Pilot Plant: Workcenter PKS and @ssetMAX Alert Manager on ... · 4 2004 Users Group Americas Symposium • Partners in Innovation Background (cont’d) WA Parish Plant –Test Site

2004 Users Group Americas Symposium • Partners in Innovation1

Pilot Plant: Workcenter PKS™

and @ssetMAX Alert Manager

on Steam Generating Units

Charles C. Longcoy

Senior Power Generation Specialist

Texas Genco


Pilot Plant: Workcenter PKS™ and

@ssetMAX Alert Manager on Steam Generating Units

Introduction• Because of its strong working relationship with Honeywell, and lengthy

experience using PHD desktop tools, Texas Genco was chosen for a Pilot Plant project to evaluate the Workcenter PKS™ and @ssetMAX Alert Manager solutions

• Presentation describes how Workcenter PKS™ and Alert Manager provide Texas Genco with an additional set of electronic “eyes and ears” to monitor plant equipment and process performance

• Discussion concerns the use of Workcenter PKS™ and Alert Manager by maintenance specialists for monitoring process variables during steam turbine start-up


Background

Texas Genco – Leading Wholesale Power Company

• Texas Genco Holdings, Inc., based in Houston, Texas, is one

of the largest wholesale electric power generating companies in

the United States

• Majority-owned subsidiary of CenterPoint Energy, Inc.

• Maintains over 14,000 MW of generation capacity

• Owns and operates 60 generating units at 11 electric power

plants




Background (cont’d)WA Parish Plant – Test Site

• WA Parish Plant is located in Thompson, Texas

• Four coal-fired steam units have total net generating capacity of 2,470 MW

• Unit 7 (test unit) is 560 MW drum-type reheat unit placed in service on June 2, 1980

• Unit 7 employs a coal-fired combustion engineering boiler with a Westinghouse turbine

• Unit 7 uses Bailey Infi90 for combustion controls and burner management

• PHD R150.1 Shadow Server configuration




Background (cont’d)

Turbine Maintenance Operations

• Texas Genco’s central maintenance division is responsible for

overhauling steam turbines

• Specialists monitor a variety of process variables during turbine

startup

• Work requires tools for monitoring alarms, trends and other

indicators

• Personnel utilize Honeywell PHD systems in most power plants






Etherlink

Board

Honeywell 45000

SEER Software

Animas Automation

SemAPI Gateway

ETHERNET SEGMENT

10BASE-2 Thin Coaxial

Router

ICI03

SCSI

Bailey Infi90

Combustion Control

Burner Management

PHD Collector Node

SemAPI RDI

PHD R150.1

Shadow Server

26651 Tags

TPPM-Reports

and Logs PC

Baystack 450

Ethernet Switch

WA Parish Unit 7

Functional Block Diagram

Client PC

Wan

Connections

WPKS Server


RequirementsImproved Asset Management

• Like other power generation companies, Texas Genco is seeking a proactive maintenance strategy to improve management of valuable plant assets

• Instead of reacting to equipment damage followed with Root Cause Analysis, predictive maintenance allows for planned service of field equipment and minimizes the need for unit shutdowns

• Due to staff reassignments, personnel working in different plants need tools that assist in process and equipment monitoring

• New solution must improve visualization and monitoring of turbine operation at a lower cost than the traditional PHD Desktop Tools




Requirements (cont’d)Improved Asset Management

• Web-based application

• Improved information security from previous TPWS (TotalPlant™

Web Site)

• Ability to gather near real-time, historical, and aggregated data in a single window

• Ability to display data from various sources




Project Description

Overview of Pilot Project

• Two-part project involving Honeywell’s Workcenter PKS™ and

@ssetMAX Alert Manager

• New server purchased and installed at Texas Genco’s Energy

Development Complex (EDC) in Houston, Texas

• Processes to be monitored are located at WA Parish Plant




Project Description (cont’d)

Overview of Pilot Project

• Honeywell provided project assistance and training at minimal cost

• Tests will evaluate setup, configuration, operation and maintenance

of Workcenter PKS™ and Alert Manager tools

• Results will be used to evaluate Honeywell solutions vs.

competitive offerings on the market





Server Hardware Requirements

• Minimum Xeon processor or later, 2.4 GHz, 512K Cache, Dual

Processor

• 2 GB RAM or higher

• 36 GB or higher hard drive

• 10 Mbps or higher Ethernet network card

• CD-ROM drive





Server Software Requirements

• Windows 2000 Server or Windows 2000 Advanced Server

• Microsoft Internet Information Server 5.0

• Internet Explorer 6.0

• Microsoft.NET Framework 1.0

• Microsoft Data Access Components 2.7

• Microsoft ASP.NET Server Controls 1.0

• Microsoft SQL 2000 Server SP3




Workcenter PKS™

A Web-based Monitoring Tool

• Texas Genco regards Workcenter PKS™ as a versatile, cost-effective tool for enterprise-wide visualization, monitoring, and analysis

