2. Let’s Take A Moment To Meet Me
Daniel Schmidt
Electrical Engineering Major
@ Georgia Institute of Technology
GPA: 3.08/4.00
Expected Graduation: May 2018
Fun Fact
I Know 6 Computer Languages (HTML, CSS, C++, Java,
VHDL, Assembly)
Possibly more to come :D
4. I&C Deliverables Checklist
Developed A Flow Chart Of Deliverables
Wrote Checklists Breaking Down Each Deliverable
Learned Processes Of A Project (The I&C Portion)
Will Be Used By Project Managers
7. Loop Diagrams
Developed Loop Diagrams
Useful for Checkout, Startup, and Troubleshooting
Combination of P&ID’s, Electrical Wiring Diagrams,
and IO List
Did Multiple Projects
Bowen Units 1-4 Ball Mill Common MATS
Bowen Unit 3 & 5 MATS Reliability
McIntosh Unit 1 ACI
8. Misc. Projects
Scherer As-Builts
Made revisions on a large number of drawings, created
a good number of new drawings.
Includes working with As-Builts Database
Yates Wiring Diagram Retrofits
Modified existing drawings for retrofit purposes, also as-
built drawings.
Barry Calcium Bromide Installation Details
Worked to create installation details for calcium
bromide tanks
9. Plant Hammond Checkout
Plant Hammond Unit 1 is replacing it’s DCS
controls from Foxboro to Ovation
All IO points, Digital and Analog, need to be
switched over to Ovation wiring
Wiring needs to be verified
Check to ensure receiving signal, sending signal, reading
correctly
Functional control testing
Following Target ZERO for Safety
Part of Startup as well
10. Plant Hammond Checkout
The Process
Using Ovation and PowerGraphix (and the small
applications bundled with) check each point
Communicate with I&C Technicians in the field
Send/Receive signals from components to ensure they
are working
IF not working, troubleshoot via multiple methods
Verify point shows correct value/range
Once working, point has been checked
This project has roughly 1600 points to check!
12. Plant Hammond Startup
Startup Phase Has Yet to Begin
When IO Checkout Is Over, Startup Will Begin
Projected startup in May
Startup Is Functional Control Testing
Testing to make sure things work as planned
Checking trip conditions
Checking alarms
Checking logic for accuracy/completion
13. Checkout/Startup
Checkout/Startup is crucial for determining
whether the DCS is configured properly or not
Why is DCS important?
It controls the plants
The DCS is an Ovation system in this case
In Ovation you build your logic that controls the components
The DCS handles trips, alarms, redundancies, and fail-
safes complying with Plant Procedure, ACE, NFPA, as
well as Target ZERO
14. What I’ve Learned
AutoPLANT (Smart P&ID)
Microsoft Visio (Flow Diagrams)
Parts of Ovation (Foundational Knowledge)
Further Understanding of Power Plant
Checkout/Startup
Understanding of Southern Style
15. Future Goals
Third Rotation with I&C
Continued Training in Ovation Controls Software
Further Work in Startup/Checkout
Increased Project Involvement (Start to Finish)
Continue on to finish my Bachelors for EE
(Halfway there!)
Good ____ everyone. My name is Daniel Schmidt and I am a second rotation co-op with I&C Design in Atlanta.
I am currently studying to become an electrical engineering major over at Georgia Tech and I won’t be graduating until 2018. My fun fact for everyone this _____ is that I know six different computer languages. I know C++, Java, Assembly, VHDL, HTML, and CSS. As part of this fun fact I’m going to tell you all that I am a fast learner, so with that in mind I plan to learn more in the future because why not?
Moving on I’m going to be talking briefly about what I’ve learned, drawing checking, deliverables checklist, loop diagrams, some miscellaneous projects that I’ve worked on, checkout/startup over at Plant Hammond, and finally some of my future goals.
