and @ssetMAX Alert Manager on Steam Generating Units Charles C. - - PowerPoint PPT Presentation

▶
and ssetmax alert manager on steam generating units
SMART_READER_LITE
LIVE PREVIEW

and @ssetMAX Alert Manager on Steam Generating Units Charles C. - - PowerPoint PPT Presentation

Feb 07, 2024 104 likes •687 views

Pilot Plant: Workcenter PKS and @ssetMAX Alert Manager on Steam Generating Units Charles C. Longcoy Senior Power Generation Specialist Texas Genco 1 2004 Users Group Americas Symposium Partners in Innovation Pilot Plant:

slide-1
SLIDE 1

2004 Users Group Americas Symposium • Partners in Innovation 1

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager

  • n Steam Generating Units

Charles C. Longcoy Senior Power Generation Specialist Texas Genco

slide-2
SLIDE 2

2004 Users Group Americas Symposium • Partners in Innovation 2

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

slide-3
SLIDE 3

2004 Users Group Americas Symposium • Partners in Innovation 3

Background

Texas Genco – Leading Wholesale Power Company

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

slide-4
SLIDE 4

2004 Users Group Americas Symposium • Partners in Innovation 4

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

slide-5
SLIDE 5

2004 Users Group Americas Symposium • Partners in Innovation 5

Background (cont’d)

Turbine Maintenance Operations

  • Texas Genco’s central maintenance division is responsible for
  • verhauling 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

slide-6
SLIDE 6

2004 Users Group Americas Symposium • Partners in Innovation 6

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

slide-7
SLIDE 7

2004 Users Group Americas Symposium • Partners in Innovation 7

Requirements

Improved 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
  • peration at a lower cost than the traditional PHD Desktop Tools

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-8
SLIDE 8

2004 Users Group Americas Symposium • Partners in Innovation 8

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

slide-9
SLIDE 9

2004 Users Group Americas Symposium • Partners in Innovation 9

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

slide-10
SLIDE 10

2004 Users Group Americas Symposium • Partners in Innovation 10

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
  • f 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

