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Extending PI for Process Improvement in Operations and Maintenance at TransAlta

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Extending PI for Process Improvement in Operations and Maintenance at TransAlta Agenda TransAlta Overview Vision Scope Standard Business Model Maintenance Operations ... – PowerPoint PPT presentation

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Title: Extending PI for Process Improvement in Operations and Maintenance at TransAlta


1
Extending PI for Process Improvement in
Operations and Maintenance at TransAlta
2
Agenda
  • TransAlta Overview
  • Vision
  • Scope
  • Standard Business Model
  • Maintenance
  • Operations
  • Integrated Decision Support
  • Conclusions
  • QA

3
TransAlta
  • Canadas largest non-regulated electricgeneration
    and marketing company
  • Coal Mining (Canada US)
  • Operations in Canada, United States, Mexico, and
    Australia
  • 10,000 MW generating capacity
  • Close to 9 billion in coal-fired, gas-fired,
    hydro and renewable assets in operation, under
    construction or in development

4
TransAlta State of the Business
Business Strategy
Generation
Corporate Services
Marketing
Finance
HR
Platforms that support the business
Portal
Document Management
BI Business Analyzer
SAP/ Back office
Infrastructure
PI data connecting disparate sources!
5
Vision
Supply
Distribution
Supply Chain
Enterprise Management
accounting periods
IT Infrastructure and Integration Platform
Production Management
operating events
Control and Automation Real-time Asset Mgmt
minute by minute second by second
  • Right-time information accessible throughout
    the enterprise.
  • Enterprise integration from the sensor to ERP
    system.
  • Customized and formatted visualization of
    information as required.
  • Centralized real time control and automation
    areas.
  • Virtual plant environments to utilize knowledge
    and expertise across the enterprise.

6
High Level Scope
  • TOP TransAlta Optimization Program
  • Purpose
  • The Integrated Enterprise
  • Vertical and horizontal integration and
    optimization
  • Scope
  • From sensor to boardroom
  • All levels Enterprise, plant, process control
  • Develop a standard business model
  • Pilot site to prove concepts
  • Deploy across the fleet
  • Seize opportunities to deploy standards as they
    arise

7
Typical Plant View
8
TOP Standard Business Model
Corporate
Engineering
Operations Production
Asset Management
Infrastructure /Data Mgmt
Marketing
War Room
Energy Trading
Enterprise Historian
Region/Fleet-Wide Analysis
Asset Management Program
Enterprise /Region
Finance
CAD/CAE
Economic Dispatch
HR
Legal
EAM/CMMS
Doc Mgmt
Project Mgmt
EHS
SCM
Inter-Application Communication
Asset Reliability Program
Outage Mgmt
Optimization
Plant Historian
Performance Monitoring and Diagnostics
Plant/Unit
Fuel Supply (Gas, Coal Mining)
CEMS
Simulation
Unit/Control System Historian
Advanced Process Control
Unit Operations Control and Monitoring
System (BMS, CCS, TCS, ), BOP
ProcessEquipment
Equipment Performance Monitoring
Asset Condition Monitoring
Asset Health Monitoring
Process Measurement Control Elements
Asset Health Monitoring Elements
Inter- Device Communication (HART, Remote IO)
Device
9
Maintenance
10
Maintenance Goals
  • Consistent routine maintenance practices fleet
    wide to produce
  • Bottom line businesses results
  • Ease acquisition installations
  • Comparability internally/externally
  • Ease introduction of new tools
  • TOPS, EDM, hand held or other technology
  • Transferability amongst people (learning)
  • Sharing of practices
  • Operational excellence repeatability

11
Maintenance Improvements
  • role
  • location
  • operational

Dashboard
12
Total Maintenance Solution xVIp?
Maintenance Best Practices and Processes
PDAs
PCs
Ver 1.0 Q1 03
Portal
Alerts
Ver 1.x Q3 03
Web- Suppliers (Info, Alerts) - Maintenance
Companies- Monitoring- Contractors
Visual Parts Catalogue
Search
Collaboration
Visual Plant Structure
Work Clearance
RCM
Process Integration(Process Maps Activated)
Document Stores- Drawings, Technical Docs -
Operating Manuals
Real-Time Plant Info.
ERP(eg., Plant Maintenance, MM, etc.)
Automated Work Packages
Data Warehouse SAP BW
Working Offline
Business Packages - iViews(Assets, Financial,
Projects , etc)
Maintenance Data
Plant Maintenance (View all Plants as one)
13
Working the Process - Before
Business Process
14
Working the Process - After xVIP
UnstructuredContent
ERP
BW
Real Time
Others
Internet
Intranet
Workflow
15
Mobile
16
Solution Overview
Users
Applications
17
xVIp Background
  • xVIp developed by NRX (SAP partner)
  • Developed with input from TransAlta
  • Incorporating Plant Maintenance best practices
  • xVIp continuing to evolve

