Process Optimization

Combustion optimizer

The task of SILO is to perform an on-line optimization of the current process operating point. The optimizer is implemented above the base control layer in a layered control structure. The SILO system calculates set points or set points corrections for controllers that operate in the base control layer. Control systems of power units in power plants are based on PI (Proportional-Integral) controllers. These controllers control sub-processes (e.g.: oxygen level in exhaust gases or windbox to furnace differential pressure in case of a power unit control system) that have an influence on a main optimized MIMO (Multi Input Multi Output) process (e.g. combustion process in case of a power unit control system).


Economic optimization

Module of economic optimization will provide the Purchaser with information used for optimal load of operating units in order to maximize financial profit related to electricity and heat production. The OPT system can operate in two independent mode: advisory and what –if. System in advisory mode, based on the current state of the process, will:

  • calculate current optimal load of working devices
  • propose turning on or off the devices.

In what-if mode user defines input data such as state of the process, availability of Power Plant devices or prices of electricity and fuel and starts optimization for further, long-term and multi-scenario analysis.

As part of the project, the OPT system will be applied to:

  • optimize units production plan
  • optimize the costs of steam production
  • minimize the costs of starting up devices
  • reduce internal demand

Sootblowing Optimizer

The ISB Sootblowing Optimizer is an artificial intelligence system that improves the performance of sootblowing process. The main goal is to reduce media consumption via intelligent management of sootblowers. The system continuously monitors heat absorption at each heat exchange section in the boiler and based of mathematical model and set of conditions decides which sootblower activates in order to improve the performance of the boiler. Additionally, the ISB system provides improved heat absorption, improved steam temperature control, reduced flue gas temperatures, reduced risk of tube surface damage.


Thermal stress monitoring

TSMS is a software solution for thermal stress and fatigue damage calculation of pressure devices in power plant with EDS Portal interface. The calculation engine includes calculation algorithm based on specific standards under client request. In this code, a series of parameters and equations have been provided to calculate the total stress.

Between the calculations performed within the system, generally we found:

  • Estimation of fatigue and creep life expenditure ratio,
  • Historical and online calculations of thermal stresses and damage ratios.
  • Calculation of damage coefficient in pressure devices.

Advanced steam temperature regulation

The STO system is an advanced control system that improves quality of steam temperature control. The system monitors such parameters like boiler load change, , etc., and based on mathematical model calculates correction to steam temperature setpoint. It compensates influence of disturbances to provide stabilization of steam temperatures. Additionally, the STO system monitors spray valve position at steam attemperators and calculates correction to steam temperature setpoints if some of valves are fully closed of fully opened.

The system can operate in advisory as well as closed-loop mode. It is able to calculate corrections to steam temperature setpoints in advance according to certain change of the boiler load.

Advanced steam pressure control

The URO system is an advanced control system that improves quality of steam pressure control. The system monitors steam pressure at certain key points in the CHP architecture and adjust steam supply to this point in order to stabilize the pressure. Based on mathematical model the URO system calculates correction to boiler load to supply steam to 9 MPa live steam manifold and calculates correction to steam supply from turbines and/or steam reduction stations to technological, internal and heating steam. The URO system considers following conditions:

  • Limits for steam production and steam flow;
  • Reserve in steam production and steam flow for changes in steam demand;
  • Stable and safe operation of the CHP plant;
  • Other, identified during project implementation.

The system can operate in advisory as well as closed-loop mode. Integration with OPT increases URO’s ability to improve the quality of steam pressure control. It is able to calculate corrections to steam flow in advance according to certain change of boilers and turbines load.

Data verification (Ultra Light Sensor)

The advanced measurement data verification module (ULS – Ultra Light Sensor) is an implementation of an empirical method of signal verification based on mathematical models of the measurements created basing on self-organizing maps. Additionally device characteristics can be implemented in the system. It is a system created as a response to the need to verify the measurements, their credibility and quality. The value that the system adds lies not only in providing continuous measurements of the process parameters but also the possibility to feed data to 3rd party systems that require this data like for example operational calculations systems, technical analysis systems or optimizers. The usage of this module in aforementioned software allows the measurement signals to be verified to increase the quality of results generated basing on them.

The role of this module in the general solution that is being offered is the verification of key measurement data, that can affect the problem of unbalanced technological system. The set of signals that will be verified using the ULS module will be determined during the feasibility study.

ULS makes it possible to validate /mode multiple signals modeled with a single or multiple neural networks or composite device characteristics. The signal models are created basing on a dedicated application. Each model can be used to verify one or more signals. Each of these signals has a weight assigned to it in the self-organizing map basing on the value of the measurement of one or more values that are treated as independent weights in the map


Performance Calculations


Software package that integrates advanced digital and analog control functionality, data management, and networking into a complete process automation solution providing a variety of performance operations and calculations.