slide-11
SLIDE 11

2004 Users Group Americas Symposium • Partners in Innovation 11

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

slide-12
SLIDE 12

2004 Users Group Americas Symposium • Partners in Innovation 12

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

slide-13
SLIDE 13

2004 Users Group Americas Symposium • Partners in Innovation 13

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

slide-14
SLIDE 14

2004 Users Group Americas Symposium • Partners in Innovation 14

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

slide-15
SLIDE 15

2004 Users Group Americas Symposium • Partners in Innovation 15

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

slide-16
SLIDE 16

2004 Users Group Americas Symposium • Partners in Innovation 16

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Home Page

slide-17
SLIDE 17

2004 Users Group Americas Symposium • Partners in Innovation 17

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Workbook

slide-18
SLIDE 18

2004 Users Group Americas Symposium • Partners in Innovation 18

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Workbook Content

slide-19
SLIDE 19

2004 Users Group Americas Symposium • Partners in Innovation 19

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Workbook Security

slide-20
SLIDE 20

2004 Users Group Americas Symposium • Partners in Innovation 20

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Worksheet Layout

slide-21
SLIDE 21

2004 Users Group Americas Symposium • Partners in Innovation 21

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Catalog content

slide-22
SLIDE 22

2004 Users Group Americas Symposium • Partners in Innovation 22

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Catalog General

slide-23
SLIDE 23

2004 Users Group Americas Symposium • Partners in Innovation 23

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Person Admin

slide-24
SLIDE 24

2004 Users Group Americas Symposium • Partners in Innovation 24

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Main Display

slide-25
SLIDE 25

2004 Users Group Americas Symposium • Partners in Innovation 25

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS WAP 7 Quick Trend Display

slide-26
SLIDE 26

2004 Users Group Americas Symposium • Partners in Innovation 26

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

TPPM Scout Main Display

slide-27
SLIDE 27

2004 Users Group Americas Symposium • Partners in Innovation 27

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

TPPM Scout Vibration vs. Load Display

slide-28
SLIDE 28

2004 Users Group Americas Symposium • Partners in Innovation 28

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

TPPM Scout Vibration vs. RPM Display

slide-29
SLIDE 29

2004 Users Group Americas Symposium • Partners in Innovation 29

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Trend Display

slide-30
SLIDE 30

2004 Users Group Americas Symposium • Partners in Innovation 30

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Trend List Display

slide-31
SLIDE 31

2004 Users Group Americas Symposium • Partners in Innovation 31

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Trend Setup Display

slide-32
SLIDE 32

2004 Users Group Americas Symposium • Partners in Innovation 32

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Trend Data Display

slide-33
SLIDE 33

2004 Users Group Americas Symposium • Partners in Innovation 33

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Trend Operations Display

slide-34
SLIDE 34

2004 Users Group Americas Symposium • Partners in Innovation 34

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

WPKS Trend Time Control Display

slide-35
SLIDE 35

2004 Users Group Americas Symposium • Partners in Innovation 35

@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

slide-36
SLIDE 36

2004 Users Group Americas Symposium • Partners in Innovation 36

@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

slide-37
SLIDE 37

2004 Users Group Americas Symposium • Partners in Innovation 37

@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

slide-38
SLIDE 38

2004 Users Group Americas Symposium • Partners in Innovation 38

Main Turbine asset

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-39
SLIDE 39

2004 Users Group Americas Symposium • Partners in Innovation 39

Bearing asset

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-40
SLIDE 40

2004 Users Group Americas Symposium • Partners in Innovation 40

Bearing Symptoms

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-41
SLIDE 41

2004 Users Group Americas Symposium • Partners in Innovation 41

Notification Step 1

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-42
SLIDE 42

2004 Users Group Americas Symposium • Partners in Innovation 42

Notification Step 2

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-43
SLIDE 43

2004 Users Group Americas Symposium • Partners in Innovation 43

Notification Step 3

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-44
SLIDE 44

2004 Users Group Americas Symposium • Partners in Innovation 44

Notification Step 4

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-45
SLIDE 45

2004 Users Group Americas Symposium • Partners in Innovation 45

Data Scout Configuration

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-46
SLIDE 46

2004 Users Group Americas Symposium • Partners in Innovation 46

Data Scout Library

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-47
SLIDE 47

2004 Users Group Americas Symposium • Partners in Innovation 47

Main Turbine alarm

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-48
SLIDE 48

2004 Users Group Americas Symposium • Partners in Innovation 48

Bearing Symptom

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-49
SLIDE 49

2004 Users Group Americas Symposium • Partners in Innovation 49

Bearing Activity Log

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-50
SLIDE 50

2004 Users Group Americas Symposium • Partners in Innovation 50

E-mail Notification

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units

slide-51
SLIDE 51

2004 Users Group Americas Symposium • Partners in Innovation 51

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

slide-52
SLIDE 52

2004 Users Group Americas Symposium • Partners in Innovation 52

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

slide-53
SLIDE 53

2004 Users Group Americas Symposium • Partners in Innovation 53

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

slide-54
SLIDE 54

2004 Users Group Americas Symposium • Partners in Innovation 54

Results (cont’d)

Reduced Downtime

  • Improved asset management strategies may reduce downtime

and associated costs  Workcenter PKS™ tools look at process variables and

  • rganize 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

slide-55
SLIDE 55

2004 Users Group Americas Symposium • Partners in Innovation 55

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

slide-56
SLIDE 56

2004 Users Group Americas Symposium • Partners in Innovation 56

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

slide-57
SLIDE 57

2004 Users Group Americas Symposium • Partners in Innovation 57

Thank You

Pilot Plant: Workcenter PKS™ and @ssetMAX Alert Manager on Steam Generating Units