Extending PI for Process Improvement in Operations and Maintenance at TransAlta

1. Extending PI for Process Improvement in Operations and Maintenance at TransAlta Ideas to Action

2. Agenda • TransAlta Overview • Vision • Scope • Standard Business Model • Maintenance • Operations • Integrated Decision Support • Conclusions • Q&A Ideas to Action

3. TransAlta • Canada’s largest non-regulated electricgeneration and marketing company • Coal Mining (Canada & US) • Operations in Canada, United States, Mexico, and Australia • 10,000 MW generating capacity • Close to $9 billion in coal-fired, gas-fired, hydro and renewable assets in operation, under construction or in development Ideas to Action

4. TransAlta … State of the Business Business Strategy Corporate Services Generation Marketing Finance HR Platforms that support the business Portal Document Management BI – Business Analyzer SAP/ Back office Infrastructure PI data – connecting disparate sources! Ideas to Action

5. Enterprise Control Production Vision Supply Distribution Supply Chain Enterprise Management accounting periods IT Infrastructure and Integration Platform Production Management operating events Control and Automation & Real-time Asset Mgmt minute by minute second by second • “Right-time” information accessible throughout the enterprise. • Enterprise integration from the “sensor to ERP system.” • Customized and formatted visualization of information as required. • Centralized real time control and automation areas. • Virtual plant environments to utilize knowledge and expertise across the enterprise. Ideas to Action

6. High Level Scope • TOP = “TransAlta Optimization Program” • Purpose: • “The Integrated Enterprise” • Vertical and horizontal integration and optimization • Scope: • From sensor to boardroom • All levels; Enterprise, plant, process control • Develop a standard business model • Pilot site to prove concepts • Deploy across the fleet • Seize opportunities to deploy standards as they arise Ideas to Action

7. Typical Plant View Ideas to Action

8. TOP – Standard Business Model Corporate Marketing Engineering Operations & Production Asset Management Infrastructure /Data Mgmt War Room Energy Trading Region/Fleet-Wide Analysis Asset Management Program Enterprise Historian Enterprise /Region Finance CAD/CAE Economic Dispatch HR Legal Project Mgmt Doc Mgmt EAM/CMMS EH&S SCM Inter-Application Communication Asset Reliability Program Outage Mgmt Optimization Performance Monitoring and Diagnostics Plant Historian Plant/Unit Fuel Supply (Gas, Coal Mining) CEMS Simulation Unit/Control System Historian Advanced Process Control Unit Operations Control and Monitoring System (BMS, CCS, TCS,…), BOP ProcessEquipment Equipment Performance Monitoring Asset Condition Monitoring Asset Health Monitoring Process Measurement & Control Elements Asset Health Monitoring Elements Inter- Device Communication (HART, Remote IO…) Device Ideas to Action

9. Maintenance Ideas to Action

10. Maintenance Goals • Consistent routine maintenance practices fleet wide to produce : • Bottom line businesses results • Ease acquisition installations • Comparability internally/externally • Ease introduction of new tools • TOPS, EDM, hand held or other technology • Transferability amongst people (learning) • Sharing of practices • Operational excellence & repeatability Ideas to Action

11. Information Processes KPIs Tools Alerts Maintenance Improvements • role • location • operational Dashboard Ideas to Action

12. Total Maintenance Solution – xVIp Maintenance Best Practices and Processes PDAs PCs Ver 1.0 – Q1 ’03 Portal Alerts Ver 1.x – Q3 ‘03 Web- Suppliers (Info, Alerts) - Maintenance Companies- Monitoring- Contractors Visual Parts Catalogue Search Collaboration Visual Plant Structure Work Clearance RCM Process Integration(Process Maps Activated) Document Stores- Drawings, Technical Docs - Operating Manuals Real-Time Plant Info. ERP(eg., Plant Maintenance, MM, etc.) Automated Work Packages Working Offline Data Warehouse SAP BW Business Packages - iViews(Assets, Financial, Projects , etc) Maintenance Data Plant Maintenance (View all Plants as one) Ideas to Action

