Sangyoung Mo, et al. 1 PI Introduction on ERP Project in KHNP Sangyoung Mo 1 and Taegheon Kwag 2, KOREA HYDRO & NUCLEAR POWER CO., LTD. PI Introduction

Sangyoung Mo, et al.1

PI Introduction on ERP ProjectPI Introduction on ERP Projectin KHNPin KHNP

May 13, 2003

Sangyoung MoSangyoung Mo11 and Taegheon Kwag and Taegheon Kwag22

1ERP Project Office, ERP Project Division,2Maint. & Eng. Office, Power Generation Team, ,

Headquarters,KOREA HYDRO & NUCLEAR POWER CO., LTD.KOREA HYDRO & NUCLEAR POWER CO., LTD.


OutlineOutline

Introduction Introduction of KHNP ERP Project in KHNP

PI Installation Scope System Layout Data Flow Interface with SAP

Trouble-shootings

Conclusion


Background and Information of KHNP (1/2)Background and Information of KHNP (1/2)

Korea Electric Power Corp. (KEPCO) officially split up its power generation sector into 6 separate companies on April 2, 2001 by the Korean government’s electric power industry restructuring program.

The goal of the restructuring is to provide users with stable supplies of high-quality and low-cost electricity by maximizing the competitiveness and efficiency of the power generation companies.

Korea’s electric power exchange market have been operating since April 2002. Although it is currently a Cost-based pool, it will be changed into TWBP (Two Way Bidding Pool) market by April 2004

As one of the subsidiaries, KHNP has been formed combining hydro and nuclear generating facilities of KEPCO.

operate 18 nuclear reactors in 4 sites, and 16 hydro plants 2 new reactors are under construction plan to build an additional 10 reactors by 2015


Background and Information of KHNP (2/2)Background and Information of KHNP (2/2)

Installed nuclear capacity : 15,716 MW (as of the end of 2002) 29.2 % of the nation’s total installed capacity

Nuclear power output : 119 billion kWh (in 2002) 38.9 % of the country’s electricity consumption

Average capacity factor of NPPs : 92.7 % (in 2002)

PWRPWR

PWRPWR

PHWRPHWR

Ulchin # 1, 2, 3 & 4 # 5 & 6

Wolsong # 1, 2, 3 & 4

Kori # 1, 2, 3 & 4

PWRPWRYonggwang # 1, 2, 3, 4, 5 & 6

In Operation : 18 (15,716MW) Under Construction : 2 (2,000MW)


Background and Objective of ERP ImplementationBackground and Objective of ERP Implementation

Strengthen Competitiveness

through Implementation of Advanced Business

Management Technique

Establish Profit Oriented Management &

Transparent Accounting Method

Need for Implementation of Business Process Innovation for Utility

Industry

Implementation of BPR & ERPManagement

Transparency/Implementation of profit oriented

business system

Gain Comparative Advantage in Power GenerationGain Comparative Advantage in Power Generation

ProjectBackground

Innovation Program

Project Objective

Changes in Utility Industry Business Environment Changes in Utility Industry Business Environment Graduate Dispersion of Demand & Open CompetitionGraduate Dispersion of Demand & Open Competition

Introduce Advanced Business Mgt.

Technique

Integrate/Implement developed information

system


Brief Process of ERP ProjectBrief Process of ERP Project

2001.4.2 : Split up of KEPCO into KHNP 2001.6.1 : Launch ERP project team 2001.12.31 : Sign contract (Anderson consortium) 2002.1.14~2.28 : SAP module training 2002.4.1 : Commence 7 key BPR processes 2002.4.10 : Complete As-is analysis 2002.7.31 : Complete To-be design 2002.10.24 : Contractor change to BP (BearingPoint) consortium 2003.1.20~1.25 : Complete final integration test 2003.1.29 : Decide on ERP system title as DREAMS (Digital

Realtime Enterprise Asset Management System) 2003.2.8 : ERP system open (on Ulchin Plant 2) 2003.4.12 : Roll-out on All plants excluding Ulchin Plant 2


PI Introduction ScopePI Introduction Scope

Server Side PI UDS : Data Storage (6 PI Servers)

Interface Side

PI RDBMSPI I/F : Site Interface I/F

PItoPI I/F : I/F between head office and each site

PI API : App. I/F (Manual input, SAP CO module I/F)

PI Activeview : Web I/F

PI RLINK : SAP PM module I/F

Client Analysis

Tool

PI DataLink : MS Excel I/F

PI PrecessBook : Mimic Implementation

✤ We intended to introduce PI ICE for web interface but PI Activeview was finally installed instead of PI ICE to improve speed on the web.


PI System LayoutPI System Layout

Ulchin Nuclear Division

Han River Site

Disch. Temp.

Disch. Rad.

ERMS

Weather Info.

TMS Chem.Plant-2 Com.Plant-1 Com.

Buffer Node

Buffer NodeBuffer Node

UJPI(RTDB)

Kori NuclearDivision

(Same as Ulchine)

TADA Sys.

