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
System Implementation
► 960 Relay Contact Inputs COS monitoring► 960 Alarm Statuses Annunciated► Input discrimination to 200μseconds► Minimum Pulse Width 500μseconds► Time Stamping Accuracy 200μseconds
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