Sequence of Events Recording for Kardia Power Station Greece Ian Loudon Omniflex International Marketing and Sales

Omniflex ► Omniflex South African Manufacturer of Industrial Electronic Products ► Founded 1965 as Conlog became Omniflex 1996 ► 50% of Turnover exported ► Sales Office JHB, UK, Australia Head Office Durban ► Wonderware and Sequence of Events recording since 1988 ESKOM, Sasol, Natref

Introduction This Project improves an ageing Coal Fired Power Station Root Cause Analysis by 90% Kardia Power Station Greece

Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary

Kardia Power Station Greece Up to 50% of Greece’s Electricity from Coal (Lignite) 6 Lignite Fired Stations Agios Dimitrios Amyntaio Florina Kardia Megalopolis Ptolemais How much coal is required to run a 100-watt light bulb 24 hours a day for a year?

Background to the Project Location : Greece Operator : Public Power Corp Configuration : 4 X 300 MW Operation : Since 1975 …… Fuel : Lignite Boiler : Stein, Ganz-Rock T/G supplier : Alstom, LMZ, Teploenergo EPC: Zarubezhenergoproekt T/G Turbine Generator EPC Engineering Procurement Construction

Business Objective ► Plant Optimization ► Reduce Downtime ► Effective Alarm Localization ► Nuisance Alarm Identification ► High Availability ► Cost effective Solution

Operational Objectives ► Root Cause Analysis ► Alarm History ► Local Alarm Indication ► Fast and Reliable Event Capture ► Redundancy of I/O Processors

Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary

Selection of Solution ► Local SI for Local Support ► Wonderware SCADA selected for ► Ease of configuration ► Minimal effort to integrate Date and Time Stamp at source event streams through OPC server

Sequence of Events Recording System

System Implementation ► 960 Relay Contact Inputs COS monitoring ► 960 Alarm Statuses Annunciated ► Input discrimination to 200μseconds ► Minimum Pulse Width 500μseconds ► Time Stamping Accuracy 200μseconds

System Diagnostics

Historical Alarms

Alarm Summary

Time Synchronization ► GPS Station Time ► OPC server Service

Controller Redundancy ► Dual Controller ► Includes Queue Services

Topology Field Inputs Marshalling Panel Ethernet Conet CAN SCADA OP C Modbus Primary Secondary

Disadvantages of Poll Response Disadvantages of a poll/response network · Poll/Response uses %100 of available bandwidth. · The data "Transport" is the "Application". You can't break them apart. · One protocol for all field equipment limits deployment of new technology & impedes migration to new topologies. · It is not a "managed" network. · One-to-One data relationship between the Host and field equipment Master Slave

Producer Consumer Subscription Producer eg SOE System Middleware Message Broker Eg Queue Service Consumer Application 1 Consumer Application 2 Consumer Application 3 Subscribe Publish Advantages: Network Traffic Minimized Efficient use of Network Bandwidth Multiple consumers

System Implementation ► In House Engineering and Testing and Configuration, SCADA, OPC, Maxiflex 1 week ► Local Panel Alarm Annunciators via Modbus RS485 ► Wonderware SCADA Final Configuration On Site ► Copy Paste for Second System 2 Days In House Engineering and Testing

Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary

Benefits / Goals Achieved ► Plant Optimization  ► Reduce Downtime  ► Effective Alarm Localization  ► Nuisance Alarm Identification  ► High Availability 

Benefits / Goals Achieved ► Root Cause Analysis  ► Alarm History  ► Local Alarm Indication  ► Fast and Reliable Event Capture  ► Redundancy of I/O Processors 

Realised Benefits ► 90% improvement in Root cause analysis ► 25% improvement in Generating Availability ► 40 to 50% time saving in Maintenance ► Huge Saving on Hard Wired Annunciation ► Project Implementation Short ► End User Empowerment on system usage, migration and on going improvement ► Rapid Deployment of next Generator system

Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary

Lessons Learned ► Learn to Speak Greek ! Real Greek ► Partnering with local Wonderware SI’s essential ► Preconfigured Wonderware for Front end Hardware from Factory simplifies field work

Agenda IntroductionIntroduction Project Solution BenefitsBenefits ConsiderationsConsiderations SummarySummary

Conclusions ► Wonderware was a good choice for seamless integration of Date and Time stamped events into an HMI for management of Alarm and Events. ► Wonderware Presence worldwide presented this opportunity for us from a South African and UK Base.

Project summary ► “The system works well and enables incidents to be tracked very efficiently”. Ilias Kalaitzis,Project Engineer, Control Systems

Project Summary ► Project Delivered in 2008 on time during Shut Down of Generator Unit Period 16 Weeks Entirety ► Second Unit simple Copy and Paste for SOE Configuration. Completed Dec 2008 ► We are expecting orders for the balance of 2 Generator Sets

Questions ? Solutions by Design