18
OSISoft and SAP NetWeaver Interoperability
SAP NetWeaver
OSISoft Solutions
People Integration
Multi-Channel AccessPortal Collaboration
Information Integration
Knowledge MgmtBusiness IntelligenceMaster Data
Mgmt
Process Integration
Integration Broker,Business Process Mgmt
Application Platform
J2EEABAP,DB and OS Abstraction
19
SAP NetWeaver Interoperability
SAP NetWeaver
Microsoft .NET
IBM WebSphere
  • Portal Dev. Kit for .NET
  • Smart Client on .NET
  • MS Office Integration
  • MS Exchange Integration
  • Portal Development Kit for WebSphere
  • Integration of Lotus Sametime

People Integration
Multi-Channel AccessPortalCollaboration
  • Integration of MS Content Management Server
  • Integration of SQL Server Analysis Services
  • Integration with IBM Content Manager

Information Integration
Knowledge MgmtBusiness IntelligenceMaster Data
Mgmt
Process Integration
  • Interoperability with MS Biztalk Server
  • Interoperability with WebSphere Business
    Integration

Integration Broker,Business Process Mgmt
Application Platform
  • Visual Studio .NET integr.
  • Technical, standards-based connectivity (XML,
    Web Services)
  • Eclipse-based Java IDE
  • Technical, standards-based connectivity (XML,
    Web Services)

J2EEABAP,DB and OS Abstraction
20
Screenshot Examples
21
xVIp example using SAP Enterprise Portal
22
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23
xVIP Roles
  • Maintainer
  • Planner
  • Supervisor
  • Operator
  • Planner
  • Engineer
  • Manager
  • Plant Manager

24
Role - Maintainer
  • Here we see a set of shop floor i-views that are
    suitable for a Maintainer as they support the
    Work Execution process .

25
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26
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27
The Result
VPS customer example accessed from within SAP PM
Entire tree audited and cleansed down to serial
number and photographed
28
Role - Engineer
  • Here we see a set of OSI PI i-views that are
    suitable for an Engineer as they support the
    Equipment Diagnostics and Condition Monitoring
    process .

29
xVIp i-Views
30
xVIp i-Views
31
xVIp i-Views
32
xVIp i-Views
33
Demonstration Collaboration in Action
34
Approach / Status
  • Strategy Phase 1
  • Implemented Proof of Concept at Centralia ACM
  • Expand xVIP with Portal Team
  • IT Plan to Support IT Strategy
  • Integrating with SAP Enterprise Portal, EDM,
    FORCE SAP R/3 Enterprise Upgrade, BW, TOP
    Real Time

35
Steps to Enabling Maintenance
  • Maintenance Strategy
  • Community Pages for Maintenance
  • KPIs Turning on BW Content
  • Document Mgmt (getting your data in order)
  • SAP Simplication (Portal, iViews for ALM)
  • Realtime Info (bringing in PI)
  • Bringing it all together (xVIP)
  • Rollout across Fleet in Sync with Other Projects
    and Opportunities (eg, New Plants, Upgrades, etc)
  • Key - IT Strategy Linked to Maintenance
    Strategy

36
Operations
37
Optimization leads to Continuous Improvement
Minimize operational variances enabling the units
to push the constraints
38
Goal Integrate, Optimize all Areas
True
Controlled Operating Region
Economic
Optimum
Unit Generation Output
Emissions
Fuel Costs
Operator's Preferred Operating Region
Unit heat ramp rates
Operational Values
39
Existing GT Performance Trends
40
Optimization in Action

Yellow differential between current operation
and model based optimal operation
41
TOP Pilot Expected Benefits
  • Production Increases
  • Avoid trips caused by process upsets
  • Soot-blower Optimization less boiler stress
  • Steam Temperature Control improvements
  • Reduced Startup times via HM monitoring
  • Improved Heat rates due to improved pressure
    control, derived from Historical Data.
  • Improved operation of unit due to control system
    improvements via APC
  • Above results in less operator intervention of
    process, allowing operator to focus on more
    details of optimizing the unit operation.

42
TOP Efficiency Benefits
  • Improved Energy Marketing communication - less
    missed trades, etc.
  • High level summary available from any networked
    PC with drill down capabilities to details
    (plant/unit/device level)
  • One source of Plant operational data for
    corporate decision making
  • Financial and non Financial information sharing
    for defined KPI's
  • Applications sharing Information with acceptable
    performance.
  • Implementation must be repeatable at reduced
    costs and using more TA resources

43
TOP Current State
  • Initiated Pilot Jan 03
  • Award contract to vendor April 03
  • Develop project plan, scope and firm Pilot costs
    March 03
  • Define the Standard Reference Model and KPIs -
    IP
  • Implementation of Vendor tools (Pilot) April
    03
  • Integration of non-Vendor tools (Pilot) May 03
  • Program 3rd quarter
  • Confirm DCS, Fit-Gap of existing plants
  • Develop deployment plan gt turnaround schedules

44
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45
Integrated Decision Support Areas
Operations
46
(No Transcript)
47
Conclusions
PI is the glue between process and
Enterprise Exploit Technologies like xVIP,
OSISoft and SAP NetWeaver to leverage your
existing investments bring it all together TOP
is another step in integration and
standardization The Integrated
Enterprise Vertical and horizontal integration
and optimization Thank you!
48
Q A
  • Keith_Christianson Keith_Christianson_at_TransAlta.
    com
  • Paul Kurchina Paul_Kurchina_at_TransAlta.com
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