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Wonderware Exchange 09 Presentation

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Wonderware Exchange 09 Presentation Powered By Docstoc
					     ESKOM’S CENTRALISED PDS
      INFORMATION HISTORIAN
                  John Viljoen    Vicki Naudé
           Corporate Consultant   Senior Advisor
Generation Business Engineering   Generation Information Management
Agenda



                 Background
               Project Solution
                       Benefits
                Considerations
                     Summary


         Eskom’s Centralised PDS Information Historian
Background
                     PLANT INFORMATION ISSUES
►   The drive for increased reliability and efficiency of operation
    requires better PLANT INFORMATION, in real time
►   Plant condition deteriorating due to aging – need to get a better
    handle on CONDITION MONITORING INFORMATION
►   Electricity supply must match the demand at all times –
    PRODUCTION INFORMATION is critical
►   Traditionally, the process automation provides OPERATING
    INFORMATION to assist the operator to operate and manage his
    plant.
►   The engineers need ASSET INFORMATION to perform asset
    lifeycle management.
►   At a site level, data volumes are exhaustive, but USEABLE
    INFORMATION is not easily accessable

                   Eskom’s Centralised PDS Information Historian
Background

             INFORMATION TECHNOLOGY ISSUES
► Drive for improved business performance and efficiency.
► Current information is TRANSACTIONAL, not Real-Time.


► INTEGRATION METHODS focused on transactional systems.
► STORAGE METHODS focused on transactional systems.
► IT ARCHITECTURE landscape is fragmented.
► IT SECURITY a continuous challenge.
► IT INFRASTRUCTURE outsourced.




               Eskom’s Centralised PDS Information Historian
Background

    THE CHALLENGE
    How can Generation manage the
  escalating complexity of merging its
 PLANT INFORMATION world with its
   INFORMATION TECHNOLOGY
                  environment


         Eskom’s Centralised PDS Information Historian
Setting the Scene

  The Current Eskom Power Generation Fleet
                                                 Number           Total
                                  Power
  Type of Generation                                of           Capacity
                                 Stations
                                                   Units          (MW)
Coal fired Power Stations            13               93          37410
Open Cycle Gas Turbine                4               20          2414
Hydro                                 2                6           600
Pump Storage                          2                6          1400
Nuclear                               1                2          1930
Total Installed Capacity             22             127          43754

                 Eskom’s Centralised PDS Information Historian
Setting the Scene

      The South African Power Network




                                                           Coal Fired
                                                           Hydro
                                                           Pump Storage
                                                           Nuclear
                                                           OCGT



           Eskom’s Centralised PDS Information Historian
Typical Plant




     Palmiet
   Power Station



                Power Station
        Koeberg Power Station
         Tutuka Power Station
         Matimba
           Eskom’s Centralised PDS Information Historian
Project Goals

► The PDS project goal is to make Generation’s plant data
   openly accessible, in a standardised format, to every area
   of the business that use it to contribute to the bottom line.
► This plant data can be readily transformed into useful
   plant information, to meet the information consumers
   specific needs.
► The more effective use of plant information will ultimately
   result in more refined performance indicators, better
   optimisation of plant and better allocation of resources.
► Plant data can be delivered to the Specialist Engineer, to
   improve incident response.


                Eskom’s Centralised PDS Information Historian
Project Motivation

► Need for near-real time information to support both
   operational and business decisions
► Lack of standardisation results in duplication of
   engineering, and multiple interface development
► Solution is based on least cost to achieve final
   functionality – sites were already developing their own
   individual solutions
► Major cost components are licenses and engineering,
   which are based on tag volume – offering economies of
   scale by including more sites
► This technology is seen as a business enabler


                Eskom’s Centralised PDS Information Historian
Agenda



                   Background
              Project Solution
                       Benefits
                Considerations
                      Summary


         Eskom’s Centralised PDS Information Historian
Why Wonderware

► Eskom issued an open Request For Proposal to the
  market, and the Wonderware solution offered the best
  cost/functional performance ratio.
► The ArchestrA framework was ideally suited to the rapid
  deployment of a standardised solution across all the
  power stations.
► Using web based viewing enabled a cost effective method
  of managing a large number of simultaneous users.
► The combination of InSQL, InTouch and the Wonderware
  Information Server met the specific requirements for real-
  time data management.



