Más contenido relacionado La actualidad más candente (20) Similar a Dhana Raj Markandu: Evolution of the PI System in Tenaga's Power Generation Fleet (Slides) (20) Dhana Raj Markandu: Evolution of the PI System in Tenaga's Power Generation Fleet (Slides)1. Evolution of
the PI System
in Tenaga’s Power
Generation Fleet
Presented by Dhana Raj Markandu
Senior Engineer, Generation Division
© Cop yri g h t 2012
Tenaga Nasional Berhad
2. Contents
• About Tenaga...
• Our journey with the PI System...
– Why we needed it...
– How we deployed it...
– What we’re doing with it...
– Where we’re going with it...
• Summary & Conclusions...
© Cop yri g h t 2012
Tenaga Nasional Berhad 2
3. About
Tenaga
© Cop yri g h t 2012
Tenaga Nasional Berhad 3
5. What we do...
Established in 1949
Largest electricity utility in Malaysia
CORE NON-CORE
USD 24 billion assets
Power Repair, maintenance
& diagnostic services USD 11.5 billion market capitalisation
Generation
Operation & maintenance
Power sector projects
28,000 employees
Power
Transmission Training & education
Installed generation capacity of 11 GW
Research & development
Power Consultancy services
Distribution
Contributes 55% of total national capacity
© Cop yri g h t 2012
Tenaga Nasional Berhad 5
7. Why we needed it...
Gas-fired
Coal-fired
Hydroelectric
Diverse power plant fleet
300 MW
300 km
400 MW
Inhomogeneous sources of operational data
1010 MW
1200 MW
2100 MW
Real-time process data locked within isolated
250 km control systems
250 MW
HQ
Technical performance & business intelligence
2300 MW reliant on offline data
760 MW
580 MW
1400 MW
300 km UNIFIED REAL-TIME DATA PLATFORM
640 MW EASILY ACCESSIBLE TO ALL STAFF
© Cop yri g h t 2012
Tenaga Nasional Berhad 7
8. How we deployed it...
Phase I (2005 - 2007) Phase II (2007 - ongoing)
Pilot project at one plant & headquarters Concurrent deployment to the other 9 plants
Turnkey project implementation Federated in-house project implementation
PROJECT VENDOR TENAGA PERSONNEL
PI System infrastructure, applications, user PI System infrastructure, applications, user
training & technical support training & technical support
No direct OSIsoft involvement OSIsoft involvement at initial project
deployment & as backup techsupport
USD 7 million savings
Staff competency in PI System
© Cop yri g h t 2012
Tenaga Nasional Berhad 8
9. How we
deployed it Generic architecture...
STATION A STATION B
Redundant PI Servers WAN Redundant PI Servers
PI PI Server PI Server PI PI Server PI Server
Interface (Primary) (Secondary) Interface (Primary) (Secondary)
Node Node
GENERATION HEADQUARTERS
Redundant PI Servers
PI Server PI Server
(Primary) (Secondary)
Station A Network Station B Network
Station Control Station Control
System System
HQ Network
Station A Clients Station B Clients
Headquarters Clients
© Cop yri g h t 2012
Tenaga Nasional Berhad 9
10. How we
deployed it Actual infrastructure...
11 sites
~ 20 unique data sources
8 unique primary plant
control systems
26 PI Servers
> 50 Interfaces
25 12 > 15
Standard PI-to-PI Custom
150,000 tags
AND GROWING...
© Cop yri g h t 2012
Tenaga Nasional Berhad 10
11. How we
deployed it Interfacing cybersecurity...
Control System PI Server PI Server DIRECTIONAL FILTERING
(Primary) (Secondary)
Data from control network
can flow to corporate network,
but not vice versa
PORT FILTERING
Firewall Only data on PI Server port
5450 is enabled
Port 5450
Station Network IP FILTERING
PI Interface can only connect
to PI servers
PI Interface
Audited & approved by
security experts from
Station Clients Tenaga ICT Division
© Cop yri g h t 2012
Tenaga Nasional Berhad 11
12. How we
deployed it Change management...
Internal branding:
GENERATION PLANT MANAGEMENT SYSTEM
Key Messages Key Tactics Key Actions
...technical & business ...empower all staff with real- ...regular and customised
performance project, time data & use quick-win live training conducted internally
NOT an IT project. demos wherever possible. for all levels of staff.
...a platform that makes data ...demonstrate multiple streams ...constant user engagement
easily available, BUT the of actual or potential cost via workshops, newsletters,
application of that data is in savings & return on investment internal conferences, & subtle
the hands of the end user. to gain management buy-in. integration into daily work.
© Cop yri g h t 2012
Tenaga Nasional Berhad 12
13. What are we doing with it...
UNLOCK
Diverse power plant fleet UNIFY
HISTORISE
Inhomogeneous
sources of
operational data DISPLAY
DATA
Real-time process data NOTIFY
locked within isolated
control systems REPORT
Technical performance DIAGNOSE
& business intelligence
reliant on offline data ANALYSE
OPTIMISE
© Cop yri g h t 2012
Tenaga Nasional Berhad 13
14. What are we
doing with it Display, notify & report...
