IntroductionHeat RateFuel TrackingFrequency Analysis PI Applications at First Energy with PlantView 2000 TM Ron Carson, First Energy Corp. Jim Scavuzzo, Engineering Consultants Group Inc. Introduction

Heat RateFuel TrackingFrequency 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

Heat RateFuel TrackingFrequency 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

Heat RateFuel TrackingFrequency 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 Anticipate completed system to approach 200,000 tags. Introduction

Heat RateFuel TrackingFrequency 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

Heat RateFuel TrackingFrequency 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

Heat RateFuel TrackingFrequency 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

Heat RateFuel TrackingFrequency Analysis PlantView 2000 TM 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

Heat RateFuel TrackingFrequency 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

IntroductionHeat RateFuel TrackingFrequency 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

IntroductionHeat RateFuel TrackingFrequency Analysis Data Validation Example Extraction Steam (T,P) FW out (T)FW in (T) Drain out (T) Drain in (T,W) Process Diagram H3hsi = W3hsi = H3hso = W3hso = H3hwi = W3hwi = H3hwo = W3hwo = Ext Flow = (FW Flow * ( FW Delta H) - Drain Flow * (Drain Delta H)) / (Ext Steam Delta H) Process Equation Programming Environment Heat Rate

IntroductionHeat RateFuel TrackingFrequency Analysis Data Validation Example Six inputs are used to calculate a singe output. Heat Rate

IntroductionHeat RateFuel TrackingFrequency Analysis Data Validation Example If any of the inputs are lost, the result of the calculation system is not valid. Heat Rate

IntroductionHeat RateFuel TrackingFrequency Analysis Data Validation Example 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

IntroductionHeat RateFuel TrackingFrequency 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 Default Error Window Default Points Graphical Adjustments Heat Rate

IntroductionHeat RateFuel TrackingFrequency Analysis Real-Time Debugging Heat Rate

IntroductionHeat RateFuel TrackingFrequency Analysis Client Interface using Excel & DataLink Heat Rate

IntroductionHeat RateFuel TrackingFrequency Analysis Client Interface using ProcessBook Heat Rate

IntroductionHeat RateFuel TrackingFrequency 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

IntroductionHeat RateFuel TrackingFrequency 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

IntroductionHeat RateFuel TrackingFrequency Analysis Data Processing FDCS System (FoxPro DB) PlantView 2000 Internal Lab Data (Flat Files) OSI PI Server OSI PI Server Manual Inputs Inputs Results Calculations and Database Relations Process Book Client MS Access Reports Vendor Lab Data (Flat Files) Fuel Tracking

IntroductionHeat RateFuel TrackingFrequency Analysis Client Interface using ProcessBook Fuel Tracking

IntroductionHeat RateFuel TrackingFrequency Analysis Client Interface using ProcessBook / VB Fuel Tracking

IntroductionHeat RateFuel TrackingFrequency 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

IntroductionHeat RateFuel TrackingFrequency 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

IntroductionHeat RateFuel TrackingFrequency Analysis Data Processing Frequency Analysis

IntroductionHeat RateFuel TrackingFrequency Analysis Raw Displacement Data (Data Generated by PlantView) Frequency Analysis

IntroductionHeat RateFuel TrackingFrequency Analysis Frequency Analysis Data (Data Generated by PlantView) Frequency Analysis

IntroductionHeat RateFuel TrackingFrequency Analysis Client Interface using ProcessBook Frequency Analysis

IntroductionHeat RateFuel TrackingFrequency 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.

IntroductionHeat RateFuel TrackingFrequency Analysis PlantView 2000 TM Demo