• Configurable, Web services-based solution employs the latest Microsoft.NET technologies, coupled with Honeywell’s HMIWeb application, to provide secure interaction with process and business data

• Personnel can monitor key performance indicators and other production-related data from different data sources

• Employees have immediate access to relevant information to facilitate collaborative decision-making and team-work




Workcenter PKS™ (cont’d)

A Web-based Monitoring Tool

• Using configurable elements embedded in HMIWeb Builder,

plant personnel can quickly assemble a graphical web page

with interactive data access to server tags

• Engineers, operators and maintenance specialists can view

real-time, historical, and aggregated data in a single window

• Providing information via a simple browser interface makes it

easy to navigate the large volume of data generated within

the unit or plant




Workcenter PKS™ Implementation

• Install Workcenter PKS software on server

• User Display Area

• Catalog Configuration

• Security – User and Group Roles

• HMI Web Builder

• Client Tools

• TPPM - Scout






WPKS Home Page




WPKS WAP 7 Workbook




WPKS WAP 7 Workbook Content




WPKS WAP 7 Workbook Security




WPKS WAP 7 Worksheet Layout




WPKS WAP 7 Catalog content




WPKS WAP 7 Catalog General




WPKS WAP 7 Person Admin




WPKS WAP 7 Main Display




WPKS WAP 7 Quick Trend Display




TPPM Scout Main Display




TPPM Scout Vibration vs. Load Display




TPPM Scout Vibration vs. RPM Display




WPKS Trend Display




WPKS Trend List Display




WPKS Trend Setup Display




WPKS Trend Data Display




WPKS Trend Operations Display




WPKS Trend Time Control Display


@ssetMAX Alert Manager

A Proactive Asset Management Tool

• @ssetMAX Alert Manager is a proactive tool for managing plant assets

and implementing preventative maintenance

Analyzes and organizes data from plant processes and field devices

Helps operators recognize and respond to alarms

Reduces data into either symptoms or faults

Automates decision support for the repair of equipment problems

Identifies and schedules required preventative maintenance

Documents maintenance activities for internal or regulatory

requirements




@ssetMAX Alert Manager (cont’d)

A Proactive Asset Management Tool

• Alert Manager’s Data Scouts send out e-mail messages or

pager messages when process variables go into alarm

• Plant personnel use Workcenter PKS™ tools to review data

contained in the e-mail messages and make informed decisions

about process operations




@ssetMAX Alert Manager Implementation

• Install @ssetMAX Alert Manager software on server

• Build Assets

• Build Symptoms and Faults

• Use Data Scout Tools




Main Turbine asset




Bearing asset




Bearing Symptoms




Notification Step 1




Notification Step 2




Notification Step 3




Notification Step 4




Data Scout Configuration




Data Scout Library




Main Turbine alarm




Bearing Symptom




Bearing Activity Log




E-mail Notification




Results

Lower Costs

• Implementation of web-based tools to replace existing PHD

systems provides significant cost savings

Cost per Workcenter PKS™ user is approximately $700

vs. $1,800 for PHD desktop tools




Results (cont’d)

Increased Efficiency

• Utilization of graphical web pages with interactive data access

eliminates the need for complex desktop tools

Development of web pages is fast and convenient

Browser interface is simple and easy to use




Results (cont’d)

Greater Predictability

• Powerful process monitoring and asset management tools

ensure greater predictability and reduced variability

Personnel have better visibility of information across units

and applications

Improved efficiencies increase the speed of executing

critical decisions

Expanded process knowledge provides the agility to take

advantage of profitable opportunities




Results (cont’d)

Reduced Downtime

• Improved asset management strategies may reduce downtime

and associated costs

Workcenter PKS™ tools look at process variables and

organize data so that personnel can make better decisions

regarding operations

Alert Manager solution increases knowledge of equipment

health and performance, allowing repair work to be

performed during planned outages




Lessons Learned• Terminal Services is not available with WPKS

• Limit number of worksheets per workbook

• Navigation Tool provide by Honeywell

• Scout Import Tool would be useful

• Anti–Spam configuration to limit the number of e-mails per hour is needed

• E-mail notification needs to be more configurable to handle shifts and weekends

• Server network connection – local to PHD or across LAN

• Training is needed in order to utilize all the features of both applications

• First complete site implementation of Alert Manager should be assisted by Honeywell




Conclusion

The Technology Works!

• Tests have shown that Honeywell’s Workcenter PKS™

technology works as promised

• Users can reduce costs and complexity by employing web-

based tools for enterprise-wide visualization, monitoring, and

analysis

• Together, Workcenter PKS™ and @ssetMAX Alert Manager

are an effective resource for managing plant assets




Thank You

