Extending PI for Process
Improvement in Operations
and Maintenance at TransAlta
Ideas to Action
Agenda
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TransAlta Overview
Vision
Scope
Standard Business Model
Maintenance
Operations
Integrated Decision Support
Conclusions
Q&A
Ideas to Action
TransAlta
• Canada’s largest non-regulated electric
generation 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
Ideas to Action
TransAlta … State of the Business
Marketing
Corporate Services
Platforms that
Generation
HR
Business
Strategy
support the business
Portal
Document Management
BI – Business Analyzer
SAP/ Back office
Infrastructure
PI data – connecting disparate sources!
Ideas to Action
Vision
Supply
Enterprise
Production
accounting periods
Enterprise
Management
operating events
Production
Management
minute by minute
second by second
Control and Automation
& Real-time Asset Mgmt
Control
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Supply Chain
Distribution
IT Infrastructure
and Integration
Platform
“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.
Ideas to Action
High Level Scope
• TOP = “TransAlta Optimization Program”
• Purpose:
• “The Integrated Enterprise”
• Vertical and horizontal integration and optimization
• Scope:
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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
Ideas to Action
Typical Plant View
TransAltaOperationalData
Corporate
PlantSite
WarRoom
External
Partners
External
Information
Generation & Corporate Backof f ice
KPI's, Rev enueForecasts, Finance
Reporting
and
Analytical
DCS
Field Device
OPS LAN
Plant
Historian
Economic Dispatch
Plant 1
Data to Web
(External Applications. e.g. "e-f f iciency "
EnergyTrading
Enterprise
Historian
Fleet Optimization
Maintenance
Scheduling
5 Year Plan &
Turnarounds
DCS
Field Device
OPS LAN
Plant
Historian
Plant X
Data to Web
(External Applications. e.g. "e-f f iciency "
Centralized
Perf ormance
Management
Production &
Rev enueForecasting
External Data
Business Applications
Plant Historian
Plant Optimizer
Asset Management
Chemicals
Maintenance & Ops
(83 Discrete Apps at Centrailia)
Ideas to Action
Operations
TOP – Standard Business Model
Operations
& Production
Corporate Marketing Engineering
Enterprise
/Region
Finance
HR
Legal
EH&S
SCM
Energy
Trading
War Room
Region/Fleet-Wide Analysis
CAD/CAE
Project
Mgmt
Asset
Management
Program
Economic Dispatch
Doc
Mgmt
Infrastructure
/Data Mgmt
Enterprise Historian
Inter-Application
Communication
EAM/CMMS
Outage
Mgmt
Plant/Unit
Asset
Management
Asset
Reliability
Program
Optimization
Performance Monitoring and
Diagnostics
Plant Historian
Fuel Supply (Gas, Coal Mining)
CEMS
Simulation
Unit/Control System
Historian
Advanced Process Control
Unit Operations Control and Monitoring System
(BMS, CCS, TCS, …), BOP
Process
Equipment
Equipment Performance
Monitoring
Asset Condition Monitoring
Asset Health Monitoring
Device
Ideas to Action
Process
Measurement
& Control Elements
Asset Health
Monitoring
Elements
InterDevice Communication
(HART, Remote IO…)
Maintenance
Ideas to Action
Maintenance Goals
• Consistent routine maintenance practices
fleet wide to produce :
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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
Ideas to Action
Maintenance Improvements
Processes
Tools
Information
• role
• location
• operational
KPIs
Alerts
Dashboard
Ideas to Action
Total Maintenance Solution – xVIp
Maintenance Best Practices and Processes
PDAs
Ver 1.0 – Q1 ’03
PCs
Portal
Alerts
Web
- Suppliers (Info, Alerts)
Visual Parts Catalogue
Search
- Maintenance Companies
- Monitoring
- Contractors
Visual Plant Structure
Ver 1.x – Q3 ‘03
RCM
Real-Time Plant Info.
Working Offline
Collaboration
Work Clearance
Process Integration
(Process Maps Activated)
ERP
(eg., Plant Maintenance, MM,
etc.)
Document Stores
- Drawings, Technical Docs
- Operating Manuals
Automated Work Packages
Business Packages - iViews
(Assets, Financial, Projects , etc)
Maintenance Data
Plant Maintenance (View all Plants as one)
Ideas to Action
Data Warehouse
SAP BW
Working the Process - Before
ERP
Intranet
BW
Workflow
Business Process
Ideas to Action
Unstructured
Content
Internet
Real Time
Others...
