Maximize the power and value of your OSIsoft PI system investment utilizing the Process Plugins™ tools to monitor the condition and performance of your equipment. The fully scalable Process Plugins™ toolset resides entirely within the OSIsoft foundation and leverages the latest OSIsoft technology within the Analysis Framework and Advanced Computing Engine. No need to juggle multiple visualization methods as all Process Plugins™ tools utilize purely OSIsoft software. Let our partner Process Innovations Inc.(PII) configure your system or have PII train your users to build their own configurations with the Process Plugins™ templates. For a more complete presentation, please click below to see how the Process Plugins™ solutions works.
All custom applications include PI WebParts displays and PI Notifications which alert users to anomalies, automatically deliver reports, and include links to the corresponding PI WebParts displays. Notifications may also be issued via a Web Service.
Using fundamental engineering principals and industry standards, the Process Plugins™ toolset is customizable to accurately monitor the performance and expected performance of various components and parameters such as the following:
The Pump Performance module monitors and presents a real-time graphic display of your pump’s key performance indicators. Pump head and efficiency are calculated and plotted against expected curves. Reference curves are scalable, dynamic, and adjust with pump speed as appropriate. real-time calculations included.
Gas constituent data is used to calculate gas density which is used in calculating real-time mass flow rates. With heating value, this is used to calculate the fuel energy delivered to the combustion turbine. Turbine efficiency is then calculated as a function of fuel input and total shaft power delivered to the Generator. The following parameters are calculated and key performance indicators (KPIs) are visually displayed in a real-time comparison to manufacturer design curves or data, or to historical data trends:
Actual vs. Design Generation as function of ambient conditions
Actual vs. Design Heat Rate as function of ambient conditions and loading
Air compressor isentropic (adiabatic) efficiency
Air compressor polytropic efficiency
Combustor efficiency
Transmission efficiency (mechanical losses)
Combustion turbine work
Combustion turbine efficiency
Applicable heat exchanger effectiveness
When a component’s performance becomes considerably worse than the expected value, then a visual display and PI Notification will communicate this information with a logically determined probable cause (such as high filter dP, fouling, bearing failure, etc.). This module includes a complete set of PI Process Book displays and corresponding PI WebParts displays.
The Gas Turbine Combustion Analysis module monitors and presents a real-time polar-plot display of the combustion turbine exhaust gas temperatures. Each exhaust thermocouple’s reading is displayed on a polar plot. Also displayed are the turbine flame tube fixed positions and the real-time corrected positions which are calculated as function of the exhaust gas swirl angle.
The Steam Turbine Performance module monitors and presents a real-time graphic display of your steam turbine’s key performance indicators. Formulations (also used by General Electric) are based upon ASME Paper No. 62-WA-209, A Method for Predicting the Performance of Steam Turbine Generators by R.C. Spencer, K.C. Cotton, and C.N. Cannon. All formulations occur entirely within PI-AF, so that there is no hidden code.
The generator reactive capability curve is displayed in a dynamic real-time display. This display is unique in that the hydrogen pressure (or temperature where applicable) D-curve accurately moves real-time with actual hydrogen pressure (or temperature) and reactive/real power is plotted within. The D-curve is plotted with extreme accuracy using true polar coordinates so that the entire limit curve is displayed dynamically around the entire 180 degree plot. This tool provides a very handy visualization of real-time operation compared to the limitations.
Compressor discharge pressure, work (brake horsepower) and efficiency are calculated and plotted against the expected curves respectively. Reference curves are scalable, dynamic, and adjust with compressor speed as appropriate. real-time calculations include isentropic efficiency and polytropic efficiency. The graphic is very useful in visualizing real-time compressor performance in comparison to the reference curves. This tool makes it easy to identify problems early, such as degradation in performance.
The Compressor Condition Monitor (above) provides calculations for the applicable shaft load. Gas inlet and outlet conditions are used to calculate the power extracted by the turbo-expander, applicable efficiencies, and shaft losses. These performance indicators are plotted real-time with corresponding design curves. The display is a handy tool as it provides a visual display used to quickly identify potential problems with the rotating equipment.
Provides real-time Heat Recovery Steam Generator (HRSG) efficiency and effectiveness and tracks these parameters. This information can be useful in determining loss of HRSG integrity due to corrosion or other problems.
This module provides real-time actual and expected primary plant and steam generator parameters. Real-time graphic displays provide visualization of actual vs. expected conditions.
This module provides real-time actual and target Chemistry data including applicable plotting visualization. This module delivers custom alerts when chemistry is approaching limitations.