Buffer NodeHYDROPI(RTDB)

Wolsong NuclearDivision

(Same as Ulchin)

Yonggwang NuclearDivision

(Same as Ulchin)

Head office

Customized KHNP LAN

HQPIWeb Server

(RTDB)PI-RLINK

Gen. Monitoring Sys.

Power Trading Sys.

DREAMS

Out of KHNP

YKPI(RTDB)

WSPI(RTDB)

KRPI(RTDB)

KPXGen. Monitoring Sys. in other companies

Legacy

PI

SAP

Korea Power Exchange Co.


Integrated Data FlowIntegrated Data Flow

Eq. reliability Gen. cost/profit Key operation

indicator Perform. index

Power Trading Sys.

Each Legacy System

NPP Monitoring Sys.

TADA System

HPP Monitoring

Dam Information

Plant Parameters

Power Generated

Env./Radiation

Power Sales

Operating History

PI Interface

BufferNodes

Nuclear Div.- Kori- Wolsong- Yonggwang- Ulchin

PI-API

PM

Head Office

DREAMS(SAP)

PI R-Link

Han RiverBufferNodes

PI Server

PI-A/V

Gen. Monitoring Sys.

PWR Output

Web Interface

PI User Interface & Analysis Tools ERP Package

RTDB

RTDBRTDBRTDBRTDB

RTDB

RDB

RDB

RDB

Legacy System

BufferNode

Client Tools- PI DataLink- PI ProcessBook


Interface with SAP PM through RLINKInterface with SAP PM through RLINK

PI RLINK provides an interface between PI and SAP PM Trigger based SAP Transaction

Transaction is triggered by the alarm tag Automated PM notifications Measurement document creation in SAP PM Additional tags are needed for alarms, PM notification number,

and measurement document number.

No way to transfer PI analog type data to SAP frequently, through RLINK

In case of manual input, the additional step resetting the alarm is necessary

Can not deliver any real time analog data from PI to SAP


SAP Transaction Steps in detailSAP Transaction Steps in detail

In case of Run/Stop signal of Rotating Equipment

Source Tag Set Alarm TagCreate PM Notification and Measurement Doc. In SAP

Return Notification & Doc. No.SAP → PI

Manually InputDummy Value(-1)

Manually InputActual Value

SetAlarm Tag

Create MeasurementDoc. In SAP

Return Doc. No.SAP → PI

ResetAlarm Tag

In case of Manual Input Data

DeleteDummy Value


Interface with SAP and Legacy systemsInterface with SAP and Legacy systems

We have developed an application using PI-API, PI RDB I/F and BAPI

GenerationMonitoring System

SAP R/3

PI System(API App.)

Power TradingSystem

①

②

②

②①

Power SalesPrices

Power GeneratedPower PurchasedIn-Site ConsumptionOperating Time

Sharing data with

other companies

CO, PP, FI, SEMAuto./Manual

Input


Web Screen Shot – Main pageWeb Screen Shot – Main page


Web Screen Shot – Unit summary pageWeb Screen Shot – Unit summary page


Web Screen Shot – Primary systemWeb Screen Shot – Primary system


Web Screen Shot – Secondary systemWeb Screen Shot – Secondary system


Web Screen Shot – TBN-GENWeb Screen Shot – TBN-GEN


Trouble Shooting on ProcessBook (1/2)Trouble Shooting on ProcessBook (1/2)

Problem: DataSet expressions are truncated after the pdi file, which include datasets, is copied to another PC.

(PB version 2.31)

Solution: After upgrading the UDS server from version 3.3.361.93 to version 3.3.362.47, the problem was disappeared.


Trouble Shooting on ProcessBook (2/2)Trouble Shooting on ProcessBook (2/2)

Original Expression

Truncated Expression after being copied


Trouble Shooting on DataLinkTrouble Shooting on DataLink

Problem: PI time strings (‘Y’,’T’, ‘*’, etc.) are not work in Excel properly(DL version 2.1)

Solution Use Excel functions such as ‘today()’, ‘Now()’, etc., instead

of PI time string

OR

Use the Application.CalculateFull method in VBA script OR press ‘Ctrl+Alt+F9’ key combination in the Excel sheet.


Trouble Shooting on Manual-Logger(1/3)Trouble Shooting on Manual-Logger(1/3)

Problem: Font Broken in Manual-Logger screen (version 1.3)

Solution:not yet

Because of this problem, we had to develop API applications instead of Manual-Logger to provide manual input function .






ConclusionsConclusions

PI is an important data path among KHNP ERP system, plant computer, and other legacy systems.

Concept of information system was changed after introducing PI system

Scope : Individual plant → Whole company Objectives : Business function based → Business process based Implementation : S/W development → Package configuration

PI began to change many people who ware opposite to PI, with impressive capabilities.

Although there is some problem and additional necessary functions, we don’t doubt PI system is very flexible, easy to use, and powerful.

PI agencies and customers must have correct understanding of all features of each PI package as well as OSIsoft, prior to PI introduction.

The end.

Documents

Sangyoung Mo, et al. 1 PI Introduction on ERP Project in KHNP Sangyoung Mo 1 and Taegheon Kwag 2, KOREA HYDRO & NUCLEAR POWER CO., LTD. PI Introduction