PI – An Enterprise Integration Tool Mark Brown – Calpine Corporation Mark Bowles – Calpine...

PI – An Enterprise Integration Tool

Mark Brown – Calpine Corporation

Mark Bowles – Calpine Corporation

Sam Jenkins – Calpine Corporation

Calpine IS Operations Engineering Services – Solutions at the Speed of Business

Who is Calpine?•Founded in 1984 •Traded in the New York Stock Exchange (CPN) •Listed on the S&P 500 •Ranked 25th among FORTUNE magazine's 100 fastest growing companies •22,000 + megawatts currently in operation (82 facilities in 23 different states as well as Canada and the United Kingdom)•Owns 1.0 trillion cubic feet of proved natural gas reserves •Uses clean, proven technologies: natural gas combined-cycle and geothermal energy •World's largest geothermal power producer


Calpine and their history with PI

•Calpine standardized on PI as their operations historian in early 2001

•Prior, a mix of control system historians and embedded historians were used

•The data gathered by these devices could not easily and efficiently be transmitted external to the facility

•Higher risk of invalid or untimely data being used to support business decisions

•The amount of historical data available was also limited to the type of historian installed


What will you see in this presentation?

Calpine has used PI to integrate data between many systems throughout the enterprise.

•We will highlight our implementation infrastructure

•Our Team Responsibilities

•How PI is leveraged to support business functions

•A focus on Continuous Emissions Monitoring

•How we monitor PI systems in our enterprise

•Question and Answers opportunity


Calpine’s PI Infrastructure

•PI is installed at 79 of Calpine’s 82 generating facilities

•We have 55 production PI servers and 24 PI API nodes

•Not all sites require a production PI server, so API nodes are installed and interfaced with a production server

•We installed 37 PI systems in 2001, 41 in 2002, and 1 so far in 2003

•PI is a standard installation at all generating facilities


Calpine’s PI Infrastructure (Continued)


Calpine Business Units Supported

•Calpine Power Company – All power plants including cogen, peaker, and geothermal facilities.

•Production Reports – hourly/daily/monthly/annual reporting periods for, MW, fuel, heat rate, duct burner usage, individual CT reports

•Support contractual obligations such as steam delivery and fuel consumption reporting.

•Plant level maintenance – interfacing with Maximo



•Turbine Maintenance Group – Provides maintenance and tuning services for Calpine’s entire fleet of turbines.

•Interfacing tools such as vibration analysis

•PI data used to support turbine performance tuning and degradation

•PI data used for preventive maintenance

•PI used to provide local access to real time turbine data that otherwise would not be available outside the plant, reducing travel costs.



•Calpine Energy Services – Performs Calpine’s trading, risk control, and marketing functions.

•PI supplies data to our Energy Management System

•PI is used to generate production reports for MW and fuel that are used in the billing and settlement process

•PI data is used to illustrate actual MW produced vs. MW available for sale



•Plant Optimization Group – Provides plant performance improvement services, focusing on thermodynamics.

•PI supplies data used to validate unit and system design

•PI is used to generate performance evaluation and plant optimization tools

•PI is used to evaluate years of operational data for application in plant betterment studies



•Calpine Natural Gas – Focuses on developing and acquiring strategic natural gas reserves to help reduce fuel costs.

•Accounting – PI data used for billing, settlement, and reconciliation

•Power Systems Manufacturing – Wholly owned subsidiary responsible for combustion turbine component engineering, design and production


IS OES Team Management and Support Functions

•System Architecture

• Custom PI Client Tool Development

• Data Validation

• Real-Time Environmental Monitoring

• Achievement of Consistent Benchmarking

• Maximizing the Value and Extending the Life of Installed Control Systems

• Improved Unit Availability and Unit Design Validation

• Collect, Manage, and Distribute Real-Time Operations Data


Examples of Custom PI Client Tools


• Preliminary – Plant monitoring

• Driver - Calpine’s Safety Health & Environmental Group

• The Role of PI

• Value creation

Calpine PI Continuous Emissions Monitoring System (CEMS)


•Requirements

•Ability to view data from 6 plants as 1 system or portfolio

•Ability to track each plant individually

•Make the same data available to anyone in the Calpine enterprise

•Interfaces – PI directly interfaces with 3 different CEMS DAS systems CISCO, ROSEMOUNT, KVB

•Data – PI Archives NOX, CO, NH3 and O2



•Performance Equation tag creation – CEMS DAS only provides limited data necessitating the creation of multiple PI performance tags.

•Multiple performance equation tags

•Units of measure and conversions – PPM, LBS, Tons

•Data Verification and Validation

•Rollup tags - create the Big Picture



•Dashboard Concept and Creation

•Process Book Dashboard is a decision assist tool

•Managing the CEMS information requires real time viewing of the data – Process Book Display

•Cap & Trade System View

•Dashboard Capabilities Ability to drill down to Site and Units specific data



•Summary

•Dashboard Processbook

•Dashboard - Decision assist tool

•The role of PI

•Value creation



•Calpine’s Field Data Acquisition group has a goal of 99% availability for it’s PI systems

•Monitoring 55 Calpine PI Systems

•Proactive monitoring minimizes troubleshooting resources required

Calpine PI Systems Monitoring



•Network Availability

•PI-Ping Interface – Used to archive the network availability at each site

• Availability Report – PI DataLink report that calculates the availability for a period and compares that value against previous availability metrics



•Monitoring Displays

•Monitoring Map Display – Indicating current network availability for each Calpine PI System

•Site Monitoring Displays – Detailed trending of key data items gathered by the PI Performance Monitor Interface. This data is used for root cause analysis of PI performance issues as well as to identify trends of degrading performance


•Notification Services/ Strategy

•Data items monitored

•Raw tag from each interface

•Critical performance equation tags

•Primary archive number to prevent archives from being overwritten

•Notification

•Email

•Text Message to Cell Phone



•Best Practices

•Monitor Proactively

•Root Cause Analysis

•Historical Metrics for Comparison



Questions?

PI – An Enterprise Integration Tool

Contact InformationMark Brown

702 West Drake Rd.

Fort Collins, CO 80526

(970) 224 – 4131 x126

[email protected]

www.calpine.com

Troy Lauterbach

702 West Drake Rd.


(970) 224 – 4131 x126

[email protected]

www.calpine.com

Sam Jenkins

702 West Drake Rd.


(970) 224 – 4131 x126

[email protected]

www.calpine.com

Mark Bowles

702 West Drake Rd.


(970) 224 – 4131 x126

[email protected]

www.calpine.com

Rob Low

702 West Drake Rd.


(970) 224 – 4131 x126

[email protected]

www.calpine.com

mailto:[email protected]

http://www.calpine.com/

mailto:[email protected]

http://www.calpine.com/

PI – An Enterprise Integration Tool Mark Brown – Calpine Corporation Mark Bowles – Calpine...

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