Deployed for KEPCO at a combined cycle power plant
The system runs unattended, with OPC UA nodes updated every second and hourly automatic CSV backups.
HRSG DAS — Data Acquisition System
Every HRSG signal, collected without interruption
Built for heat recovery steam generators (HRSGs), HRSG DAS (HRSG Data Acquisition System) is an industrial data acquisition system with standard TCP/UDP and OPC UA communications, redundant servers for uninterrupted operation and real-time updates every second. Deployed for Korea Electric Power Corporation (KEPCO), it runs unattended at a combined cycle power plant.
Core Features
Key features
A single system covers the entire data acquisition chain, from field measurement to external system integration.
- Real-time data acquisition over standard TCP / UDP / OPC UA communications
- Conversion of analog field signals, plus a built-in engineering-unit conversion module (Calculation Module)
- Redundant servers for uninterrupted operation
- High-speed data storage (MariaDB time series) with a real-time monitoring user interface
- OPC UA nodes updated every second · hourly automatic CSV backups
- Integration with external systems through an OPC UA client
Architecture — Data Flow
One data flow, from sensors to external integration
Raw signals from field sensors go through calculation and batch processing on the server, accumulate in a time-series database, and are delivered simultaneously to a real-time dashboard and an OPC UA client.
Sensors
NI cRIO-9073
Acquires raw signals from field instruments
Transmission
TCP / NI 6340
Sends data to the server over standard protocols
Server
Console
Calculation + batch processing
MariaDB
Time-series storage
High-speed data accumulation
User interface
Real-time dashboard / CSV
Monitoring · backup output
Parallel output. Collected data is provided simultaneously to the user interface (real-time dashboard / CSV) and the OPC UA client (external integration).
Calculation Module
Four engineering-unit conversions
Key equations of the built-in calculation module that converts raw instrument signals into field engineering units.
Current → pressure
4–20 mA → −500 to 500 Pa
Linearly converts the analog current signal from the instrument into pressure in engineering units.
Density (ideal gas)
ρ = P / (R · T)
Calculates fluid density from pressure and temperature using the ideal gas equation of state.
Velocity (pitot tube)
V = Cf · √(2ΔP / ρ)
Calculates flow velocity from the pitot tube differential pressure and the density.
Flow rate
Q = V · A · 3600
Converts velocity and cross-sectional area into hourly flow rate.
Why HRSG DAS
Three key differentiators
Uninterrupted reliability
Redundant server architecture, demonstrated in unattended system operation.
Open standard communications
Vendor-neutral integration with distributed control systems (DCS) and external systems via OPC UA.
Proven signal conversion
Built-in Calculation Module that automatically converts raw instrument signals into field engineering units.
Impact
Benefits
- Automatic accumulation of operating data builds the input data foundation for life assessment with BSE (Boiler Safety Evaluation) and PINN AI Hybrid (Physics-Informed Neural Network)
- Unattended operation reduces the workload on measurement staff
- Hourly CSV backups prevent data loss
Field Reference
Field reference
| Item | Specification |
|---|---|
| Communications | Standard TCP / UDP / OPC UA communications |
| Update interval | OPC UA nodes updated every second |
| Backup | Hourly automatic CSV backups |
| Storage | MariaDB time-series database |
| Availability | Redundant servers for uninterrupted operation |
| Integration | External system integration via OPC UA client |
Ready When Reliability Matters
When integrity needs proof, PILETA delivers
The PILETA Test & Evaluation Center is accredited by the Korea Laboratory Accreditation Scheme (KOLAS) as a testing laboratory (Accreditation No. KT921). From testing and failure analysis to digital solution consultations, our engineers respond to you directly.
T. +82-42-368-0180 · pileta@pileta.co.kr