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
2004 Users Group Americas Symposium • Partners in Innovation2
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
2004 Users Group Americas Symposium • Partners in Innovation3
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation4
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation5
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation6
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
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
2004 Users Group Americas Symposium • Partners in Innovation7
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation8
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation9
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation10
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation11
Project Description (cont’d)
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation12
Project Description (cont’d)
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation13
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation14
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation15
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation16
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Home Page
2004 Users Group Americas Symposium • Partners in Innovation17
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Workbook
2004 Users Group Americas Symposium • Partners in Innovation18
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Workbook Content
2004 Users Group Americas Symposium • Partners in Innovation19
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Workbook Security
2004 Users Group Americas Symposium • Partners in Innovation20
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Worksheet Layout
2004 Users Group Americas Symposium • Partners in Innovation21
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Catalog content
2004 Users Group Americas Symposium • Partners in Innovation22
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Catalog General
2004 Users Group Americas Symposium • Partners in Innovation23
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Person Admin
2004 Users Group Americas Symposium • Partners in Innovation24
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Main Display
2004 Users Group Americas Symposium • Partners in Innovation25
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS WAP 7 Quick Trend Display
2004 Users Group Americas Symposium • Partners in Innovation26
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
TPPM Scout Main Display
2004 Users Group Americas Symposium • Partners in Innovation27
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
TPPM Scout Vibration vs. Load Display
2004 Users Group Americas Symposium • Partners in Innovation28
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
TPPM Scout Vibration vs. RPM Display
2004 Users Group Americas Symposium • Partners in Innovation29
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Trend Display
2004 Users Group Americas Symposium • Partners in Innovation30
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Trend List Display
2004 Users Group Americas Symposium • Partners in Innovation31
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Trend Setup Display
2004 Users Group Americas Symposium • Partners in Innovation32
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Trend Data Display
2004 Users Group Americas Symposium • Partners in Innovation33
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Trend Operations Display
2004 Users Group Americas Symposium • Partners in Innovation34
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
WPKS Trend Time Control Display
2004 Users Group Americas Symposium • Partners in Innovation35
@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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation36
@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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation37
@ssetMAX Alert Manager Implementation
• Install @ssetMAX Alert Manager software on server
• Build Assets
• Build Symptoms and Faults
• Use Data Scout Tools
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation38
Main Turbine asset
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation39
Bearing asset
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation40
Bearing Symptoms
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation41
Notification Step 1
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation42
Notification Step 2
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation43
Notification Step 3
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation44
Notification Step 4
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation45
Data Scout Configuration
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation46
Data Scout Library
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation47
Main Turbine alarm
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation48
Bearing Symptom
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation49
Bearing Activity Log
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation50
E-mail Notification
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation51
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation52
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation53
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation54
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation55
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation56
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
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units
2004 Users Group Americas Symposium • Partners in Innovation57
Thank You
Pilot Plant: Workcenter PKS™ and
@ssetMAX Alert Manager on Steam Generating Units