Performance calculations module further known as PCALCS provides specific modules targeting and evaluating the following equipment and process performance

Specific Plant Processes blocks

PCALCS includes predefined solutions for individual elements of the power plant. Depending on the type of power plants, its structure and the available data. The following information and data will be recorded and used for GPA.

Accuracy of acquired data

The results calculated by PCALCS ensure accuracy. Each solution requires specific data that are collected by the EDS system as analog and digital points. The analog values are averaged within a certain time range, which can be modified. In the case of the quality of calculated values, PCALCS promotes them in assessing the quality of the entry points.

Performance monitoring diagrams

Diagrams performance monitoring system display the results obtained from the calculations of PCALCS and are available in the system EDS for each user with properly configured permissions. Graphics are configured to be able to reflect the scheme of the plant.

Automatic report system

Using the functionality of the system EDS it is possible to create a fully customizable and automatic report generation system. With the appropriate settings, this system is able to produce periodic reports in various file types (pdf, html, txt, csv, etc.). Thanks to that you will have access to the entire tree of  reports for specific time ranges. Using the capabilities of the Web Portal you can access the reports from any computer with internet access as well.

Presentation of results

In addition to supervising the data within the DCS and EDS systems, using the features of Web Portal we are able to obtain a secure access to actual and historical data of PCALCS’s results.

Software package that integrates advanced digital and analog control functionality, data management, and networking into a complete process automation solution providing a variety of performance operations and calculations.

The basis for the calculations is ASME standards and plant data from DCS.


Operator Logbook

It is a mobility solution to reduce manual rounds in a Plant. Single Digital tool for performing operator rounds & maintenance procedure. The application is capable to do Digital Operator Rounds, Maintenance SOPs, Mobile Workbench. The application would work on client server architecture and support online and offline operation. Ability to access live and archival data (entire database), on and off-site through web-based and mobile solutions.

  • The application is capable to do Plant asset performance monitoring & management
    • To select maintenance action that truly matter, due to detection and identification of the sources of failures and breakdowns as early as possible by constant monitoring of crucial parameters
    • To focus on assets that require your attention due to their current condition
    • Effective management of equipment and devices through constant monitoring.
  • The application has functionality to upload maintenance SOPs and tag them to assets. These shall be available to maintenance engineer during field maintenance.
  • The application has functionality to upload document/file on the Asset dashboard. Eg: this feature will support file types such as photographs or standard operating procedures for upload
  • The application is able to annotate/add comments /raise issue on the captured asset photos.
  • The application is able to e-mail the attachment to other assigned personnel through the logbook page.
  • The application supports log entry form with operator shift detail, operator group
  • The application is be capable to capture data from digital displays of instruments utilizing the camera of mobile phone/tablet.
  • The application has the possibility to display graphics so that they looks the same as in Control Room Displays or as in P&ID diagram.


Leakage Detection

Leakage Detection and Management Module (LDMM)

LDMM is a system designed to perform leakage and breakage detection in the pipelines. Water leakage is not only calculated from minimum of night flow obtained in specified cycle but on the base variation of this flow.  LDMM shows economic intervention points to the operator. It eliminates the leakages regarding cost and effectiveness – cycles and real rate of rise in leakage. The LDMM is flexible with integration with CMMS systems (Computerized Maintenance Management Systems) and with DCS.

Benefits of Leakage Detection tool:

    • aids in maximized savings of water,
    • guarantees the execution of Least Cost Plan of water supply (including Economic Level of Leakage),
    • is tunable to local conditions in LDMM
    • has a capability of current oversight of leakage control progress (ALC or/and SR)
    • allows remote access to water network control system.


Laboratory Information Management

A laboratory information management system (LIMS), is a software-based solution with features that support a modern laboratory’s operations. Key features include—but are not limited to—workflow and data tracking support, flexible architecture, and data exchange interfaces, which fully „support its use in regulated environments”. The features and uses of a LIMS have evolved over the years from simple sample tracking to an enterprise resource planning tool that manages multiple aspects of laboratory informatics.

System functionalities function in two levels.

  1. Backend layer responsible for:
    • Samples and related process/status data database.
    • Communication modules. Business workflow management.
    • Background calculation.
    • Batch reporting.
  1. Fronted layer responsible for
    • Graphical User Interface.
    • System configuration.
    • Reporting.
    • Manual data entry.


Billing and Reporting

Billing and reporting is the outlet of the operation of the whole enterprise. It is a single solution that allows to turn raw data from automation systems into invoice items.

This solution allows for maximum simplification of the billing process. Data is imported directly from automation systems, source interfaces, files, or even e-mails, and processpoints are mapped to allow the values to be turned into quantifiable items in the invoices and reports or used for further calculations.