-I developed a deliverables checklist for I&C which will be used by project managers, or at the very least given to them, to guide them through the process of a project
-The checklist consists of two parts, the flow diagram and the individual checklists themselves.
-This flow chart shows the process of a project through I&C from receiving vendor drawings and SCS drawings all the way to startup/checkout then turnover.
-The accompanying checklists then break down each deliverable so that you may check off what you have and ensure you are completing everything before moving on
-Transition from these bullet points to next slide, starting next slide with talking about flow from left to right, reading the legend, brief explanation
If you look at this flow chart, you will see that things move from left to right. I know this may be a little hard to see because the scale is off so I’ll try to explain as much as I can without wasting time. The flow chart here is broken down into simple components that if you could read the legend you would understand. But for now I’ll act as your legend. The parallelograms are the deliverables themselves and are the different things that must be completed for the project, think milestones. The white squares are the things that you need to complete the deliverable, or what you need to help complete the deliverable. Some deliverables are used to create other deliverables. If you have questions about this chart or would like to see it closer up feel free to see me after the presentation and I’ll be more than willing to show you and explain to you.
Next project I worked on was loop diagrams. I did some of these last rotation and I was able to do some more this semester. Here you can see a typical loop diagram, and for those who don’t know this drawing shows the individual component on the left, in this case a valve with all it’s solenoids and limit switches, moving toward it’s field terminations in the center, and finally to the DCS in the DCS cabinet.
So with the loop diagrams I was developing them from scratch. I took P&ID’s, data sheets, and electrical drawings along with vendor drawings to create these loops. The loop sheets dictate from start to finish a singular component of the system from it termination in the field it’s termination in the DCS cabinet. This makes it easy for troubleshooting a component while you are doing checkout and startup. The loop sheet has references to all drawings necessary and/or relevant to the component so that if you need to go look something up you can just grab the loop and use it to find the drawings you need. This will save a lot of time rather than searching through drawing after drawing in hopes of finding the component you need. This rotation I did three large projects for loop diagrams which were Bowen Units 1-4 Ball Mill, Bowen Units 3&5 MATS, and McIntosh Unit 1 ACI system.
Unit 5 is Common Node
When I wasn’t doing loops or the checklist I would go and ask around for work, as I am not much for sitting around doing nothing. Some of the projects I got from doing this where Scherer As-Builts, Yates Wiring Diagram Retrofits, and Barry Calcium Bromide Installation Detail.
-The As-Builts consisted of updating old drawings and revising them as they were built on site, hence it’s name. This consisted of a couple hundred of drawings being revised, as well as a couple of new ones needing to be created. All old drawings were also placed on the new company border.
-The Yates wiring diagrams were nothing more than drawing revisions on wiring sheets, implementing what was done on site.
-One of the other small projects I worked on was at Plant Barry and their new Calcium Bromide system. For the system, they were installing a day tank and a storage tank. For those tanks, I drew installation details following company standards. ****Ask Major what part of the process this comes from, include specifics. What part of the the tank did we work on? Specific****
The largest project I’ve done this semester has been Plant Hammond Checkout.
-For those that don’t know, Plant Hammond Unit 1 is currently in an outage and during this time it’s control system is being changed over from Foxboro to Ovation.
-With this, all wiring needs to be switched over to Ovation’s style of wiring. Ovation wiring is all terminated inside the DCS cabinets as opposed to Foxboro where….
-Once all this wiring is changed over it needs to be verified that all points were hooked back up correctly and that they still send and receive signal to and from the DCS. This way we know once the system goes back online that everything will work correctly. Here we are also checking to make sure that the components are reading the correct numbers in the DCS room.
-Functional Control Testing – Running the Components from the graphics making sure the logic works
** Using Target Zero for safety as components in field can be dangerous when operated, especially if we do not know that they work
The process is as follows:
-Communicate with your Technicians in the field. There are team members that go around to each individual component of the system such as say a thermocouple and will place a meter on the component.
