Empowering

operations with
PI System

Presented by Marcin Błasiak

Chief Production Management Systems Specialist at PGNiG
Termika

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Agenda

• About PGNiG Termika

• PI System in PGNiG Termika – business case

• Examples of PI applications

• Conclusions

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History…
• 1904 – first power plant in Warsaw – CHP Powiśle

• 1914 – CHP Pruszków

• 1954 – first turbine in CHP Żerań

• 1961 first turbine in CHP Siekierki

• 1974 – HOB Wola

• 1983 – HOB Kawęczyn

• 2000 – Vattenfall Heat Poland

• 2012 – PGNiG Termika

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 About PGNiG Termika
• Since January 2012 Vattenfall Heat
Poland became PGNiG Termika
1904 – first Power Plant in Warsaw
• 5 Power plants (3 CHP’s and 2
HOB’s
• First Heat Accumulator in Poland 1 554 MWt
298 MWe
CHP Siekierki
• PGNiG Termika produces over 40 465 MWt

mGJ of heat covering 70 % of

Warsaw’s heat demand
• Annual electricity sales covers 50 %
of Warsaw’s electricity consumption
(cogeneration)
186 MWt
• PGNiG Termika supports district 9 MWe
heating grid owned by Dalkia Polska
• Fuels: hard coal, biomass

465 MWt

2 014 MWt
622 MWe

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 Background
The beginning …
5 independent Power Plants
Lack of detailed central planning
lack of central monitoring of technological
process
Not optimal production process

Target… efficiency improvement

The beginning of Production Dispatch

Need for detailed information exchange with partners
A lot of calculations & reporting… very quickly
Quick access to information about production process
Need for production process optimization

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 Challenge…
Information exchange
Dispatch Centre layer CHP
Production Planning Main devices status Production coordination
• short-term Information about
Asset Management
• long-term services
Production plans
Production process control
On-line analysis
• Emission reporting and reporting Distributed Control
• efficiency reporting Systems
• on-line optimization

Production coordination External partners

Production plans
Portfolio management Trading plans Power grid coordination
• fuel register Statistic reporting
Heat network coordination
• products register Main devices status
Trading
Analysis

Distributed Control
Support required !!! Systems

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 Business case
VHP: Operational Data Protected

“We needed to gather the complex information

about technological process and store it in one
place. W needed a system that would make these
information easily accessible for many person. We
also needed system that would provide tools for
analyses and reporting”

Customer Business Challenge Solution Customer Results / Benefits

• Providing the possibility of central • Implemented PI system to provide

production management data from production area to all • Incrased number of analysis in the
production and business area same amount of time
• Providing complex information about
technological process and tools for • Provided view to the data using • Decreased variable costs caused by
analysis ProcessBook (synoptic screens) and on-line cost calculations (ca. 50 kEUR
DataLink (analysis) per year)
• Making the system user-friendly and
easily accessible for many users • Provided ACE for continuous • Increased efficiency in consequence of
advanced calculations on-line efficiency calculations (3–5 %)
• System should be flexible for
upgrades and development • Provided MCN Health monitoring to • Increased accesibilty to information
secure the system efficiency about production process

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 Areas of benefits
• Process KPI’s • Exchange of
• Condition of production plans
devices • Devices status
• Settlements reporting
• Reporting • Production
Production Process
Production monitoring
Monitoring and
coordination
reporting

Production
optimization
• Data for
scenario
analysis
Main goal: • On-line
calculation and
Implementing user-friendly analysis
and time-saving tool for • Support for
data analysis and reporting decision making

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 Architecture
Business Network Office workstations IFS, Optima etc.
(5 locations)

PI Servers ACE / RtWebParts

Production VLAN
(5 locations - >40 int.)

PI Interfaces

DCS Systems
DCS 1 DCS 2 DCS n

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IT Systems in PGNiG
Business IT DCS Systems

• IFS • AC800xA – Melody ABB

• Data Warehouse • SYMPHONY ABB
• Optima Controlling • Ovation – Westinghouse
• LM system Pro • MetsoDNA – Metso
• Weibull Analysis • WIZCON
• RCM++ • Freelance 800F – ABB
• ESSII • Asix - Askom
• BOFIT

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Implementation of PI System in PGNiG
Termika
First implementation of PI System was done by
PlantSoft – German based company operating mostly in
Germany, Czech Republic and Poland

Implementation was done in two steps:

1. PI Server implementation with few major interfaces – apx. 2000

data streams
2. Upgrade of server cluster and 50000 data streams

PGNiG Termika has SLA with OSISoft (Server

maintenance) and Plantsoft (PI applications
maintenance)
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Implementation of PI System in PGNiG
Termika
Installed packages:

