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
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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 .
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Who am I?
• Robert ‘Dean’ Lee – Hired with Virginia Electric and Power Company (VEPCO),
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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Business Solution
 The Operational Excellence Team began developing
a plan:
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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 .
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Business Solution Requirements
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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
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and below ‘Normal’
Viewable alert limits
Interactive color changes
Tune-able trigger points
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Plant site rollups
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Dependable delivery
Maintenance Manageable
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Corporate Level Rollups
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Email and/or text
messaging capable
for alerting
Minimal O&M or
Capital Investments
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Use what we have, if
possible
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Mobile Accessibility
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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 .
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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 .
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Delivered Solution
© 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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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 .
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Grey is GOOD
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Station View
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Station View
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Station View
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .
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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 .