Architecting Powerful Portals Agenda Company Background Industry and Information Challenges Case Study – TransAlta’s ODC SAP Interactions and Modules Lessons Learned Summary
TransAlta – Company Background One of Canada’s largest non- regulated electric generation and wholesale marketing companies Founded in 1911 50 Facilities operating in Canada, United States, Mexico, and Australia 10,000 megawatts generating capacity Fuel mix of coal,gas, hydro and renewables
Current Utility Industry Challenges Environmental Challenges Cost pressures on fuel sources Aging workforce Competition for scarce workforce resources (Alberta especially!) Pressure to provide uptime while reducing maintenance costs Companies are looking for solutions to mitigate these challenges
Enterprise Plants Information Technology Strategic Framework The BIG picture Marketing DATA HISTORIAN DCS Enterprise Reporting & Analysis DASHBOARDS -- Executive -- Manager -- Supervisor -- Worker CORPORATE INDICATORS Visualization Generation Golden Tags Operating Data Automated Performance Monitoring Analytics FIELD DEVICES Engineering & Operations Billing Meter Vendors Meter Tags Smart Signal SAP Planning, maintenance and operational tools Business Analysis Business Analytics Business Warehouse PM PS MM HR FI Calculations
Operational Diagnostic Center Vision “The Operational Diagnostics Center (ODC) is intended to improve the bottom line for TransAlta, reduce the environmental impact of our operations and position us well for future growth opportunities while managing the aging demographic in our workforce. ”
Plant to Fleet Data Flow Distributed Control Systems (DCS) Historians Business Intelligence Reliability KPI’s Dashboards Fleet Optimization Plant Alarms, DCS Real-time Easy Access to Information Plant Level Operations Dashboards Engineering Applications Smart Signal Predictive Monitoring Optimization Discrete data Limited value Actionable Information
Technology Experience Previous Portals and Portal connected technology – IBM, Plumtree, Netweaver SAP Customer since 1992 (Currently ECC6.0) Experience with vendor integration with SAP modules Experience working with vendors to surface iViews in portal for seamless user interface
Operational Diagnostics Center Design Principles –Centralized engineering analyses of equipment performance –Centralized equipment condition monitoring –Condition based predictive maintenance plans –Fleet visibility of equipment condition and performance to the TransAlta technical experts –Direct interface with plant operators for alarm review and management
Previous Situation Internet Intranet Power Plant Manager PDA SAP R/3 Databases DCS Scheduling Energy Trading Systems User Site Management Generation Operations Marketing Complex information is hard to manage!
Enterprise-wide Decision Support Power Plant Manager Users Sites Management Generation Operations Operational Diagnostic Support Operational Diagnostic Support Systems Marketing
Enterprise-wide Decision Support The Benefits Role-based presentation of information Provision of expert knowledge about the plants facilitates: Fast remedies in all plants Best practice sharing Availability of power plant fleet as information for energy trading Improvement of risk assessment and management : “2 nd set of eyes” Improved process control and low expenses for repair reduces costs Increased MWh generation, especially at peak load times (elimination of bottlenecks) Transparency and synergies created
Getting Started ODC Design Study Objectives Initial engagement with vendor partner to develop: –Current state of software –Functional gaps –Recommendations to address gaps –Detailed scope and project schedule Functional Specs. Design Study Fleet Build Out Prototype Production Build Activities and Project Timelines
Getting Started Defining the “as is” landscape Analyze condition of installed historians Analyze reliability of data collection Review configured equipment diagnostics (SmartSignal) models Review configured Thermal Performance Monitoring systems Review configured off-line and on-line Vibration Monitoring systems Review DCS and Power IT landscapes Review configured SAP Plant Maintenance Review configured maintenance related workflows Review configured SAP Enterprise Portal
TransAlta ODC Power Portal: SAP EP, SAP PM and IP.21 Plant Manager User Roles - access rights via TA AD - info content via TA SAP EP portal page design Plants IP.21 based data collection TA Management ODC Center Operational Diagnostics Technology Operational Diagnostics Technology SAP EP navigation to portal pages -------------------- SAP EP to ERP R/3 link Technical / Engineering Center
Integration Considerations SAP PM and Siemens M3000 M3000 Case Logging M3000 Early warning Diagnostic System DCS Field Device etc. Manual data input Signals via HART/ Fieldbus or Profibus etc.. Pre-alarms processing Fault Notification EW Notification Signal Values Status Update Alarms 1. 2. 3. 4. standard optional Relevant problems (Faults) influencing actual operation Potential problems influencing future operation Maintenance or calibration of measurement unit necessary Event registration irrelevant signals x. Steps Plant Maintenance Work orders planning Work orders execution Status Update
Crystal Reports Data Links SAP Enterprise Portal Early Warning System Data Storage Hierarchy (Aspen ODM) Data Structure ODC Historian (IP21) TransAlta Operations Diagnostic Centre Plant Data Predictive Diagnostics Thermodynamic Modeling SAP PM Document Management Case Logging Tool EWS Interface Interface Screens (Aspen Web 21) Plant Data (Historian) Plant Data (Vibration Analysis)
Alarm Processing Workflow Adding Value to the Portal Disappear Scan-Off Evalua ted New Alert Valid Fault Case Resolv ed Dismis s Watch List Correc tive Action Alarm Ack SAP PM Fault Notificat ion Inspec tion Repair Case Resolv ed Dismis s Correc tive Action Alarm Ack Analy sis Validation
ODC Early Warning System Operator Interface – Portal Presentation
ODC Business Processes When received in the ODC, alerts are investigated, following ODC process guidelines.
SPPA-M3000 - Case Logging Supports the following tasks: –Recording of cases in case logs –Collecting significant signal value as KPI –Documentation of shift crews –Semi-automatic triggering of cases and fault notifications –Overall evaluation of operational conditions –Supporting shift takeover and handover
Business Value of the ODC The ODC will input close to “real-time” process data to monitor equipment condition Provide immediate feedback to the Operations team. Results in improved plant equipment performance – and implementation of maintenance practices based on equipment reliability impacts and known equipment condition. Potential benefits include improved the heat rate, decreased fuel costs, improve plant reliability and reduced environmental emissions.
Business Value of the ODC Other business benefits: –Providing a central contact point and visibility for plant operations –Identify and correct plant equipment problems before they become a process concern – thereby avoiding catastrophic failure of critical equipment –Measuring and sustaining other capital improvement projects’ benefits –Plant alarm monitoring and back-up capability –Improving knowledge retention, transfer and sharing
How We Did IT Lessons Learned so Far Top design consideration was to create a portal with SAP interactions for diagnostic and performance monitoring using existing technology – Netweaver 7.0 Justified the project based on the business value of having an operational diagnostics and performance center Learned what integration points from production to maintenance need to be addressed Need to move to a Netweaver CE 7.1 to take advantage of newer composition techniques
Summary Have a strong business case that motivates the project Work with integration partners where cost and time and resources are in short supply Know business processes that the solution is going to support Do a current technology assessment and identify gaps in moving to a portal solution Show value often and early – A prototype can do this Integration is key to taking the plant data and systems information to management in a meaningful way