PI ProcessBook
Real-time fleet monitoring
Linked to outage management system
Scheduled reports automatically
compiled, formatted & e-mailed daily
Ad-hoc snapshots delivered on-demand
using e-mail or text message
Trip notifications by e-mail & text message
Fleet status anytime, anywhere
All notifications done using customised
VBA coding within PI ProcessBook Management buy-in
© Cop yri g h t 2012
Tenaga Nasional Berhad 14
15. What are we
doing with it Diagnose...
PI ProcessBook
Real-time process data overlaid on static
plant schematics
Hyperlinked plant schematics for fast
navigation & drill-down
Ad-hoc trending
Historical playback
Virtual on-site presence
Faster plant troubleshooting
Improve technical competencies
© Cop yri g h t 2012
Tenaga Nasional Berhad 15
16. What are we
doing with it Analyse...
PI ProcessBook, PI Datalink, PI ACE, PI AF
Real-time performance analysis of
individual equipment & overall plant
Mass & heat balance analysis
Degradation tracking
Recoverable losses
Justification for plant improvement projects
Over USD 10 million expected
annual fuel cost savings
Greater performance awareness
© Cop yri g h t 2012
Tenaga Nasional Berhad 16
17. What are we
doing with it Optimise...
PI ProcessBook, PI Datalink, PI ACE, PI AF
Real-time unit dispatch optimiser for
hydroelectric plant
Potential savings by displacing gas units
Dynamic tracking of unit efficiency curves
Load advisor & what-if simulator
Daily automated report via e-mail
USD 3000 average daily fuel
cost savings in 2011
Greater optimisation awareness
© Cop yri g h t 2012
Tenaga Nasional Berhad 17
18. Where are we going with it...
Installation Derive value from the PI System
STATION A
Redundant PI Servers by going beyond being just an end user
PI PI Server PI Server
Interface (Primary) (Secondary)
Node
Interfacing
Training
2010 - Provide PI System deployment services for others
Station A Network
2008 - Continuous in-house application development
Station Control
System
Station A Clients
2007 - Deploy the PI System with internal personnel
Tech Support
2005 - Engage vendor for pilot PI System deployment
Internally-developed
applications
60+ years of power industry experience
© Cop yri g h t 2012
Tenaga Nasional Berhad 18
19. Where are we
going with it Internal & external services...
Internal Clients External Clients
Expand PI System to other Tenaga divisions Provide full scope of PI System deployment
services to external customers
Pilot project with Distribution ongoing
Completed projects: Two independent power
plants in Malaysia & one integrated water
Preliminary talks with Transmission ongoing and power plant in Saudi Arabia
Offering PI System infrastructure for corporate Additional training & application development
Facility Energy Management project requested after project completion
The PI System as preferred data Establish track record as PI
unification platform System service provider
Enterprise agreement for Tenaga Non-core revenue for Tenaga
© Cop yri g h t 2012
Tenaga Nasional Berhad 19
20. Where are we
going with it Enhancing ourselves...
Enterprise
agreement?
2014
2013 Data mining
PI Coresight
2012
Staff training Application development
Tag expansion
Hardware (+ 60,000) Dedicated
technology diagnostics
refresh team
Improved cybersecurity
(ISO 27001)
Deployment for
3 new plants
Tag expansion
© Cop yri g h t 2012
Tenaga Nasional Berhad 20
22. EVOLUTION OF THE PI SYSTEM IN
TENAGA’S POWER GENERATION FLEET
“Deploying the PI System provides the infrastructure to
unify, store, visualise and analyse our data. The real
challenge is to transform this data into actionable
information in order to make the right decisions and thus
improve our technical and business performance.”
Abd Ghafar Abd Latif
Project Manager
Generation Plant Management System
BUSINESS CHALLENGE SOLUTION RESULTS & BENEFITS
Diverse power plant fleet Deploy the PI System as a unifying Plant data available to all personnel
data infrastructure for the entire fleet
Inhomogeneous sources of Over USD 7 million savings from in-
operational data Adopt in-house implementation house project implementation approach
approach to build internal competencies
Real-time process data locked within Over USD 10 million tangible savings
isolated control systems Continuous change management from plant analysis & optimisation
Technical performance & business Continuous in-house application Generate revenue by providing PI
intelligence reliant on offline data development System deployment service to others
© Cop yri g h t 2012
Tenaga Nasional Berhad 22
23. Conclusions...
Tenaga has reaped the benefits of the PI System not just as a
user, but also as a project implementer & service provider
Tangible benefits Intangible benefits
Project cost savings PI SYSTEM INTERNAL Skills development
PROJECT IMPLEMENTER
Operational cost savings PI SYSTEM USER Operational awareness
Revenue generation PI SYSTEM EXTERNAL Business diversification
SERVICE PROVIDER
© Cop yri g h t 2012
Tenaga Nasional Berhad 23
Notas del editor Sites (11) – HQ, JMJG, GLGR, CBPS, PJPS, TJPS, PGPS, PKPS, SGPK, CHPS, KNYRControl Systems (8) – ABB Procontrol P14, ABB Symphony Infi90, GE MkV, GE MkVI, Siemens Teleperm, MHI Diasys Netmation, Toshiba TOSMAP, Onsite SCADAOther sources (10) – Web, Slamat, Callisto, ODBC, GC, CBPS Wireless, TJPS PEMS, GLGR Boiler Monitoring, GLGR TMOS, JMJG CoalStockyard