel Tracking Frequency Analysis
PI Applications at First Energy
with PlantView 2000TM
Ron Carson, First Energy Corp.Jim Scavuzzo, Engineering Consultants Group Inc.
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
Outline
• Who is First Energy
• PI installation at First Energy
• Who is ECG
• PlantView 2000
• Applications:– Heat Rate Monitoring– Digital Fuel Tracking– On-Line Condition Monitoring & Analysis
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
Who is First Energy
• 12th Largest Utility in USA.• Formed in 1998 by the merger of Ohio
Edison and CEI.• Additional Facts:
– 2.2 million customers. – 13,200-square-mile service area in
central and northern Ohio and
western Pennsylvania. – $5 billion in annual revenues and more
than $18 billion in assets. – Nearly 12,000 megawatts of generating capacity. – 7,500 miles of transmission lines, and 35 interconnections with 8
electric systems.
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
PI installation at First Energy
• Base PI Phase I system installed at 10 power plants.
• Presently 90,000 tags in operation.• Interfaced with 7 different DCS/DAS systems
including 4 custom PI-API interfaces.• Phase II PI installation at remaining 5 plants to
be completed in 1999.• Anticipate completed system to approach
200,000 tags.
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
PI Project Objectives
• Improved Decision Support
• Enhanced equipment and process troubleshooting capability
• Improved asset/resource utilization
• Reduced plant clerical load and improved input quality
• Facilitate for distributed deployment of technical staff
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
Custom PI Applications
• Custom applications emphasize the true power of PI.
• Need a powerful and easy to use middle-ware software application for migrating data and performing complicated calculations.
• Standardize the plants and applications on a single middle-ware package.
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
Who is ECG
• Engineering Consultants Group.• Formed in 1990, ECG has focused on
process control, testing, monitoring and analysis.
• Consulting with FEC since 1992, concentrating on solving power generation related problems.
• Working with FEC to migrate their legacy systems to PI and develop new PI application uses.
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
PlantView 2000TM
• PlantView 2000 is the solution to the transport and manipulation of vital company/plant data.
• Features:– Open development environment utilizing Visual Basic
technology.– Transportation of data from external sources (database,
field DAS, manual inputs, etc.) to PI.– Host for advanced logic and mathematical calculations.– Integrated data validation to ensure only “good”
information is used in the application.– Method to import manual data from operator logs.– Migration of legacy calculation/software to PI.
Introduction
Introduction Heat Rate Fuel Tracking Frequency Analysis
Real-Time Heat Rate Monitoring
• Requirements:– Standardized core system easily configured for
each plants eccentricities.
– Calcs easily modified.
– Ready interfaced to PI for data acquisition and company-wide presentation of results.
– Use of as much legacy system as possible.
– Number of points may include 250 inputs and 500 calculated outputs on a single generation unit.
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Integration Obstacles Solved using PlantView
• Provides Integrated Data Validation
• Provides Calculation Environment– Real-time debugging is necessary for large
calculation systems– Allows access to third party libraries for steam
tables.
• Provides Interface to PI for Inputs & Calculated Outputs
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Data Validation ExampleExtraction Steam (T,P)
FWout (T) FWin (T)
Drainout (T)Drainin (T,W)
Process Diagram
H3hsi = 1328.4 W3hsi = 79865.9H3hso = 388.8 W3hso = 176599.7H3hwi = 370.0 W3hwi = 1135000H3hwo = 443.0 W3hwo = 1135000
Ext Flow = (FW Flow * ( FW Delta H) - Drain Flow * (Drain Delta H)) / (Ext Steam Delta H)
Process Equation
Programming Environment
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Data Validation Example
FW Flow
FW Out Temp f(x)
FW In Temp
Ext SteamTemp
Drain Temp
Ext SteamPress
f(x)
f(x)
f(x,y)
14.7
+
x
+
+
/ Extraction Flow
-
+
+
-
Energy givenup by Steam
Energy toFeedwater
Gage toAbsolute
Raw Signalfrom DCS (PI)
EnthalpyCalculation
Six inputs are used to calculate a singe output.
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Data Validation Example
FW Flow
FW Out Temp f(x)
FW In Temp
Ext SteamTemp
Drain Temp
Ext SteamPress
f(x)
f(x)
f(x,y)
14.7
+
x
+
+
/ Extraction Flow
-
+
+
-
Energy givenup by Steam
Energy toFeedwater
Gage toAbsolute
Raw Signalfrom DCS (PI)
EnthalpyCalculation
X XIf any of the inputs are lost, the result of the calculation system is not valid.
