Dominion Power GenerationUsing the PI System as a Standardized Enterprise Data Infrastructure Presented by Greg Kashmer and Dean Lee © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . Who am I? • Greg Kashmer, 1986 Clarkson University Graduate, BS in Mechanical Engineering • • • • • • • • 27 years service with Dominion 21 years primarily functioning as a Plant Engineer focused on plant performance 6 years in Power Generation IT Support Functioned as the plant PI System Administrator (PI-POC) Long time PI System End-User Now, responsible for supporting PI System operations and related products Also responsible for researching and implementing new PI System related products Our objective is to implement products and processes related to PI System data that enables our PI System users to be more “proactive” in critical business decisions © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 2 Who am I? • Robert ‘Dean’ Lee – Hired with Virginia Electric and Power Company (VEPCO), • • now named Dominion, in 1974. Held many positions at various locations within Dominion. These positions include Operator, Control Room Operator, Shift Supervisor, Instructor, Superintendent, Production Director, Technical Consultant and his current title Manager of Operations Excellence. The Operations Excellence group is located at Dominion’s Power Generation Headquarters at Innsbrook, Virginia. They are responsible for corporate oversight of Dominion Generation’s power generation non-nuclear fleet. His team supports compliance with Operating Policies, Procedures, and Standards of Excellence. His team also has the responsibility and oversight of the OE Standards, station assessments, chemistry programs, Lessons Learned Database, knowledge retention programs. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 3 Dominion Profile Power and Natural Gas Infrastructure Leading provider of energy and energy services in the Midwest, Northeast and Mid-Atlantic regions of the U.S ~23,500* MW of electric generation 6,400 miles of electric transmission NY 11,000 miles of natural gas transmission, gathering and storage pipeline 947 billion cubic feet of natural gas storage operated Cove Point LNG Facility 2.5 million electric customers in VA and NC 1.3 million natural gas customers in OH & WV 2.1 million non-regulated retail customers in 15 states (not shown) PA OH MD WV VA NC *Excludes ~4,000 MW of announced planned facility divestitures and decommissionings. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 4 Dominion Profile Generation Resource Type Leading provider of energy and energy services in the Midwest, Northeast and Mid-Atlantic regions of the U.S NY PA OH MD WV VA NC *Excludes ~4,000 MW of announced planned facility divestitures and decommissionings. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 5 Dominion - OSIsoft Footprint • ~26 PI Server installations in Dominion Power Generation (275,000 PI System tags) – OSIsoft PI System in use since 1997 – Smart Client Tools • PI ProcessBook & PI DataLink primarily. – PI Manual Logger – 1998/2008 – Moving to PI Server 2012, which includes PI AF, PI Notifications, PI ACE • 1 PI Server Collective installation in Dominion Nuclear © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 6 Dominion – OSIsoft Partner Products Transpara – Visual KPI Exele – Topview, EdictVB, PI Tuning Tools Data South Systems (DSS) – DCS to PI ProcessBook graphic conversion tool © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 7 Dominion’s PI System Architecture Overview PI Manual Logger Performance Alerting Application Transpara Calculations PI DataLink PI ProcessBook PI Server Dominion CEMS Applications Interface Nodes Interface Nodes © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 8 Dominion – Business Challenge Get more value out of the OSIsoft investment and the data we collect. Start using the data we collect in ways that can help prevent plant issues and equipment failures. Share Best Practice information. Provide data to users in various platforms, i.e. mobile accessibility. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 9 Dominion – Solutions to Challenge After attending an OSIsoft Conference, an eye opening experience, we formulated some creative ideas. Management approved 2 FTE’s to support the PI System. We implemented some low cost OSIsoft partner applications to find out if our customers found value in the data presented. Began having internal PI User Group meetings. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 10 Dominion – Solutions Alerting – With a robust amount of PI System information available at most of our generating plants, we implemented Topview from Exele. Started with Unit On/Off line status to Executive, Station Management, and Support Teams. Grown to all forms of station operational data, providing KPI status. Delivery thru email, text messaging, and telephony device. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 11 Dominion – Solutions PI Manual Logger – Sites were asking for ways to eliminate paper logs, and have more accountability of the data collected. Invested in Windows Mobile devices, that were now much more manageable in size, and could provide various solution options. Data collected, becoming part of the PI System database, provides enormous value, that now has become a Power Generation ‘Best Practice’. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 12 Dominion – Solutions PI Tuning Tools - The PI-POC’s were provided tools to help tune the existing PI System tags. Tuned PI System tags will store data with known compressions, which will provide more value when needed. Data being supplied for other implemented solutions would require trusted data. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 13 Dominion – Solutions EdictVB – A performance calculation tool that required little VB coding experience. The ability to perform calculations across the Fleet PI Servers, and bring back information used for Executive portal pages. Extract data from outside data sources, like weather stations, that could be used with existing PI System data. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 14 Dominion – Solutions Transpara – Data mobility. Web based information delivered to mobile devices and desktop web browsers. Using PI System data as the primary data source we are able to stay in touch with operational KPI’s from anywhere. The chosen platform for creation and implementation of the ‘Grey Screen’ project now in Phase I development. