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Architecting Powerful Portals

Architecting Powerful Portals. Martin Mysyk. Architecting Powerful Portals Agenda. Company Background Industry and Information Challenges Case Study – TransAlta’s ODC SAP Interactions and Modules Lessons Learned Summary.

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Architecting Powerful Portals

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  1. Architecting Powerful Portals Martin Mysyk

  2. Architecting Powerful PortalsAgenda • Company Background • Industry and Information Challenges • Case Study – TransAlta’s ODC • SAP Interactions and Modules • Lessons Learned • Summary

  3. 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 TransAlta – Company Background

  4. 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

  5. Plants Enterprise PM PS Engineering & Operations SAP MM HR FI Information Technology Strategic FrameworkThe BIG picture Visualization Meter Tags Meter Vendors Enterprise Reporting & Analysis CORPORATE INDICATORS FIELD DEVICES DATA HISTORIAN Golden Tags DCS Golden Tags Operating Data Calculations Calculations • DASHBOARDS • - Executive • - Manager • - Supervisor • - Worker Planning, maintenance and operational tools Business Analysis Business Warehouse Business Analytics Analytics Smart Signal Automated Performance Monitoring Billing Marketing Generation

  6. 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.”

  7. Plant to Fleet Data Flow KPI’s Dashboards Fleet Optimization Actionable Information Business Intelligence Reliability Predictive Monitoring Optimization Plant Level Operations Dashboards Plant Alarms, DCS Real-time Easy Access to Information Engineering Applications Smart Signal Distributed Control Systems (DCS) Historians Discrete data Limited value

  8. 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

  9. Operational Diagnostics CenterDesign 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

  10. Previous Situation Management Complex information is hard to manage! Marketing Generation Operations Power PlantManager User Systems Scheduling DCS Internet Databases EnergyTrading SAP R/3 PDA Intranet Site

  11. Enterprise-wide Decision Support Management Marketing Generation Operations Power PlantManager Users Operational Diagnostic Support Systems Sites

  12. Enterprise-wide Decision SupportThe 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

  13. 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 Production Build Fleet Build Out Activities and Project Timelines

  14. 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

  15. TransAlta ODC Power Portal: SAP EP, SAP PM and IP.21 TA Management Technical / Engineering Center User Roles- access rights via TA AD- info content via TA SAP EP portal page design PlantManager ODCCenter SAP EP navigation to portal pages -------------------- SAP EP to ERP R/3 link Operational Diagnostics Technology PlantsIP.21 based data collection

  16. Performance Performance Performance Turbine / Vibrations Turbine / Vibrations Turbine / Vibrations Boiler / Equipment Diagnostics Boiler / Equipment Diagnostics Boiler / Equipment Diagnostics Leveraging Information and Resources Centralized Operational Diagnostic Center Engineering Trading Executive Reporting Maintenance

  17. Integration ConsiderationsSAP PM and Siemens M3000 1. 3. Status Update Manual datainput M3000 Case Logging 4. FaultNotification Work ordersplanning Work ordersexecution Alarms Event registration 2. 1. Relevant problems (Faults) influencing actual operation Plant Maintenance M3000 Early warning Diagnostic System DCSField Device etc. EW NotificationSignal Values Potential problems influencing future operation Maintenance or calibration of measurement unit necessary Signals via HART/Fieldbus or Profibusetc.. Status Update Pre-alarms processing standard Steps x. irrelevant signals optional

  18. Data Links TransAlta Operations Diagnostic Centre Predictive Diagnostics Thermodynamic Modeling Plant Data (Historian) Plant Data (Vibration Analysis) Plant Data ODC Historian (IP21) Data Storage Hierarchy (Aspen ODM) Data Structure Early Warning System SAP Enterprise Portal Interface Screens (Aspen Web 21) Case Logging Tool EWS Interface Document Management SAP PM Crystal Reports

  19. ODC Process Graphics

  20. Validation Alarm Processing WorkflowAdding Value to the Portal WatchList Evaluated DisappearScan-Off NewAlert Analysis Corrective Action Alarm Ack Case Resolved Dismiss Valid Fault Corrective Action Alarm Ack SAP PM Fault Notification InspectionRepair Case Resolved Dismiss

  21. ODC Early Warning System Operator Interface – Portal Presentation

  22. When received in the ODC, alerts are investigated, following ODC process guidelines. ODC Business Processes

  23. 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

  24. Case Logging – Shift Management

  25. Case Logging –Shift Resources

  26. Case Logging – Shift Detail

  27. Case Logging – Cases

  28. Case Logging – Case Detail

  29. The Operational Diagnostics Center

  30. 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.

  31. 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

  32. How We Did ITLessons 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

  33. 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

  34. Martin Mysyk TransAlta Corporation martin_mysyk@transalta.com

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