The solution is designed to provide tools for the facilitation of everyday task thanks to solutions such as the following, for instance – time-zones assigned to each project along with a selection of currencies to choose from, contractors and contracts stored within the system with all the necessary information in one place, user groups and profiles allow targeting of issues and access management, tariff calculators can be added to make the billing process quicker and easier.

Microsoft Excel-based templates are used to create simple templates that are then uploaded and saved in the system and can be applied to an infinite number of invoices or reports that belong to the same type. Templates use keywords which, during the generation process, are automatically substituted with relevant values. Tariff calculators and calculations templates are based on the same mechanism, therefore making the process simple and automatic, retaining irrelevant data in the background and providing only meaningful information.

Fully customizable access to each project and each of its modules for each user or user group ensures that each member of the staff can access all the needed functions and won’t have to bother themselves with issues that do not require his or her attention. It is also possible to add Contractors to the Address Book, for their staff to access the data they need, for example project-specific reports or invoices with their company. It ensures that only authorized users will have access to the information that is relevant to them – while also being able to combine inter-project data and calculations for analytical and billing purposes.

GUI is intuitive, user friendly, and offers a wide range of customization without the need of programming or even advanced IT knowledge. The solution is web-based, so it operates via any modern browser without cumbersome installation. Each user logs in using username and password and has full control over project dashboards, which are personalized to display selected data.

Invoices and reports can be exported into PDF or MS Excel files to be processed further. Invoices and reports can be generated automatically, on schedule, or on demand (manually). All generated documents are stored in the system to be downloaded anytime. Log of changes displays changes of status, content, naming, etc. with date, time and username of the user. Document workflow allows for maximum control and transparency. Documents and files related to them (templates, attachments, etc.) are stored and can be directly downloaded from the system.


Environmental Monitoring

Solution that provides environmental reports based on data from automation system, external sources, web pages, manual data, and any other external system.

Architecture of the system is based on web application that consists of two main modules: connection module and EMS Engine module, where all reports are generated and stored.

EMS purpose is to generate environmental report based on data from automation system, external web pages, manual data or any other external system. It covers the whole data flow starting from automation systems and ending with emission reports documents to be provided for internal and external audits. The system generates weekly, monthly, quarterly and yearly reports. EMS could be integrated with billing system which supports the business process.

EMS is based on the Microsoft Office Excel engine, where previously prepared calculation templates are automatically filled with data of chosen granulation (e.g. hourly) for a specified aggregation period (e.g. month). Such prepared MS Excel or .pdf files could be send to the printer, via e-mail, or to external systems, in accordance with specific customer needs. The main purpose of EMS is to monitor emissions and manage reports of air emissions, water discharges, hazardous waste management, and hazardous materials management and noise levels. EMS as a solution can be customized to the needs of the customer, as one of its strengths lies in flexibility.

EMS is an Excel-based solution for implementation of report formulas which makes the customization process short, transparent, and easily verified.

The solution serves as the primary source for relevant data and metrics for emission and environment monitoring system and identification of important KPIs. It allows for the management of data, procedures, notifications, assignment of responsibility, assignment of root cause investigation of safety incidents, all non-conformances, incidents, risk, risk analyses, audits, assessments, and improvement suggestions.


Business Intelligence

BI is a solution dedicated for clients with big amounts of data collected from different place. Everything is stored in one place and presented in a friendly way on mobile devices or the Web. Relations between clients data are made so the end user can obtain information that he or she is searching for. Using BI we have a more complex structure. We can group points into tools, tools into types of tools and add locations. We can assign event logs or operator logbooks.
Create precisely defined reports. With our historian for collecting data, millions of point values are stored in the database each hour. After time this builds enormously large datasets from which very useful information can be obtained if using the right tools. Thats where our Analytics tool comes in hand.

Working flexibly on large datasets with proper aggregation, Analytics provides information what happened by presenting data with many filtering options on user friendly dashboards. Using build in applications users can navigate to Failure Analysis tools to obtain information why it happened. And, furthermore, track the forecast applications or set notifications to prevent future failures.


Enterprise Asset Management

Technical asset management system is solution which allows the user to personalize the software using modules. It consists of a base set of modules which provide a defined series of functionalities. Depending on the requirements a particular enterprise has, the modules are adjusted to fit specific needs.

It combines processes related to industrial process dispatching, technical equipment maintenance and asset management into one interoperable web interface with individual adjustable user features.

– combines online process supervision and asset management into a single system with a common user interface. 
– enhances assets data with metrics derived from live measurements and calculations.
– provides tree-browser and graphics for easy assets navigation. 
– monitors how process operation influences assets condition / life cycle.