               Eskom’s Centralised PDS Information Historian
Why Bytes

► Bytes Technology Group were chosen as preferred SI:
   ▪ ArchestrA certified integrator in South Africa
   ▪ Track record of implementing large and small PDS-like
       solutions on-time and in budget
   ▪   Existing knowledge of Eskom solutions with respect to
       SeeBeyond and Business Objects
   ▪   Experience with implementing Wonderware products
       and securing several awards such as:
        Largest InSql implementation
        Best integrated solution
        Best Integrated Archestra solution
        Best Integrator

                Eskom’s Centralised PDS Information Historian
Architectural Considerations
►    Governance Compliance
      Eskom Information Systems Architecture Review
       Committee

►    Architectural Requirements
    ▪ Role based access and content management
    ▪ Active Directory synchronised with Eskom’s Identity
        Management System (Novell).
    ▪ Business Continuity through Application Server
        redundancy.
    ▪ Object Oriented model development
        Ease of configuration management
        Re-use of models
               Eskom’s Centralised PDS Information Historian
Products Used

Wonderware Suite used by PDS
► Wonderware System Platform 3.0
   ▪ Wonderware Information Server 3.0
   ▪ Wonderware Historian 9.0 (InSQL)

► Wonderware InTouch HMI 10
► Wonderware Active Factory 9.2




             Eskom’s Centralised PDS Information Historian
PDS Project Description

► The PDS project goal is to provide a standard platform for
  obtaining Generation plant data via a single interface.


► The PDS project scope included:
    ▪ Interface to 13 coal fired, 1 nuclear and 6 peaking
      (hydro, gas and pumped storage) sites.
    ▪ Define and develop a plant model for each of these
      sites.
    ▪ Provide a web interface with screens for each site.
    ▪ Provide Active Factory to identified superusers on sites.


               Eskom’s Centralised PDS Information Historian
Topology
                                              Megawattpark LAN




   Galaxy Repository           Domain Controller              InSQL Server                Wonderware
 Configuration Database         Active Directory             Central Historian         Information Server                 Router
      PDSMPKGR                  NDS replication              PDSMPKINSQL                   Web Server
                                 PDSMPKDC                                                 PDSMPKSV



                                        Matla LAN


                                                                                                            Router                 Eskom WAN




  Application Server   Application Server           InSQL Server                     Firewall
    Primary AOS         Redundant AOS               Site Historian
   PDSMAPAOS1            PDSMAPRDT                 PDSMAPINSQL




                                                                 Matla Process LAN




      Unit1 SCADA               Unit2 SCADA              Unit3 SCADA             Unit4 SCADA                Unit5 SCADA             Unit6 SCADA



                                   Eskom’s Centralised PDS Information Historian
Interfacing
► The mechanism of obtaining data is via OPC.



     Station       Source Info System
Arnot          ABB PGIM
Duvha          Visual Automation 3
Majuba         Visual Automation 4
Matimba        Visual Automation 4
Lethabo        Wonderware InSQL 9                       PDS provides a
Tutuka         ABB PGIM
Kriel          OSISoft PI                            standard interface to
Camden         Visual Automation 4                   the Generation Fleet
Komati         OSISoft PI                           Historians irrespective
Grootvlei      Honeywell PHD                           of the underlying
Matla          Citect
Kendal         OSISoft PI                                  technology
Hendrina       TBD
Peaking        Wonderware InSQL 8 and 9
Koeberg        Wonderware InSQL 8
               Eskom’s Centralised PDS Information Historian
PDS S-95 Model

► Data models according to Eskom’s Generic Plant
  Breakdown Guide and the ISA-95 standard.
► The ISA-95 standard defines the interface content
  between manufacturing control functions and other
  enterprise functions in order to reduce the risk, cost, and
  errors associated with implementing these interfaces.




               Eskom’s Centralised PDS Information Historian
PDS S-95 Galaxy




         Eskom’s Centralised PDS Information Historian
User Base

►    Users;
      ▪ 80 super users (Active Factory)
      ▪ 500 users (Web clients)

    ► Training
       ▪ Custom 3 day training course compiled and presented
         by Wonderware.
       ▪ Specific to PDS
       ▪ Condensed course covers aspects of the entire
         Wonderware suite used by PDS.