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 15 Dominion – Solutions PI Server 2012 – Dominion has upgraded licensing to move to the latest PI Server platform, that will include access to a variety of OSIsoft products. PI AF, PI Asset Framework. The building block for most of the OSIsoft PI Client tools, we have configured our 1st PI AF Server. PI Notifications – A Client configurable tool, requiring the PI AF (PI Asset Framework) for implementation. PI ACE (PI Advanced Computing Engine), capable of a variety of robust calculation solutions. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 16 Business Challenge Determine how Dominion can use the enormous amount of PI System data in a proactive method. Dominion historically has used PI System data to help determine the root cause of failures, and events that lead up to the resulting issue. IT provided the Business Unit with some Market available products that can help move us from a reactive mode to a preventative mode. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 17 Business Challenge (cont.) Some pilots were performed, and after careful evaluation and review capital investment requirements, $,$$$,$$$, a choice was made….. Why not try this ourselves? Many highly experienced Operational team members on staff. Enormous amounts of operating history in PI Server archives. Tools to extract this data, and staff to evaluate. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 18 Business Solution The Operational Excellence Team began developing a plan: Determining Phase I points to configure. Extracting data from PI System via PI DataLink. Creating a Visibility mechanism – PI ProcessBook Graphics. Soon after starting, they ran into some logistic issues. IT PI Support was consulted and a list of project requirements (Wish List) was developed. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 19 Business Solution Requirements • • • • • • • • Displays that could be easily viewed Displays that can fit screens without any or little scrolling Displays that are interactive, real-time information Displays that would not require mandatory interaction to deliver vital information Data description – tag details Actual Data values Real time trending without switching applications 3 Levels of alerting above • • • and below ‘Normal’ Viewable alert limits Interactive color changes Tune-able trigger points • Plant site rollups • • Dependable delivery Maintenance Manageable • Corporate Level Rollups • • Email and/or text messaging capable for alerting Minimal O&M or Capital Investments • Use what we have, if possible • • • • Mobile Accessibility • Dependable data source Ability to segregate the data by plant systems Ability to ‘Mask’ trigger points during plant transitions Ability to ‘Mask’ alerts to minimize false alerts. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 20 Delivered Solution….. With the core data being the OSIsoft PI System. Delivery made using the OSIsoft partner, Transpara KPI. Presenting…the Dominion ‘Grey Screen’ solution. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 21 Delivered Solution © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 22 Grey Screens Why ‘Grey Screen’, what’s with the name A program that monitors equipment based on 2 year operating history Uses Colors to Alert Operating Personnel Blue (5 to 10 degrees above the 2 year history) Yellow (5 to 10 degrees above the Blue) Red (10 degrees above the Yellow) Grey is Good (Normal) © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 23 Grey is GOOD © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 24 Station View © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 25 Station View © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 26 Station View © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 27 Why We Needed Grey Screens – Manufacturers alarms are set so we react to equipment problems – Alarm system settings are generally rigid and hard to change. (Hardware, Software and Control Policies) – Alarm systems can become an audible nuisance if settings are too close to the normal operating conditions © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 28 What Can the System Do – Alerts using color changes – E-mails key personnel when alerts are too high – Points are easily adjusted and don’t require change management programs (Alerts not Alarms) • Example after a turbine outage vibration levels change – Alerts any piece of equipment that is monitored by OSIsoft PI System. Much of our non-critical equipment and older equipment is not alarmed © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 29 What Can the System Do (cont) – Alerts can be changed based on the equipment status (Off or On) – Alerts can be changed based on ambient conditions – Helps inexperienced employees identify unusual or abnormal conditions (Training and Knowledge Retention) © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 30 How Did We Make it Happen – Management support of the vision – Dedicated team to test and prove value of the concept – Executive that approved the money being spent on an idea – Dedicated team to train station personnel and sell the vision that this is their program, not corporate’s vision © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 31 How Did We Make it Happen (Cont) – Executive that believed in the program and pushed management to use it – Information Technology (IT) expert that knew how to get the system into the control rooms © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 32 Dos and Don’ts When Introducing a Monitoring System – Do Train all personnel so you get buy in (Eliminate the Spy in the sky thinking) – Don’t by pass your work order system by sending or calling personnel directly when alerts come in. © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 33 The Results of the Alerting – ID Fan Vibration Increasing • Finding low oil level – Cooling Tower Pump Motor (not monitored in control system) • Found the motor wrapped in plastic – EHC oil pump running on unit that was in an outage • Control room was not staffed – Air Pre Heater bearing temperature increasing • Found lube oil pump running backwards © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C . 34 Brought to you by Operational Excellence at Dominion Power Generation, “Powered by the OSIsoft PI System” © C o p yr i g h t 2 0 1 3 O S Is o f t , L L C .
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