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Adding a new dimension to running the plant in the optimum
way, made possible by PI System.
Mat Isa b. OsmanStesen Janakuasa Sultan Azlan Shah.
Manjung, Perak.
24 October 2007
Intro – Stesen Janakuasa Sultan Azlan Shah, Manjung.
• A wholly owned subsidiary of TNB.
• Commercially Operation in 2003.
• 3 x 700 MW coal fired power plant.
• EPC by Alstom.• Location : Teluk Rubiah,
Manjung, Perak.
Glimpse Views of SJSAS
Look Ahead
Vision
To be the Region’s BestIndependent Power Producer by Year 2010
Mission
We are Committed to Adopt Service Excellence in Driving our IPP Business to Deliver the Best Products, Services
and Customer Satisfaction
GPMS at SJSAS Manjung• Plant information system via Portal accessible to every
LAN users.• Online real-time dispatch optimization• E-mail alerts is useful in giving reminder on critical plant
status.• On line PI - Alarm System.• Plant information is on the desktop for reports and
troubleshooting task.• More calculated data are available to PI-System users
e.g. Integrator readings, auxiliary power consumption.
TNBG Architecture – Pilot PhaseTNBG Architecture – Pilot Phase
BaileysDCS
BaileysDCS Turbine
ControlTurbine Control
Boiler Control
Boiler Control
Manjung PI Enterprise ServerManjung PI Enterprise Server
Corporate WANCorporate WAN
SharePointRtWebPartsStation OverviewsKPI VisualisationReports
SharePointRtWebPartsStation OverviewsKPI VisualisationReports
PI Enterprise ServerPI Enterprise Server RtPortal ServerRtPortal ServerUsersUsers
20K PI ServerPI-DAPPI-ACEReport GenerationPerformance EquationsOPC Server to SAPPI to PI Interface to SJRDBMS Interface to EMS
20K PI ServerPI-DAPPI-ACEReport GenerationPerformance EquationsOPC Server to SAPPI to PI Interface to SJRDBMS Interface to EMS
Corporate GPMS UsersInternet Explorer
Corporate GPMS UsersInternet Explorer
10K PI ServerPI-DAPReport GenerationPerformance Equations
10K PI ServerPI-DAPReport GenerationPerformance Equations
PI-API NodeInterface to DCS (OPC/INICU)Interface to Boiler Control (Modbus)Interface to Turbine Control (Modbus)
PI-API NodeInterface to DCS (OPC/INICU)Interface to Boiler Control (Modbus)Interface to Turbine Control (Modbus)
Other systems…SAPDocument Mgt SysMaintenance System
Other systems…SAPDocument Mgt SysMaintenance System
Station LANStation LAN
Station UsersProcessBookDataLinkPI Manual LoggerInternet Explorer
Station UsersProcessBookDataLinkPI Manual LoggerInternet Explorer
TNBG Architecture – In ProgressTNBG Architecture – In Progress
SJ ManjungSJ Manjung SJ Tuanku JafaarPort Dickson
SJ Tuanku JafaarPort Dickson
SJ Sultan Ismail PakaSJ Sultan
Ismail Paka
Corporate WANCorporate WAN
PI Enterprise ServerPI Enterprise Server RtPortal ServerRtPortal ServerUsersUsers
TNBG WANTNBG WAN
SJ PutrajayaSJ Putrajaya SJ Sultan IskandarPasir Gudang
SJ Sultan IskandarPasir Gudang
SSJ CameronHighlands
SSJ CameronHighlands
SJ KenyirSJ Kenyir SJ PerakSJ Perak SJ GelugorPral
SJ GelugorPralSJ Jambatan
ConnaughtKlang
SJ JambatanConnaught
Klang
TNB Gen Div – GPMS Home PageTNB Gen Div – GPMS Home Page
Manjung’s – GPMS Home Page
PI - Alarm System
Online real-time alarm system
Based on OEM Operating Instruction
Advise operator on how and what action to take.
Operator could record on which action has been acted on for future reference
Online PI - Alarm System
• Online real-time alarm system
• Based on OEM Operating Instruction
• Advise operator on how and what action to take.
• Operator could record on which action has been acted on for future reference
Online PI - Alarm System
• Online real-time alarm system
• Based on OEM Operating Instruction
• Advise operator on how and what action to take.
• Operator could record on which action has been acted on for future reference
Plant AMS Optimiser
Online real-time dispatch optimization
Online performance monitoring calculations based on ASME for all major equipment e.g. Boiler Efficiency, Heat Exchanger Effectiveness, etc.
Sootblowing calculations consist of frequent assessment of the heat transfer values for the various exchanger banks.
Online real-time Dispatch Optimization
Plant Heatrate Monitoring
Online performance monitoring calculations
Auxiliary Power Consumption Calculation
Boiler Heat Transfer Multiplier Monitoring (tube cleanliness)
Usage of PI ProcessBook and PI-Datalink in Manjung
Personal screens were developed by individuals according to their needs.
Tedious data taking task is made easy by PI-Datalink.
Calculated data feature in PI-Datalink help user to calculate data to useful common statistical results. Installation of expensive equipment is not longer required. E.g. convert flow reading to a totaliseddata.
Personalised Monitoring Screen (1/3)
Personalised Monitoring Screen (2/3)
Personalised Monitoring Screen (3/3)
Report - Offline Energy (Start up Energy Requirement)
• Sample of PI Datalink application.
• Start up energy used during plantstart up could calculated.
E-mail Alerts
• PI will generate e-mail alerts on critical plant status.
• Trigger set point can be customised as required.
• Information now available in your mail box even away from site.
Easy Distillate Consumption Monitoring (1/2)
• Fuel consumption during plant start-up is easily calculated.
• Data convey to Operator for post mortem info for improvement process.
• Fuel consumption during plant start-up is easily calculated.
• Data convey to Operator for post mortem info for improvement process.
Easy Distillate Consumption Monitoring (2/2)
Distillate consumption calculation using PI- Datalink
Expensive equipment is not longer require
Distillate consumption calculation using PI- Datalink
Expensive equipment is not longer require
Plant Condition Monitoring (Condenser Effectiveness)
• Result is made available by the AMS Optimizer.
• Trending would be easy to monitor plant over a period of time
Coal Performance Tracking
This spreadsheet is a summary of tedious data
collection task.
This spreadsheet is a summary of tedious data
collection task.
NOW is achievable within few
clicks
NOW is achievable within few
clicks
Weekly Performance Report
Data extraction is effortless by
using PI Datalinkin Microsoft Excel
Environment.
Customised Plant Information Display
Above display which currently in use was designed by Plant Operator
Customised Plant Information Display
Above display which currently in use was designed by Plant Operator
In Conclusion
Remote monitoring which made possible by PI System would enhance plant operation.
Plant information is on your desktop readily available for reports and troubleshooting task.
The PI System brings all operational data into a single system that can deliver it to users at all levels of the company – from the plant floor to the enterprise level.
Thank You For Your Attention