Boiler Losses are calculated real-time and compared to expected losses and overall boiler efficiency. Air heater exit gas temperature (corrected to zero leakage), gas side efficiency, and x-ratio are calculated and compared to expected real-time values. Gross turbine cycle heat rate is provided based upon the boiler’s steam-side heat input to the turbine cycle. Boiler Efficiency is calculated by the loss method, which is the most accurate way of ultimately calculating real-time coal flow and net unit heat rate.
Each feedwater heater is modeled to predict the feedwater outlet temperature, terminal temperature difference (TTD), drain cooler approach (DCA), and steam extraction flow. These parameters are compared real-time to the corresponding actual conditions which are also calculated. Differences in expected results could indicate problems with heater operation or physical condition.
The condenser is modeled to predict pressure, temperature difference (TTD), and cleanliness. These parameters are compared real-time to the corresponding actual conditions which are also calculated. Differences in expected results could indicate problems with condenser operation or physical condition, which often has a substantial impact on plant heat rate.
Provides real-time expected cooling tower outlet temperature based upon wet bulb temperature and range (circ-water temperature rise). The Process Plugins™ tool will calculate wet bulb temperature from humidity or dew-point as necessary. This information can be useful in determining problems with cooling tower operation or physical condition. Curves are customized upon installation and can be easily adjusted anytime afterward. Expected values calculations require the availability of appropriate curves (from the manufacturer or actual historical data).
This module provides real-time optimal Circulating Pump configuration in order to minimize the unit’s (or entire plant’s) net heat rate. This tool requires the Condenser Performance package in order to determine the effects of various pump configurations on condenser pressure, and resultant effects on turbine cycle heat rate. Circ water pump power consumption is considered in determining the optimal CW pump configuration for the real-time given conditions.
This module provides real-time optimal ACC Fan configuration in order to minimize the unit’s (or entire plant’s) net heat rate. ACC Fan power consumption is considered in determining the optimal ACC Fan configuration for the real-time given conditions.
Real-time display is provided for all applicable emissions calculations from Environmental Protection Agency (EPA) 40 CFR Part 60 (Code of Federal Regulations) per revision of July 1, 1993. Also included are any provided calculations necessary to accommodate state, local, or international government regulations. This customization may include totalizing in defined time-blocks as required.
The generation capacity of gas turbine (simple or combined cycle) plants is affected by weather. With the Process Plugins™ Turbine Generation Forecaster, you will see your generation capability one week into the future. Every minute, this tool automatically imports weather conditions from the National Weather Service (weather.gov) for your plant’s exact latitude and longitude. The National Weather Service interpolates your location between their nearest stations, and supplies requested data for the present through the next seven days. The Process Plugins™ Turbine Generation Forecaster uses these data in conjunction with your performance curves to predict and chart your plant’s generation capacity throughout the rolling forecasted duration. Each combined cycle configuration (number of gas turbines, chiller/cooler, and duct burners) is analyzed and reported. Gas turbine heat rates and combined cycle heat rates are also forecasted in the same manner. The applicable curves are customized upon installation and can be easily adjusted anytime afterward. This tool may also be accompanied by a stand-alone Microsoft Excel version.
The Process Plugins™ Forecaster uses weather data to determine your generation capability one week into the future. Every minute, this module automatically imports weather conditions from the National Weather Service (weather.gov) for your site’s exact latitude and longitude. The National Weather Service interpolates your location between their nearest stations, and supplies requested data for the present through the next seven days. The Process Plugins™ Forecaster uses these data in conjunction with your performance curves to predict and chart your site’s generation capacity throughout the rolling forecasted duration. The applicable curves are customized upon installation and can be easily adjusted anytime afterward.
Wind asset parameters are organized by Region, Site, Turbine, and Component within PI-AF. A master display is provided with drill-down capabilities to support five levels of hierarchy: Executive, Regional, Site, Turbine, and Component screens. Calculations include Availability, Capacity Factors, and totalizing functions.
Solar array parameters are organized by Region, Site, and Components within PI-AF. A master display is provided with drill-down capabilities to support multiple levels of hierarchy as applicable. Calculations include Availability, Capacity Factors, and totalizing functions.
The Compressor Wash Advisor is a handy tool for determining the most economically advantageous time to perform an offline compressor wash. The advisor calculates this date/time using: Maximum Net Profit Analysis.
The Process Plugins™ toolset includes a complete set of Thermodynamic Steam Functions for use in Microsoft Excel. Note that this add-in requires a licensed copy of PI-ACE (Advanced Computing Engine).
The Kiviat Display feature mathematically converts PI data so that a polar plot may be easily displayed within Process Book’s XY (Cartesian) plotting object. The Process Plugins™ Kiviat Display feature supports an unlimited number of displays.
With our philosophy of AF Template devlopment that allows us to put toghether monitoring and performance solutions from this rich set of tools please contact Process Plugins to inquire about your particular application needs that you do not see represented here.