Working the Process - After xVIP
ERP
Intranet
Ideas to Action
BW
Workflow
Unstructured
Content
Real Time
Internet
Others
Mobile
Ideas to Action
Solution Overview
Users
Reporting
Software
Process
Optimization
mySAP BW
ABB
KFx
DB Riley
GE
Westinghouse
Uttramax
Lehigh
KnowledgeScape
Ideas to Action
Real-Time
Operating
Statistics
OSI PI
Siemens
Work and
Asset
Diagnostic
Materials
Content
and
Management Management Reliability
and Cost
Software
NRX ACM
Control
mySAP ALM
Bentley Nevada
(Various Homegrown
Systems)
Document
Management
SAP DMS
FileNet
Preventive
and
Predictive
Maintenance
(i.e. RCM)
Applications
xVIp Background
• xVIp developed by NRX (SAP partner)
• Developed with input from TransAlta
• Incorporating Plant Maintenance best
practices
• xVIp continuing to evolve
Ideas to Action
OSISoft and SAP NetWeaver Interoperability
OSISoft
Solutions
SAP NetWeaver
People Integration
Multi-Channel Access
Portal Collaboration
Information Integration
Knowledge Mgmt
Business Intelligence
Master Data Mgmt
Process Integration
Integration Broker,
Business Process Mgmt
Application Platform
J2EE
ABAP,
DB and OS Abstraction
Ideas to Action
SAP NetWeaver Interoperability
IBM WebSphere
• Portal Development Kit for
WebSphere
• Integration of Lotus
Sametime
SAP NetWeaver
People Integration
Multi-Channel Access
Portal
Collaboration
Information Integration
• Integration with
IBM Content Manager
• Interoperability with
WebSphere Business
Integration
• Eclipse-based Java IDE
• Technical, standards-based
connectivity (XML,
Web Services)
Ideas to Action
Knowledge Mgmt
Business Intelligence
Master Data Mgmt
Microsoft .NET
• Portal Dev. Kit for .NET
• Smart Client on .NET
• MS Office Integration
• MS Exchange Integration
• Integration of MS Content
Management Server
• Integration of SQL Server
Analysis Services
Process Integration
Integration Broker,
Business Process Mgmt
Application Platform
J2EE
ABAP,
DB and OS Abstraction
• Interoperability with
MS Biztalk Server
• Visual Studio .NET integr.
• Technical, standards-based
connectivity (XML,
Web Services)
Screenshot Examples
Ideas to Action
Condition
Monitoring
xVIp example using
SAP Enterprise Portal
Business
Intelligence
Click
on a
KPI
CMMS
Ideas to Action
Ideas to Action
xVIP Roles
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Maintainer
Planner
Supervisor
Operator
Planner
Engineer
Manager
Plant Manager
Ideas to Action
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 ….
Ideas to Action
Click
on an
alert
Ideas to Action
Go to OEM
documents
to identify
parts
“Drag” a Notification
to “create order”
…navigates to the relevant
part of the equipment
hierarchy and displays past
/ current notifications and
Ideas to Action
orders for this equipment
Simplified iViews
allow creation of
new transactions
The Result
VPS customer
example accessed
from within SAP PM
Hotpointed diagram
links to OEM parts
list (data not image)
Automatically navigated to
correct part of equipment
OEM part # linked to
SAP item, Hotlinked to
photo of item in
warehouse
tree from work order
checking box, adds part to
SAP Work Order
Ideas to Action
Entire tree audited
and cleansed down
to serial number
and photographed
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 ….
Ideas to Action
xVIp i-Views
Ideas to Action
xVIp i-Views
Ideas to Action
xVIp i-Views
Ideas to Action
xVIp i-Views
Ideas to Action
Demonstration – Collaboration in Action
Ideas to Action
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
Ideas to Action
Steps to Enabling Maintenance
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Maintenance Strategy
Community Pages for Maintenance
KPI’s – 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)
Ideas to Action
Operations
Ideas to Action
Optimization leads to Continuous
Improvement
Minimize operational variances enabling the units to “push” the
constraints
Specification
or Limit
Average
Average
Current
Operation
Ideas to Action
Variations
Reduced with
Advanced Control
Move Average
Closer to
Specification or Limit
Goal: Integrate, Optimize all Areas
Controlled
Operating
Region
True
Economic
Optimum
Unit Generation Output
Emissions
Fuel Costs
Operator's
Preferred
Operating
Region
Unit heat & ramp rates
Operational Values
Ideas to Action
Existing GT Performance Trends
Ideas to Action
Optimization in Action
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Yellow = differential between current operation and model based optimal operation
Ideas to Action
TOP – Pilot Expected Benefits
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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.
Ideas to Action
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
Ideas to Action
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 KPI’s - 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 > turnaround schedules
Ideas to Action
Ideas to Action
Integrated Decision Support Areas
Operations
Plant Operations
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Generation schedule
execution
Unit capability and
availability
Unit performance and
optimization decisions
Shift management
Resource allocation
(O&M)
Energy Marketing
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Ideas to Action
Balancing marginal
costs and market prices
Generation risk and
market commitment
decisions
Scheduling generation
units
Power reserves for
handling of forced
outages
Performance
Reporting & Bench
Marking
Maintenance &
Repair
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Diagnostics of deratings
and component failures
Maintenance and repair
scheduling decisions
Equipment isolation and
occupational safety
requirements
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Collection and
prediction of
performance data
Benchmarking of units
and operation modes
Environmental
monitoring
Ideas to Action
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!
Ideas to Action
Q& A
Keith_Christianson – Keith_Christianson@TransAlta.com
Paul Kurchina – Paul_Kurchina@TransAlta.com
Ideas to Action