Dhana Raj Markandu: Evolution of the PI System in Tenaga's Power Generation Fleet (Slides)
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The document summarizes Tenaga Nasional Berhad's evolution with the PI data infrastructure system. It deployed PI across its diverse power generation fleet to unify real-time plant data previously locked in isolated control systems. This provided visibility and analytics to improve performance. Tenaga benefited from cost savings and revenue from internal PI system management and external deployment services. It continues enhancing PI usage and skills to further optimize operations.
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Dhana Raj Markandu: Evolution of the PI System in Tenaga's Power Generation Fleet (Slides)
- 1. Evolution of the PI System in Tenaga’s Power Generation Fleet Presented by Dhana Raj Markandu Senior Engineer, Generation Division © Cop yri g h t 2012 Tenaga Nasional Berhad
- 2. Contents • About Tenaga... • Our journey with the PI System... – Why we needed it... – How we deployed it... – What we’re doing with it... – Where we’re going with it... • Summary & Conclusions... © Cop yri g h t 2012 Tenaga Nasional Berhad 2
- 3. About Tenaga © Cop yri g h t 2012 Tenaga Nasional Berhad 3
- 4. Where we’re from... Images courtesy of Google Maps © Cop yri g h t 2012 Tenaga Nasional Berhad 4
- 5. What we do... Established in 1949 Largest electricity utility in Malaysia CORE NON-CORE USD 24 billion assets Power Repair, maintenance & diagnostic services USD 11.5 billion market capitalisation Generation Operation & maintenance Power sector projects 28,000 employees Power Transmission Training & education Installed generation capacity of 11 GW Research & development Power Consultancy services Distribution Contributes 55% of total national capacity © Cop yri g h t 2012 Tenaga Nasional Berhad 5
- 6. Our journey with the PI System © Cop yri g h t 2012 Tenaga Nasional Berhad 6
- 7. Why we needed it... Gas-fired Coal-fired Hydroelectric Diverse power plant fleet 300 MW 300 km 400 MW Inhomogeneous sources of operational data 1010 MW 1200 MW 2100 MW Real-time process data locked within isolated 250 km control systems 250 MW HQ Technical performance & business intelligence 2300 MW reliant on offline data 760 MW 580 MW 1400 MW 300 km UNIFIED REAL-TIME DATA PLATFORM 640 MW EASILY ACCESSIBLE TO ALL STAFF © Cop yri g h t 2012 Tenaga Nasional Berhad 7
- 8. How we deployed it... Phase I (2005 - 2007) Phase II (2007 - ongoing) Pilot project at one plant & headquarters Concurrent deployment to the other 9 plants Turnkey project implementation Federated in-house project implementation PROJECT VENDOR TENAGA PERSONNEL PI System infrastructure, applications, user PI System infrastructure, applications, user training & technical support training & technical support No direct OSIsoft involvement OSIsoft involvement at initial project deployment & as backup techsupport USD 7 million savings Staff competency in PI System © Cop yri g h t 2012 Tenaga Nasional Berhad 8
- 9. How we deployed it Generic architecture... STATION A STATION B Redundant PI Servers WAN Redundant PI Servers PI PI Server PI Server PI PI Server PI Server Interface (Primary) (Secondary) Interface (Primary) (Secondary) Node Node GENERATION HEADQUARTERS Redundant PI Servers PI Server PI Server (Primary) (Secondary) Station A Network Station B Network Station Control Station Control System System HQ Network Station A Clients Station B Clients Headquarters Clients © Cop yri g h t 2012 Tenaga Nasional Berhad 9
- 10. How we deployed it Actual infrastructure... 11 sites ~ 20 unique data sources 8 unique primary plant control systems 26 PI Servers > 50 Interfaces 25 12 > 15 Standard PI-to-PI Custom 150,000 tags AND GROWING... © Cop yri g h t 2012 Tenaga Nasional Berhad 10
- 11. How we deployed it Interfacing cybersecurity... Control System PI Server PI Server DIRECTIONAL FILTERING (Primary) (Secondary) Data from control network can flow to corporate network, but not vice versa PORT FILTERING Firewall Only data on PI Server port 5450 is enabled Port 5450 Station Network IP FILTERING PI Interface can only connect to PI servers PI Interface Audited & approved by security experts from Station Clients Tenaga ICT Division © Cop yri g h t 2012 Tenaga Nasional Berhad 11
- 12. How we deployed it Change management... Internal branding: GENERATION PLANT MANAGEMENT SYSTEM Key Messages Key Tactics Key Actions ...technical & business ...empower all staff with real- ...regular and customised performance project, time data & use quick-win live training conducted internally NOT an IT project. demos wherever possible. for all levels of staff. ...a platform that makes data ...demonstrate multiple streams ...constant user engagement easily available, BUT the of actual or potential cost via workshops, newsletters, application of that data is in savings & return on investment internal conferences, & subtle the hands of the end user. to gain management buy-in. integration into daily work. © Cop yri g h t 2012 Tenaga Nasional Berhad 12
- 13. What are we doing with it... UNLOCK Diverse power plant fleet UNIFY HISTORISE Inhomogeneous sources of operational data DISPLAY DATA Real-time process data NOTIFY locked within isolated control systems REPORT Technical performance DIAGNOSE & business intelligence reliant on offline data ANALYSE OPTIMISE © Cop yri g h t 2012 Tenaga Nasional Berhad 13
