Sequence of Events Recording for Kardia Power Station Greece

1. Sequence of Events Recording for Kardia Power Station Greece Ian Loudon Omniflex International Marketing and Sales

2. Omniflex • Omniflex South African Manufacturer of Industrial Electronic Products • Founded 1965 as Conlog became Omniflex 1996 • 50% of Turnover exported • Sales Office JHB, UK, Australia Head Office Durban • Wonderware and Sequence of Events recording since 1988 ESKOM, Sasol, Natref

3. Introduction This Project improves an ageing Coal Fired Power Station Root Cause Analysis by 90% Kardia Power Station Greece

4. Introduction Project Solution Agenda Benefits Considerations Summary

5. Kardia Power Station Greece Up to 50% of Greece’s Electricity from Coal (Lignite) 6 Lignite Fired Stations Agios DimitriosAmyntaioFlorinaKardiaMegalopolisPtolemais How much coal is required to run a 100-watt light bulb 24 hours a day for a year?

6. Background to the Project Location : GreeceOperator : Public Power CorpConfiguration : 4 X 300 MWOperation : Since 1975 ……Fuel : LigniteBoiler : Stein, Ganz-RockT/G supplier : Alstom, LMZ, TeploenergoEPC: Zarubezhenergoproekt T/G Turbine Generator EPC Engineering Procurement Construction

7. Business Objective • Plant Optimization • Reduce Downtime • Effective Alarm Localization • Nuisance Alarm Identification • High Availability • Cost effective Solution

8. Operational Objectives • Root Cause Analysis • Alarm History • Local Alarm Indication • Fast and Reliable Event Capture • Redundancy of I/O Processors

9. Introduction Project Solution Agenda Benefits Considerations Summary

10. Selection of Solution • Local SI for Local Support • Wonderware SCADA selected for • Ease of configuration • Minimal effort to integrate Date and Time Stamp at source event streams through OPC server

11. Sequence of Events Recording System

12. System Implementation • 960 Relay Contact Inputs COS monitoring • 960 Alarm Statuses Annunciated • Input discrimination to 200μseconds • Minimum Pulse Width 500μseconds • Time Stamping Accuracy 200μseconds

13. System Diagnostics

14. Historical Alarms

15. Alarm Summary

16. Time Synchronization • GPS Station Time • OPC server Service

17. Controller Redundancy • Dual Controller • Includes Queue Services

18. Topology SCADA Primary OPC Marshalling Panel Conet Field Inputs Ethernet Secondary Modbus CAN

19. Disadvantages of Poll Response Disadvantages of a poll/response network · Poll/Response uses %100 of available bandwidth. · The data "Transport" is the "Application". You can't break them apart. · One protocol for all field equipment limits deployment of new technology & impedes migration to new topologies. · It is not a "managed" network. · One-to-One data relationship between the Host and field equipment Master Slave

20. Producer Consumer Subscription Consumer Application 1 Middleware Message Broker Eg Queue Service Producer eg SOE System Consumer Application 2 Publish Subscribe Subscribe Consumer Application 3 • Advantages: • Network Traffic Minimized • Efficient use of Network Bandwidth • Multiple consumers

21. System Implementation • In House Engineering and Testing and Configuration, SCADA, OPC, Maxiflex 1 week • Local Panel Alarm Annunciators via Modbus RS485 • Wonderware SCADA Final Configuration On Site • Copy Paste for Second System 2 Days In House Engineering and Testing

22. Introduction Project Solution Agenda Benefits Considerations Summary

23. Benefits / Goals Achieved • Plant Optimization  • Reduce Downtime  • Effective Alarm Localization  • Nuisance Alarm Identification  • High Availability 

24. Benefits / Goals Achieved • Root Cause Analysis  • Alarm History  • Local Alarm Indication  • Fast and Reliable Event Capture  • Redundancy of I/O Processors 

25. Realised Benefits • 90% improvement in Root cause analysis • 25% improvement in Generating Availability • 40 to 50% time saving in Maintenance • Huge Saving on Hard Wired Annunciation • Project Implementation Short • End User Empowerment on system usage, migration and on going improvement • Rapid Deployment of next Generator system

26. Introduction Project Solution Agenda Benefits Considerations Summary

27. Lessons Learned • Learn to Speak Greek ! Real Greek • Partnering with local Wonderware SI’s essential • Preconfigured Wonderware for Front end Hardware from Factory simplifies field work

28. Introduction Project Solution Agenda Benefits Considerations Summary

29. Conclusions • Wonderware was a good choice for seamless integration of Date and Time stamped events into an HMI for management of Alarm and Events. • Wonderware Presence worldwide presented this opportunity for us from a South African and UK Base.

30. Project summary • “The system works well and enables incidents to be tracked very efficiently”.Ilias Kalaitzis ,Project Engineer, Control Systems

31. Project Summary • Project Delivered in 2008 on time during Shut Down of Generator Unit Period 16 Weeks Entirety • Second Unit simple Copy and Paste for SOE Configuration. Completed Dec 2008 • We are expecting orders for the balance of 2 Generator Sets

32. Questions ? Solutions by Design