-The team member will send a signal through the electrical wiring to ensure that in the DCS room I am receiving signal from that component. We will then communicate to ensure that the value I am reading off from the DCS room is in fact the value that the technician has sent through the wiring and at that point we can call the point good.
-IF the point is not receiving signal in the DCS room or is showing incorrect values we must move into trouble shooting which involves them checking the wiring in the field and me checking the wiring in the DCS cabinets. If the point is still not fixed the technician will then check any intermediary connections until the problem is resolved and we are again receiving signal to the DCS.
Here are some pictures from the process. Open on the computers is Ovation and PowerGraphix, tools that we use to check these points.
After checkout we will move into Startup which is functional control testing. Which is just a complicated way of saying that we will be physically running the components. For example if one of the components is a valve we will shoot a signal from the DCS room telling the valve to open or close and a technician in the field will verify that the valve did in fact close or open depending on what I sent. We will have to do this for every point that we checked to ensure that each component I working as planned. With this we can also take to checking trip conditions, alarms, and accuracy of the logic to ensure nothing was missed and that the process works as a whole without any hitches.
I’ve been talking about the DCS this entire presentation and for those of you who don’t deal with it daily that term might be foreign to you. DCS stands for distributed control system and in short the DCS is the brains of the plant. The DCS controls everything and handles all trips, alarms, redundancies, and fail-safes that comply with Plant Procedure ACE as well as Southern Company’s Target ZERO. This ensures we are all working in a safe work environment by giving the plant many different ways to deal with any issues that may come up and prevent any accidents from happening if possible. By adding in these layers of protection it makes it harder for anyone on site to get hurt.
Those things aside, the DCS also takes in all data given off by each component so that the operators may see it and allows for them to control which parts of the plant are on and working and alter the output of the plant.
ACE – Accelerating Change toward Excellence
NFPA – National Fire Protection Association – determines burner safety logic
Describe each briefly in detail
-AutoPLANT – Allows for creation of P&ID’s on the I&C portion including instrumentation tagging and DCS points
-Visio – Allows for flow diagrams to be created to show processes and easier understanding for said processes
-Ovation – DCS control software, critical in most plants. Used in Plant Barry, Plant Hammond, etc.
-Power Plant – When visiting Hammond (I’ll talk about why in a bit) I was taken on a tour of the plant and was explained many parts of the plant I still did not know. I am working in the office and don’t’ have much opportunity to learn these things. This helps with work that I am doing as it helps me to better understand what is going on.
-Checkout/Startup – allowed me to utilize knowledge I had and gain new knowledge in the process
-Southern Style – now in the office you see southern style day by day. But you don’t see it to a great extent. You see people acting in respectable office ways and you just keep moving on with your work/life. When I went out to Plant Hammond I gained a further understanding of what Southern Style actually meant. Every morning we would begin with a safety topic and southern style. And I never really thought about the things that we do as a team until I started hearing these southern style behaviors from my coworkers. Those meetings every morning have really helped me gain a further understanding of what Southern Style truly means and to me I find that wonderful. I encourage everyone to do your best to use southern style even outside of the workplace as it’ll take you far.
-Finally my future goals are to continue co-oping with I&C, I really do enjoy the work that I do.
-I would love to continue training and learning about Ovation and would really enjoy working with it in the future
-Speaking of things I would love to do, I would love to do more startup/checkout as that has been one of the most fun projects I have worked on while co-oping at Southern Company. I did startup for a couple of weeks last rotation and I thoroughly enjoyed it then as well.
-I would also love to see an increased project involvement from start to finish. I see many of my fellow co-ops are given projects and told to take it to the end. I would love to see something like this in my future as I am usually brought in mid project and miss a good portion of the project.
-Lastly I’m going to continue working hard at Georgia Tech and continue on my way to getting my Bachelors of Science in Electrical Engineering.
Thank you for your time and if you have any questions feel free to ask away.