Sequence of Events Recording for Kardia Power Station Greece

Ian LoudonOmniflex 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

IntroductionIntroductionIntroductionIntroduction

Project SolutionProject SolutionProject SolutionProject Solution

BenefitsBenefitsBenefitsBenefits

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

Kardia Power Station Greece

Up to 50% of Greece’s Electricity from Coal (Lignite)

6 Lignite Fired Stations

Agios DimitriosAmyntaioFlorinaKardiaMegalopolisPtolemais

How much coal is required to run a 100-watt light bulb 24 hours a day for a year?

Background to the Project

Location : GreeceOperator : Public Power CorpConfiguration : 4 X 300 MWOperation : Since 1975 ……Fuel : LigniteBoiler : Stein, Ganz-RockT/G supplier : Alstom, LMZ,

TeploenergoEPC: Zarubezhenergoproekt

T/G Turbine GeneratorEPC 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

IntroductionIntroductionIntroductionIntroduction

Project SolutionProject SolutionProject SolutionProject Solution

BenefitsBenefitsBenefitsBenefits

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

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

Marsh

alling

Pan

elEthernet

Conet

CAN

SCADA

OPC

OPC

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 SystemMiddleware Message BrokerEg Queue Service

Consumer Application 1

Consumer Application 2

Consumer Application 3

Subscribe

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

IntroductionIntroductionIntroductionIntroduction

Project SolutionProject SolutionProject SolutionProject Solution

BenefitsBenefitsBenefitsBenefits

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

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

IntroductionIntroductionIntroductionIntroduction

Project SolutionProject SolutionProject SolutionProject Solution

BenefitsBenefitsBenefitsBenefits

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

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

IntroductionIntroductionIntroductionIntroduction

Project SolutionProject SolutionProject SolutionProject Solution

BenefitsBenefitsBenefitsBenefits

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

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