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THE IMPLEMENTATION OF LUMUT ADVANCED REAL-TIME INFORMATION SYSTEM (LARIS) AT LUMUT POWER PLANT

THE IMPLEMENTATION OF LUMUT ADVANCED REAL-TIME INFORMATION SYSTEM (LARIS) AT LUMUT POWER PLANT. Mohd Helmy Ibrahim Sufyan Mohd Nor. Segari Energy Ventures. Contents (1). Introduction - Lumut Power Plant & Teknik Janakuasa Sdn. Bhd. The Changing Scenario

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THE IMPLEMENTATION OF LUMUT ADVANCED REAL-TIME INFORMATION SYSTEM (LARIS) AT LUMUT POWER PLANT

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  1. THE IMPLEMENTATION OF LUMUT ADVANCED REAL-TIME INFORMATION SYSTEM (LARIS) AT LUMUT POWER PLANT Mohd Helmy Ibrahim Sufyan Mohd Nor Segari Energy Ventures

  2. Contents (1) • Introduction - Lumut Power Plant & Teknik Janakuasa Sdn. Bhd. • The Changing Scenario • Our Business Processes - Planning and Asset Management • Integration of Technical and Financial Data • The Technical Model • Why PI ?

  3. Contents (2) • Introducing LARIS • LARIS - Graphics, Reports, Trends, Calculations • Linking with Automatic Billing System • Visual Basic Program - An Example • Pre-PI Days versus Now • Looking Back • Final Words

  4. Introduction • Teknik Janakuasa Sdn Bhd (TJSB) operates & maintains Lumut Power Plant (LPP) • TJSB is a 100% Malaysian company, specializing in O&M services • O&M Contract with Segari Energy Ventures (SEV), the Owner of LPP • Business relationship governed by Power Purchase and Operation & Maintenance Agreements (PPA and O&MA) • Payments are directly proportional to Availability, Reliability and Efficiency

  5. TJSB’s Mission Statement • To continuously generate electrical energy safely, reliably and efficiently to meet the needs of the customers • To procure the best returns to the shareholders • To be the best service company in the Operation & Maintenance of a power plant

  6. Lumut Power Plant - Business Structure

  7. LPP - A Brief Description • Largest combined cycle gas turbine power plant in Malaysia ~ 1303 MW net • 2 generating blocks with 3 x ABB 13E2 gas turbines, 3 HRSGs and 1 steam turbine in each block • Main fuel : Natural gas, Back-up fuel : Diesel • Off-taker : Tenaga Nasional Berhad (privatized national utility) • Commercial operation 1996

  8. Where is Lumut Power Plant ?

  9. Lumut Power Plant, Malaysia

  10. The Changing Scenario • Imminent deregulation of Malaysian electricity market • Generating plants will be selected based on merits - heat rate / operating cost / grid stability • Key word - competitiveness!!! • The Malaysian national grid will be operated by IGSO in the year 2000 • The need for integrated information available at fingertips

  11. Business Process ~ Planning • To develop plans/forecasts that support the allocation of resources with respect to demand, profit potential, etc. • Example : Revenue Forecasting, Long Term Major Inspection Scheduling, Identification of Capital Project Improvements, Maintain Environmental Compliance, etc.

  12. Business Process ~ Asset Management • To maximize the life of plant major components • Example : Analysis of Trade-offs Between Efficiency and Availability, Prioritization of Tasks for Capital Improvement, Optimization of Spare Parts Procurement, etc.

  13. Bottom Line : Integration of Business Data • Technical data to be provided to PI from plant Distributed Control System (ABB PROCONTROL) and Computerized Maintenance Management System (SAP/R3) • Financial data to be imported from Auto Billing System (ABS) • Further integration in later phase e.g. from Performance Monitoring, Condition Monitoring, Finance packages

  14. Technical Model • Decision support tool • To assist in maximizing profitability and efficiency of LPP • To provide technical support for the plant • Top management monitoring • Central data historian - PI

  15. Technical Model (continued) • Interfacing with other systems - Auto Billing System (ABS), SAP/R3, Condition Monitoring, etc. • Evaluation of what-if scenarios • Tailor-fit to facilitate business processes • Give edge to O & M services

  16. Technical Model - Architecture

  17. Technical Model - Schedule • Phase 1 - Implementation of PI and linking to Auto Billing System (ABS) : LARIS • Phase 2 - Further development with links to other applications : SAP, Performance Monitoring, etc. • Phase 3 - Complete implementation of Technical Model as decision support tool

  18. Why PI ? • The need for a database system to act as historian and central linkage for information flow • Establishment of a Technical Model to be used as tool for planning/forecasting • Experience of PI being used by National Power’s Deeside and Killingholme • Availability of local support

  19. LARIS - Main Functions • Collection of data from ABB PROCONTROL • Present snapshot process values on customized graphics • Generate reports • Perform customized calculations • Historization of process data • Retrieve net energy and plant availability information from Auto Billing System

  20. TJSB 2 LPP Personnel (Technical Support Group) 2 HQ Personnel (Technical Services) PI-CSE Systems Engineering 2 Systems Engineers 1 Assistant Engineer LARIS Project Team

