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.
Sangyoung Mo, et al.2
OutlineOutline
Introduction Introduction of KHNP ERP Project in KHNP
PI Installation Scope System Layout Data Flow Interface with SAP
Trouble-shootings
Conclusion
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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
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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)
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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
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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
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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.
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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.
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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
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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
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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
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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
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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.
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Trouble Shooting on ProcessBook (2/2)Trouble Shooting on ProcessBook (2/2)
Original Expression
Truncated Expression after being copied
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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.
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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 .
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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.