Riverside Public Utilities MKVIe Core Upgrade S6.5

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Presentation for WTUI 2013. Riverside did a major software update and these slides cover some areas of issue and things to look at when upgrading controls equipment. This plant operates GE MKVIe …

Presentation for WTUI 2013. Riverside did a major software update and these slides cover some areas of issue and things to look at when upgrading controls equipment. This plant operates GE MKVIe Control System.

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  • 1. Unit 4 raise/lower voltage from the DCS.2. The constant ding is fixed when no alarms are in.3. Historian data collection for 30 Days.4. Unit 1 Nox water page PT2030 Liquid fuel Secondary manifold pressure (shows 0.00, but when boxis clicked and opens another box and the value is displayed. This should be a quick screen fix oncethe screen is sent to Houston and the screen can be sent back.5. On unit three when the screens are changed a pop up box shows up saying Amvocx Setup doesnot exist. This does not affect anything on the HMI screen. The display still indicated all data.
  • This is a result of failed CF cards.
  • U1 and U2 never failed CF modules until S6.5. U3 and U4 had several Pre S6.5
  • SOV-2038 is open all of the time on U1 and U2. This is the NOX water stop valve. It should be shut when we are shutdown. The NOX water control valve (FCV-2019) is the only thing stopping water from flowing. It is leaking by and we are filling our waste drain tank to the tune of 1.8 gpm. The other thing about this that is very bad is that the check valve just downstream of the NOx water flowmeter is the only thing that is holding back gas from the NOx water system when we start up (before we start to flow mater). This is bad as you can imagine.
  • Inspect you controls equipment. Perform controlled shutdown on equipment when taking long power outages. Do regular checks on mother boars and power supplies.
  • Inspect you controls equipment. Perform controlled shutdown on equipment when taking long power outages. Do regular checks on mother boars and power supplies.

Transcript

  • 1. Riverside Public Utilities S6.5HMI Upgrade and Addition ofBlack Start ProjectBryan Atkisson – Utilities Generation Plant ManagerWilliam Patton – Utilities Sr. Generation Test TechnicianMarch 2013
  • 2. Project Overview• Add Remote Black StartCapability• Replace HMI Hardware• Add Sprint Optimization• Update Site HMI Software
  • 3. Background• Daily diagnostics• Nuisance alarms• False shutdowns• Loss of communications• Outdated PCs• Cost savings with less water used• More reliable / stable control system• Ability to start plant black
  • 4. Timeline3/2011• Discuss S6.5 with GE• Discuss black start with GE2/2012• Sent GE all 8 HMI backup of SITE software directory• Black start drawing review with GE5/2012• S6.5 kickoff• Black start kickoff
  • 5. Pre S6.5 IssuesI/O ghost diagnostics. You had to go “off lineonline” to clear this prior to S6.5
  • 6. Pre S6.5 IssuesControllers for U1 and U2 commissionedwith EGD communication to EX2100. Thisunit uses BRUSH AVR and can’t read/writeEGD. This had to be corrected during S6.5upgrade.
  • 7. Timeline7/3/2012• GE troubleshooting control systems– GE field services onsite7/25/2012• GE troubleshooting control systems– GE field services onsite10/22/2012• GE troubleshooting control systems– GE field services onsite
  • 8. Post S6.5 IssuesError when depressing CONTROL MODE
  • 9. Post S6.5 IssuesController R and S not in agreement
  • 10. Post S6.5 IssuesFailed Compact Flash Cards. After long lead times forreplacements I started patching system up using off the shelf32mb cards.
  • 11. Issues and Resolutions• Sprint Optimization not working on two units.• All units behave and operate differently and no two are alike.– PSS would not enable from BOP on U3 and U4.– the NOx water stop valve was programmed to stay open at shutdown on U1 and U2– Units would ding for alarms that did not display (ghost alarms)– U1 Sprint must be re-enabled after trip on low pressure, all other units auto restart oncealarm clears (sometimes you have to disable and re-enable sprint to get it working again)• Old HMIs operated on 24vdc and new HMIs utilize 120vac• GE made multiple trips to the site to correct issues.• This impact was major as we spent months tracking new issues.– Total project was scheduled to be a week long outage. Actual time required was six monthswhich included multiple trips to complete.
  • 12. Current Status• Riverside Energy Resource Center can blackstart• S6.5 Is installed and running• Punch list is closed• Sprint Optimization is a failure
  • 13. Things to do for your upgrade• Review everything• Take screen shots of every screen prior to upgrade and compare toyour new screens after update• Capture running data and look your operational screen over• Attend factory acceptance test• Review your service reports• Maintain a punch list• Print and note everything• Make sure your site software settings are correct before GEperforms your upgrade.• Make sure your old corrections are still working when project iscomplete.• Get trained on new features, learn what is no longer supported byGE. (trends, alarm data, etc)
  • 14. Capacitor PlagueGOODBADCurrent andTemperature caneffect your circuitboards. Don’t allowyour control systemto drain yourbattery system.
  • 15. Questions?Bryan Atkissonbatkisson@riversideca.govWill Pattonwpatton@riversideca.gov