• PI ProcessBook
• PI DataLink
• PI WebParts
• PI Notifications
• PI MCN Health Monitor
• PI ACE (Advanced Computing Engine)
• PI Module Database

Over 45.000 tags in use

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Implementation of PI System in PGNiG
Termika
PI applications:

• PI ProcessBook screens
• PI Datalink reports
• Efficiency calculation and monitoring
• Reports
• Manual data storage (laboratory analysis)
• Data source for other systems

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 Benefits: Monitoring & reporting
Process of settlements before Process of settlements after PI System
PI System Implementation Implementation

Production network
DCS Systems

Production network

Production network

Production VLAN

PI Servers
End user

Business network

Providing data from each Providing data from each system End user
system requires a person requires no extra staff – we need
responsible for data export only interface (ex. OPC).
In VHP we saved ca 500 hours per year with PI
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 Benefits: Monitoring & reporting
PI System is an important place of data preparation for Data
Warehouse

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 Benefits: Optimization
Optimal operating point Efficiency report - boiler losses

&
100%

80%

60%

40%

Condition based 20%

0%
08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07-
10 11 12 13 14 15 16 17 18 19 20

maintenance Time

Loss 1 Loss 2 Loss 3 Loss 4 Loss 5 Loss 6 Loss 7 Loss 8 Loss 9 Loss 10

On-line data analysis

Production optimization
support with PI System
KPI’s

Variable cost
PLN / MWh

On-line calculation
Load / Max. load

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Benefits: Operating point
On-line efficiency monitoring
helps us to operate only the most
efficient units at their optimal point
and save up to 2…3% of fuel

Efficiency report - boiler losses

100%

80%

60%

40%

20%

0%
08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07- 08-07-
10 11 12 13 14 15 16 17 18 19 20
Time

Loss 1 Loss 2 Loss 3 Loss 4 Loss 5 Loss 6 Loss 7 Loss 8 Loss 9 Loss 10

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 Benefits: KPI monitoring
Data aquisition Data analysis Results

PI graphics

on-line
values
On-line KPI’s
data analysis
Manualy validation engine
entered data

Values that are inputs

for other calculations
• Data analysis processed by ACE • Efficiency calc.
engine.
• Variable costs calc.
• Input and output data stored in
• Data validation
PI archive
• Thermal calc.
• Calculation time-triggered
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Benefits: KPI monitoring

KPI monitoring helps us to define

strategic goals and take
the right actions
In the right time

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 Benefits: KPI monitoring
Basic info on KPI monitoring tools:
● All KPI’s are calculated in PI ACE environment
● Input data come from live objects (raw data) and manual entry
(manual data)
● Input data is tested and verified in validation algorithms

KPI’s that are monitored:

● Efficiency indicators (losses, specific energy consumption, specific
production costs etc.
● Performance & condition indicators (key maintenance parameters,
availability etc.

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 Benefits: Condition based maintenance
Neural networks (production parameters prediction)

G, P, T Turbine
Electricity 3 steps to define a calculation
production
Steam from boiler

G Ne
Ne = f(G,P,T,Q)
Q
Heat flow to
heat-exchanger Model definition – Neural networks

Real values

Prediction Translating model into ACE module

By finding relationships between

device operational parameters
Applying ACE calc. Into PI graphics
and overall eficiency we can easily
Indicate device failure or
bad condition © Copyri g h t 2012 OSIso f t , LLC.
 Benefits: Efficiency monitoring
96,00 Efficiency loss

95,00

94,00

93,00

92,00

91,00

90,00

89,00

Instead of complex measurement procedure twice a year we provide online calculation

(in connection with neural networks) to see how device (boiler behaves)
On-line calculation = another 50.000 EUR saving per year

© Copyri g h t 2012 OSIso f t , LLC.

 Benefits: Variable costs monitoring

Max.
On-line variable cost
3% Calculation gives possibility
PLN / MWh

to choose between optimal

devices set
to provide optimal configuration

Optimal configuration =
ca. 50.000 EUR saving per year

Load / Max. load

© Copyri g h t 2012 OSIso f t , LLC.

Summary of benefits

• Improvement of data storage safety.

• Improvement of efficiency and quality of analysis.
• Improvement of production efficiency.
• Improvement of data accessibility.
• Large scalability of PI System.
• Quick and easy integration with other IT Systems

• And many more depending on user requirements…

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Contanct

Marcin Błasiak
[email protected]
+48 22 587 89 98

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