  21. LARIS Project Schedule

  22. LARIS - System Architecture

  23. 10,000 tags PI Server - Alpha 2100 DCS - 6147 tags Calculation - 187 tags Manual input - 24 tags ABS - 34 tags PointType - Float16 for analog points Naming convention - KKS code for DCS tags Naming convention - AA_xxx.C for calculated tags CompDevPercent = 0.1% Archive capability of one year LARIS - Salient Features

  24. Plant Overview Plant Generation Status Block Overview GT Overview GT Condition Monitoring GT TET Distribution HRSG Overview ST and Condenser Overview ST Condition Monitoring Block Single Line Overview Block Auxilliary Power Consumption Block Water Chemistry LARIS Graphic Displays

  25. LARIS Graphic Displays

  26. Block Emissions Monitoring Block Main Cooling Water System Gas Metering Station Block Main Pumps Condition Monitoring LARIS Graphics Displays

  27. LARIS Reports • Block Daily Performance • GT Daily Performance • ST Daily Performance • Condenser Performance • Auxiliary Consumption • Plant Proforma

  28. LARIS Trends • GT Trends • ST Trends • HRSG Trends • Water/Steam Cycle Trends • Main Cooling Water and B.O.P Trends • Single Line Trends • Common Trends

  29. LARIS Trends

  30. LARIS Calculations • Plant heat rate / efficiency • Block heat rate / efficiency / fuel consumption / auxiliary consumption • GT heat rate / efficiency / load factor / compression ratio • ST heat rate / efficiency

  31. LARIS Calculations • Energy payment / generation cost • Heat rate deviation / fuel saving • Condenser subcooling • Steam energy flows

  32. Done in PI-PE Simple, straight forward calculations Some are used in the VB programs Mostly instantaneous Example : totalised gas flow, load factor, heat rate, etc. Done in VB Programs Slightly complex Reference table and Steam programs Scheduled calculations Example : heat rate deviations, energy payment, steam energy calculations, etc. LARIS Calculations

  33. SAT - Criteria for Acceptance • Functionality - correct graphics and links • Overall layout - including graphics, reports • Calculations - checked against manual calculation using MS Excel • Verification - tags are what they are, with reasonable accuracy (+/- 0.5%) • Manual entry - test for up-dating

  34. SAT - Criteria for Acceptance • Visual Basic programs - check that they are correct and give the expected results • Speed test - internal test as a baseline case • Linking to ABS - grabs data as scheduled • System stability

  35. Linking to Auto Billing System • ABS is used by TJSB to bill SEV / TNB • ABS reads data from a stand-alone energy metering system • ABS converts text file data to meaningful figures • ABS calculates the total net energy from LPP, availability figures and total payments • Energy data is in MWh for every 30 minutes

  36. Linking to Auto Billing System • ABS Server resides at HQ • LARIS access ABS Server every 2 hours to grab net generation data for each machine and store in PI database • Special program to calculate all net performance calculations • Plant personnel now have more feel for relationship between income and performance

  37. VB Program - Calculating Block Gross Heat Rate Deviation (1) Establish connection to PI Server Get the timestamp for calculation Get actual Block Heat Rate e.g. Blk1_DGHR.C Determine time periods for when any GT changes status e.g. check 11MKA10GS100_XU19 For identified time periods, get average gross generation e.g. Blk1_GGEN.C Next Slide

  38. VB Program - Calculating Block Gross Heat Rate Deviation (2) Look up strapping table for PPA guaranteed net heat rate e.g. 2 GT @ 390.9 MW = 7843 BTU/kWh Calculate guaranteed fuel consumption (MJ) for each time period identified Totalize the guaranteed fuel consumption and block energy for one day Calculate daily guaranteed net heat rate e.g. DGNHR = DGFC / Daily Block Energy Compare with actual actual daily block heat rate e.g. Blk1_DGHR - DGNHR (Blk 1) Calculate block heat rate deviation e.g. Blk1_GHRDVTN (in %)

  39. Pre-PI Days • Manual acquisition of process data from ABB PROCONTROL and Auto Billing System • Manual calculation of performance parameters in MS Excel • Extensive plant manual readings • No instantaneous plant status to HQ • Limited process database

  40. Now ….. • Steadily shifting towards more automated data flow • Set up of central information flow for future phases of Technical Model • Better communication, especially with HQ (Kuala Lumpur is 360km away)

  41. Looking Back - Plus Points • Full backup of top management • Consultants did a decent job with the programming • Dedicated team - maximum involvement and transfer of skills • Readiness of all staffs to adapt to a new system • Hiccups during implementation and testing - good learning ground

  42. Looking Back - Minus Points • Client was not informed about the Steam Program Package • Wrong PI-Net tape delivered ~ 2 weeks of delay • Not enough bandwidth between Lumut and KL ~ slow response • Consultants limited knowledge on process • Price is on high side • Project schedule slightly ambitious

  43. Looking Back - More Minus Points • OSI’s standard format on the Services and License Agreement - inflexible and ambiguous with respect to the role of a local dealer • Local support - present consultants may not be around ?

  44. Final Words • Competition in the power industry is inevitable • Data on plant operations and maintenance is invaluable • Technical Model relies on archival of accurate data • PI is flexible and friendly to use

  45. Thank You

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