PI : Information on hand for Operational Analytics - OSIsoft

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<strong>PI</strong> : <strong>Information</strong> on
hand for
Operational Analytics
Presented by:
Ranjith Ramachandran
Chandra Prakash Dewangan

AGENDA
• <strong>Information</strong> Enhancement
• ABT System.
• Auto Reports.
• Enhancement of data.
• Performance Monitoring, Analysis & Improvement
• Plant Performance Monitoring.
• Plant Performance Improvement.
3

<strong>PI</strong> System Integration
Wind
Trombay Jojobera Haldia Hydro
Central <strong>PI</strong>
Enterprise
Systems
Maithon
Mundra T&D

<strong>PI</strong> System - Network
U4 U5 U6 U7 U8
Legend
- Existing
- Proposed
TROMBAY
SERVER
WIND
SERVER
REGE
ENERCON SUZLON
N
LD
U1 U2 U3
HALDIA
SERVER
T&D SERVER
(DHARAVI)
SCADA DAS AMR
TATA POWER WAN
ABT
U1 U2 U3 U4 U5 PH#6
MAITHON
SERVER
U1 U2
JOJOBERA
SERVER
BELGAUM LODHIVLI
MUNDRA
SERVER
MULSHI
3MW
EMS
U1 U2 U3 U4 U5
KHP
<strong>PI</strong>-<strong>PI</strong>
INTERFACE
MIS / HYPERION
BHVP
HYDRO
SERVER
CENTRAL
<strong>PI</strong> SERVER
BHIRA
RDBMS
INTERFACE

<strong>PI</strong> System Monitoring

<strong>PI</strong> System Monitoring

<strong>PI</strong> System Monitoring

ABT SYSTEM
2

ABT System
∗ 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.

Integration of ABT System with <strong>PI</strong>
∗ RDBMS Interface connectivity with <strong>PI</strong> 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 <strong>PI</strong> being utilized by Load Control
Centre for planning and forecasting.

AUTOMATED REPORTS
2

Automated Reports
Daily operational and maintenance report on E-mail
Created Visual Basic application which utilizes <strong>PI</strong> DataLink to
generate reports.
Reports are in MS Excel format. The values are available as static.
Hence, no need of <strong>PI</strong> DataLink on the recipients computer.
Reports saved on a network drive.
E-mail the report using <strong>PI</strong> notifications to a list of recipients by
setting time based triggers.

Automated Reports

ENHANCEMENT OF DATA
QUALITY
2

Solution to Energy Meter commn. error
Before
Energy meter communication problems during shutdown which
results in error of the source data affecting calculations .
8.902E+07
8.9E+07
8.898E+07
8.896E+07
8.894E+07
8.892E+07
8.89E+07
8.888E+07
8.886E+07
8.884E+07
8.882E+07
15/12/2010 12:00:00 AM 5.37 hours
15/12/2010 5:21:55 AM
TR U7 SATE
8.9014E+07
KWH

Solution to Energy Meter commn. error
After
Created a performance equation for storing the last reading of the
energy meter and the same tag used for energy calculations.
8.9029E+07
8.9E+07
8.895E+07
8.89E+07
8.885E+07
8.88E+07
15/12/2010 12:00:00 AM 5.37 hours
15/12/2010 5:21:55 AM
TR U7 SATE
8.9014E+07
KWH

Energy Meter reset
Before
Energy meter resets to zero after reaching the maximum of
cumulative reading which affects energy calculations.
Result : Negative

Energy Meter reset
After
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.
Modified PE
IF (TAGVAL('TR U7 SATEC STG KWH NO ERROR','T')-TAGVAL('TR U7
SATEC STG KWH NO ERROR','Y'))

Multiple interface status
Before
Single tag for OPC interface status based on a particular watchdog.
No direct monitoring over the data received from various
functional areas.
OPC Server
<strong>PI</strong> Interface
<strong>PI</strong> ICU
<strong>PI</strong> Server
OPC tag Watchdog tag
Interface status

Multiple interface status
After
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.
OPC Server
<strong>PI</strong> Interface
<strong>PI</strong> ICU
<strong>PI</strong> Server
OPC tag Watchdog tag
Interface status
OPC tag
OPC tag
OPC tag
Watchdog tag
Watchdog tag
Watchdog tag
OR

Trigger based PE
Before After
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.

THERMAL POWER PLANT
PERFORMANCE MONITORING
2

Performance Monitoring
<strong>PI</strong> 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 - “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
2

SANKALP
• 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 <strong>PI</strong> System to take
informed decisions.
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Online Data for 500 MW Coal Fired Unit

History Data for analysis

Trend format for analysis
555.0
550.0
545.0
540.0
Temp
535.0
530.0
525.0
520.0
4:25 PM
6:25 PM
8:25 PM
10:25 PM
12:25 AM
2:25 AM
4:24 AM
6:24 AM
8:24 AM
10:24 AM
12:24 PM
2:23 PM
MS Temp
4:23 PM
6:23 PM
Date & time
8:23 PM
10:23 PM
12:22 AM
2:22 AM
4:22 AM
6:22 AM
8:22 AM
10:21 AM
12:21 PM
SH Temp SH Temp SH Spr
2:21 PM
12.0
10.0
8.0
6.0
4.0
2.0
0.0

Trend format for analysis
250.0
230.0
210.0
190.0
170.0
150.0
130.0
110.0
90.0
70.0
Unit 8
Last 100 Data only captured in Graph
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
Load Cur Avg Suc Pr Avg
-400.0
-350.0
-300.0
-250.0
-200.0
-150.0
-100.0
-50.0
0.0

Predictive Analysis

Questions