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Architecting Powerful Portals Martin Mysyk © 2008 Eventure Events. All rights reserved. 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 nonregulated 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 Information Technology Strategic Framework The BIG picture Plants Enterprise Meter Tags Meter Vendors FIELD DEVICES DCS DATA HISTORIAN Calculations Golden Tags Operating Data Business Analysis Enterprise Reporting & Analysis Golden Tags Calculations SAP Engineering & Operations Planning, maintenance and operational tools Visualization Business Warehouse Business Analytics PM PS MM HR FI CORPORATE INDICATORS DASHBOARDS -- Executive -- Manager -- Supervisor -- Worker Analytics Smart Signal Generation Automated Performance Monitoring Marketing Billing 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 Actionable Information KPI’s Dashboards Fleet Optimization Business Intelligence Reliability Predictive Monitoring Optimization Plant Level Operations Dashboards Plant Alarms, DCS Real-time Easy Access to Information Engineering Applications Smart Signal Discrete data Limited value Distributed Control Systems (DCS) Historians 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 Complex information is hard to manage! Management Marketing Generation Operations Power Plant Manager User Systems PDA Site Internet Intranet SAP R/3 Databases DCS Scheduling Energy Trading Enterprise-wide Decision Support Management Marketing Users Systems Sites Generation Operations Power Plant Manager Operational Diagnostic Support 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 : “2nd 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 Design Study Functional Specs. Prototype Activities and Project Timelines Production Build Fleet Build Out 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 TA Management User Roles - access rights via TA AD - info content via TA SAP EP portal page design SAP EP navigation to portal pages -------------------SAP EP to ERP R/3 link Plants IP.21 based data collection Technical / Engineering Center Plant Manager ODC Center Operational Diagnostics Technology Leveraging Information and Resources Performance Performance Turbine / Vibrations Performance Turbine / Vibrations Turbine / Vibrations Centralized Operational Diagnostic Center Boiler / Equipment Diagnostics Boiler / Equipment Diagnostics Boiler / Equipment Diagnostics Engineering Trading Executive Reporting Maintenance Integration Considerations SAP PM and Siemens M3000 1. 3. Manual data input Status Update 4. M3000 Case Logging Fault Notification Work orders planning Alarms Event registration 2. 1. Relevant problems (Faults) influencing actual operation Diagnostic System M3000 Early warning DCS Field Device etc. Signals via HART/ Fieldbus or Profibus etc.. EW Notification Signal Values Pre-alarms processing Plant Maintenance Potential problems influencing future operation Maintenance or calibration of measurement unit necessary Status Update x. irrelevant signals Work orders execution Steps standard optional TransAlta Operations Diagnostic Centre Thermodynamic Modeling Plant Data (Vibration Analysis) Plant Data (Historian) Predictive Diagnostics Plant Data Data Storage ODC Historian (IP21) Data Structure Hierarchy (Aspen ODM) Early Warning System Data Links SAP Enterprise Portal Interface Screens (Aspen Web 21) Crystal Reports EWS Interface Case Logging Tool SAP PM Document Management ODC Process Graphics Alarm Processing Workflow Adding Value to the Portal New Alert Validation Watch List Evalua ted Correc tive Valid Fault Analy sis SAP PM Fault Notificat ion Action Alarm Ack Inspec tion Repair Disappear Scan-Off Case Resolv ed Dismis s Correc tive Action Alarm Ack Case Resolv ed Dismis s 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 Case Logging – Shift Management Case Logging –Shift Resources Case Logging – Shift Detail Case Logging – Cases Case Logging – Case Detail The Operational Diagnostics Center 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 Martin Mysyk TransAlta Corporation [email protected] © 2008 Eventure Events. All rights reserved.