- 14. What are we doing with it Display, notify & report... PI ProcessBook Real-time fleet monitoring Linked to outage management system Scheduled reports automatically compiled, formatted & e-mailed daily Ad-hoc snapshots delivered on-demand using e-mail or text message Trip notifications by e-mail & text message Fleet status anytime, anywhere All notifications done using customised VBA coding within PI ProcessBook Management buy-in © Cop yri g h t 2012 Tenaga Nasional Berhad 14
- 15. What are we doing with it Diagnose... PI ProcessBook Real-time process data overlaid on static plant schematics Hyperlinked plant schematics for fast navigation & drill-down Ad-hoc trending Historical playback Virtual on-site presence Faster plant troubleshooting Improve technical competencies © Cop yri g h t 2012 Tenaga Nasional Berhad 15
- 16. What are we doing with it Analyse... PI ProcessBook, PI Datalink, PI ACE, PI AF Real-time performance analysis of individual equipment & overall plant Mass & heat balance analysis Degradation tracking Recoverable losses Justification for plant improvement projects Over USD 10 million expected annual fuel cost savings Greater performance awareness © Cop yri g h t 2012 Tenaga Nasional Berhad 16
- 17. What are we doing with it Optimise... PI ProcessBook, PI Datalink, PI ACE, PI AF Real-time unit dispatch optimiser for hydroelectric plant Potential savings by displacing gas units Dynamic tracking of unit efficiency curves Load advisor & what-if simulator Daily automated report via e-mail USD 3000 average daily fuel cost savings in 2011 Greater optimisation awareness © Cop yri g h t 2012 Tenaga Nasional Berhad 17
- 18. Where are we going with it... Installation Derive value from the PI System STATION A Redundant PI Servers by going beyond being just an end user PI PI Server PI Server Interface (Primary) (Secondary) Node Interfacing Training 2010 - Provide PI System deployment services for others Station A Network 2008 - Continuous in-house application development Station Control System Station A Clients 2007 - Deploy the PI System with internal personnel Tech Support 2005 - Engage vendor for pilot PI System deployment Internally-developed applications 60+ years of power industry experience © Cop yri g h t 2012 Tenaga Nasional Berhad 18
- 19. Where are we going with it Internal & external services... Internal Clients External Clients Expand PI System to other Tenaga divisions Provide full scope of PI System deployment services to external customers Pilot project with Distribution ongoing Completed projects: Two independent power plants in Malaysia & one integrated water Preliminary talks with Transmission ongoing and power plant in Saudi Arabia Offering PI System infrastructure for corporate Additional training & application development Facility Energy Management project requested after project completion The PI System as preferred data Establish track record as PI unification platform System service provider Enterprise agreement for Tenaga Non-core revenue for Tenaga © Cop yri g h t 2012 Tenaga Nasional Berhad 19
- 20. Where are we going with it Enhancing ourselves... Enterprise agreement? 2014 2013 Data mining PI Coresight 2012 Staff training Application development Tag expansion Hardware (+ 60,000) Dedicated technology diagnostics refresh team Improved cybersecurity (ISO 27001) Deployment for 3 new plants Tag expansion © Cop yri g h t 2012 Tenaga Nasional Berhad 20
- 21. Summary & Conclusions © Cop yri g h t 2012 Tenaga Nasional Berhad 21
- 22. EVOLUTION OF THE PI SYSTEM IN TENAGA’S POWER GENERATION FLEET “Deploying the PI System provides the infrastructure to unify, store, visualise and analyse our data. The real challenge is to transform this data into actionable information in order to make the right decisions and thus improve our technical and business performance.” Abd Ghafar Abd Latif Project Manager Generation Plant Management System BUSINESS CHALLENGE SOLUTION RESULTS & BENEFITS Diverse power plant fleet Deploy the PI System as a unifying Plant data available to all personnel data infrastructure for the entire fleet Inhomogeneous sources of Over USD 7 million savings from in- operational data Adopt in-house implementation house project implementation approach approach to build internal competencies Real-time process data locked within Over USD 10 million tangible savings isolated control systems Continuous change management from plant analysis & optimisation Technical performance & business Continuous in-house application Generate revenue by providing PI intelligence reliant on offline data development System deployment service to others © Cop yri g h t 2012 Tenaga Nasional Berhad 22
- 23. Conclusions... Tenaga has reaped the benefits of the PI System not just as a user, but also as a project implementer & service provider Tangible benefits Intangible benefits Project cost savings PI SYSTEM INTERNAL Skills development PROJECT IMPLEMENTER Operational cost savings PI SYSTEM USER Operational awareness Revenue generation PI SYSTEM EXTERNAL Business diversification SERVICE PROVIDER © Cop yri g h t 2012 Tenaga Nasional Berhad 23
- 24. Dhana Markandu dhana@tnb.com.my © Cop yri g h t 2012 Tenaga Nasional Berhad 24
- 25. Brought to you by © Cop yri g h t 2012 Tenaga Nasional Berhad
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