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Data Validation Example
FW Flow
FW Out Temp f(x)
FW In Temp
Ext SteamTemp
Drain Temp
Ext SteamPress
f(x)
f(x)
f(x,y)
14.7
+
x
+
+
/ Extraction Flow
-
+
+
-
Energy givenup by Steam
Energy toFeedwater
EnthalpyCalculation
X
Valid
Load Based Default
Invalid
Load Based Default
Valid
Load Based Default
Valid
Load Based Default
Valid
Load Based Default
Valid
Load Based Default
Invalid inputs are replaced by Default Values estimated by the overall load of the mechanical system. The Extraction flow is estimated using five actual inputs and one load-dependant Default Value.
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Integrated Data Validation Tool
Load Based Defaults
Defaults Adjusted per Point
Adjustable Query Time Range
Least Square Curve Fit
Graphical Interface
Point Correlation Tool
DefaultError
WindowDefault Points
Graphical Adjustments
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Real-Time Debugging
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Client Interface using Excel & DataLink
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Client Interface using ProcessBook
Heat Rate
Introduction Heat Rate Fuel Tracking Frequency Analysis
Digital Fuel Tracking
• Requirements:– Track all fuel entering, resident and leaving
the plant coal yard.– Standardized modular system easily
configured for each plants eccentricities.– Ready interfaced to PI for data acquisition
and company-wide presentation of results.– Interface with existing FDCS system.
Fuel Tracking
Introduction Heat Rate Fuel Tracking Frequency Analysis
Integration Obstacles Solved by using PlantView
• Provides Real-Time Inputs from:– Relational Databases (FoxPro, MS Access,
Oracle, SQL Server, etc.)– Flat Files (ASCII, Excel,etc.)– Omega Data Loggers
• Provides Calculation Environment
• Provides Interface to PI for Inputs & Calculated Outputs
Fuel Tracking
Introduction Heat Rate Fuel Tracking Frequency Analysis
Data Processing
FDCS System
(FoxPro DB) PlantView2000
Internal Lab Data
(Flat Files)
OSI PIServer
OSI PIServer
Manual Inputs
Inputs
Results
Calculations and Database Relations
ProcessBookClient
MS Access Reports
Vendor Lab Data
(Flat Files)
Fuel Tracking
Introduction Heat Rate Fuel Tracking Frequency Analysis
Client Interface using ProcessBook
Fuel Tracking
Introduction Heat Rate Fuel Tracking Frequency Analysis
Client Interface using ProcessBook / VB
Fuel Tracking
Introduction Heat Rate Fuel Tracking Frequency Analysis
On-Line Condition Monitoring & Analysis
• Requirements:– Continuous condition monitoring of critical field
devices.– Couple local DAS with powerful analysis
systems (FE analysis, Spectrum analysis, etc.)– Ready interfaced to PI for company-wide
presentation of results.– Coordinate plant operating data and analysis
results in real-time for troubleshooting.
Frequency Analysis
Introduction Heat Rate Fuel Tracking Frequency Analysis
Integration Obstacles Solved using PlantView
• High Speed Data Acquisition Triggered by Other Inputs
• Provides Calculation Environment– Accesses frequency analysis algorithms (Fast
Fourier Transforms, statistical functions, etc.)
• Provides Interface to PI for Inputs & Calculated Outputs
Frequency Analysis
Introduction Heat Rate Fuel Tracking Frequency Analysis
Data Processing
Run Timed DataAcquisition Test
(3000 points at 23 Hz)
Valid TestCriteria
Inputs
RawDisplacement
Data
Yes
Process VibrationAnalysis
(Fast FourierTransforms)
PI ServerCalculate
Final Results
No
Frequency Analysis
Introduction Heat Rate Fuel Tracking Frequency Analysis
Raw Displacement Data(Data Generated by PlantView)
Frequency Analysis
Introduction Heat Rate Fuel Tracking Frequency Analysis
Frequency Analysis Data (Data Generated by PlantView)
Frequency Analysis
Introduction Heat Rate Fuel Tracking Frequency Analysis
Client Interface using ProcessBook
Frequency Analysis
Introduction Heat Rate Fuel Tracking Frequency Analysis
FEC PI Integration Conclusion
• New uses for PI are being conceived daily. • Recurring data manipulation must handle data
compression, checksums, errors, login, data and application security issues.
• Applications that use PI must be standardized for administration consistency from plant to plant.
• Applications should be open for future modifications.• By working closely with the integrator, FEC and ECG have
molded PlantView into our corporate middle-ware package for non-standard interfacing.
Introduction Heat Rate Fuel Tracking Frequency Analysis
PlantView 2000TM Demo