                 Eskom’s Centralised PDS Information Historian
PDS Screenshots




         Eskom’s Centralised PDS Information Historian
PDS Screenshots




         Eskom’s Centralised PDS Information Historian
PDS Screenshots




         Eskom’s Centralised PDS Information Historian
Active Factory Screenshots




                                              Typical Light up
                           MW Load                of a unit




          Eskom’s Centralised PDS Information Historian
Active Factory Screenshots


         Daytime highs




                         Nightime lows
                                             Typical load profile
                                                over 7 days




            Eskom’s Centralised PDS Information Historian
Agenda



                   Background
               Project Solution
               Considerations
                       Benefits
                      Summary


         Eskom’s Centralised PDS Information Historian
Considerations

Lessons Learnt
► Must have buy-in from Sites
► Must have an empowered project champion
► Must have plan to train and retain resources
► Should have done a more detailed interface assessment
  upfront – some surprises later on
► Go fully redundant from beginning
► Have a different project strategy (parallel not sequential)
Positive outcomes
► Spending the upfront time on the Models was worth it
► Standardisation the way to go (hardware, config etc)



               Eskom’s Centralised PDS Information Historian
Agenda



                  Background
              Project Solution
               Considerations
                     Benefits
                     Summary


         Eskom’s Centralised PDS Information Historian
Benefits / Goals Achieved


► Real-time plant data now a reality.
► Standardisation has been achieved.
► Definitely a cost effective approach.
► Has significantly raised the “visibility” of the
  benefits of open access to plant data.
► Closer relationship between Plant and IT
► Numerous applications now using the PDS data.




             Eskom’s Centralised PDS Information Historian
Keeping the lights burning – IGCC


 ► Initiated by the Jan 2008 power crisis
 ► No central Generation info facility existed
 ► No real time info available
 ► The Integrated     Generation Control Centre (IGCC)
   business model Developed
 ► Srategy based on Short, Medium and Long term
   view
 ► Phase 1 to “Go Live” with the Confederations Cup




               Eskom’s Centralised PDS Information Historian
Keeping the lights burning – the IGCC
                             • Manipulated Data
                             • Lower Granularity
                            • Business Relevant
                           • Strategic Decisions
                                                        IGCC                      Wonderware




                                                              Performance
     • Detailed Data
   • High Granularity
  • Function Relevant
• Operational Decisions
              Wonderware




                                                                                  Primavera
                                                    Phoenix




                                                                                              Oracle
                                 Oracle


                                           Oracle




                                                              Prism




                                                                                                       SAS
                                                                            SAP


                                 Eskom’s Centralised PDS Information Historian
IGCC Platform

 The IGCC uses the following products:
 ► Wonderware System Platform 3.0
     ▪ Wonderware Information Server 3.0
     ▪ Wonderware Historian 9.0 (InSQL)
 ► Wonderware InTouch HMI 10
 ► Wonderware Active Factory 9.2




             Eskom’s Centralised PDS Information Historian
Integrated Generation Control Centre




            Eskom’s Centralised PDS Information Historian
Integrated Generation Control Centre




            Eskom’s Centralised PDS Information Historian
Integrated Generation Control Centre




            Eskom’s Centralised PDS Information Historian
IGCC Screen Shots




        Eskom’s Centralised PDS Information Historian
Intelligent Plant Monitoring - PRiSM


PRocess Information Signal Monitoring
► Purpose:
   ▪ Reduce overall maintenance and capital costs by
      allowing engineers to more effectively detect
      equipment problems before they lead to failures and
      therefore more accurately allocated resources and
      reduce unnecessary downtimes.
► Method:
   ▪ Model objects of plant to compare normal operating
     parameters with actuals and alarm any deviations.
► PRiSM sources process data from PDS in real
  time through FSGateway.

              Eskom’s Centralised PDS Information Historian
PRiSM Screen Shots




        Eskom’s Centralised PDS Information Historian
Agenda



                 Background
              Project Solution
                     Benefits
              Considerations
                   Summary


         Eskom’s Centralised PDS Information Historian
PDS Project summary

► Project Started Jan ’07
► Implementation on time and budget – minor
  delays due to site issues
► Completion target May ’09
► Will also include future power stations
► Numerous applications now using PDS
► Will meet the objective of being a business
  enabler
► Definitely seen as a success already!

           Eskom’s Centralised PDS Information Historian
Conclusions

► The overall intent is still valid (even more so)
► Fundamental Scope has not changed
►Through ArchestrA, the PDS system
  System Integrator route was successful
      has succeeded in bringing the
► Some implementation issues could have
         improved
  been PLANT AUTOMATION and
  ▪ Availability of Site resources were a key issue
     INFORMATION TECHNOLOGY
  ▪ worldschanged from serial to parallel
    Roll-out
               within Generation together!
  ▪ Training issues due to staff turnover
  ▪ Technology transfer did not yet materialise


             Eskom’s Centralised PDS Information Historian
Project summary




   Questions

          Eskom’s Centralised PDS Information Historian

				
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