13. UnstructuredContent Real Time BW ERP Internet Others... Intranet Workflow Working the Process - Before Business Process Ideas to Action

14. Working the Process - After xVIP UnstructuredContent ERP BW Real Time Others Internet Intranet Workflow Ideas to Action

15. Mobile Ideas to Action

16. Reporting Software mySAP BW Process Optimization ABB KFx DB Riley GE Westinghouse Uttramax Lehigh KnowledgeScape Real-Time Operating Statistics OSI PI Siemens Work and Materials Management and Cost Control mySAP ALM Asset Content Management NRX ACM Diagnostic and Reliability Software Bentley Nevada (Various Homegrown Systems) Document Management SAP DMS FileNet Preventive and Predictive Maintenance (i.e. RCM) Solution Overview Users Applications Ideas to Action

17. xVIp Background • xVIp developed by NRX (SAP partner) • Developed with input from TransAlta • Incorporating Plant Maintenance best practices • xVIp continuing to evolve Ideas to Action

18. OSISoft and SAP NetWeaver Interoperability SAP NetWeaver OSISoft Solutions People Integration Multi-Channel AccessPortal Collaboration Information Integration Knowledge MgmtBusiness IntelligenceMaster Data Mgmt Process Integration Integration Broker,Business Process Mgmt Application Platform J2EEABAP,DB and OS Abstraction Ideas to Action

19. SAP NetWeaver Interoperability IBM WebSphere SAP NetWeaver Microsoft .NET • Portal Development Kit for WebSphere • Integration of Lotus Sametime • Portal Dev. Kit for .NET • Smart Client on .NET • MS Office Integration • MS Exchange Integration People Integration Multi-Channel AccessPortalCollaboration • Integration with IBM Content Manager • Integration of MS Content Management Server • Integration of SQL Server Analysis Services Information Integration Knowledge MgmtBusiness IntelligenceMaster Data Mgmt • Interoperability with WebSphere Business Integration Process Integration • Interoperability with MS Biztalk Server Integration Broker,Business Process Mgmt • Eclipse-based Java IDE • Technical, standards-based connectivity (XML, Web Services) Application Platform • Visual Studio .NET integr. • Technical, standards-based connectivity (XML, Web Services) J2EEABAP,DB and OS Abstraction Ideas to Action

20. Screenshot Examples Ideas to Action

21. xVIp example using SAP Enterprise Portal Condition Monitoring Business Intelligence Click on a KPI CMMS Ideas to Action

22. Ideas to Action

23. xVIP Roles • Maintainer • Planner • Supervisor • Operator • Planner • Engineer • Manager • Plant Manager Ideas to Action

24. Role - Maintainer Here we see a set of shop floor i-views that are suitable for a Maintainer as they support the Work Execution process …. Ideas to Action

25. Click on an alert Ideas to Action

26. …navigates to the relevant part of the equipment hierarchy and displays past / current notifications and orders for this equipment Go to OEM documents to identify parts “Drag” a Notification to “create order” Simplified iViews allow creation of new transactions Ideas to Action

27. The Result Hotpointed diagram links to OEM parts list (data not image) OEM part # linked to SAP item, Hotlinked to photo of item in warehouse Automatically navigated to correct part of equipment tree from work order checking box, adds part to SAP Work Order VPS customer example accessed from within SAP PM Entire tree audited and cleansed down to serial number and photographed Ideas to Action

28. Role - Engineer Here we see a set of OSI PI i-views that are suitable for an Engineer as they support the Equipment Diagnostics and Condition Monitoring process …. Ideas to Action

29. xVIp i-Views Ideas to Action

30. xVIp i-Views Ideas to Action

31. xVIp i-Views Ideas to Action

32. xVIp i-Views Ideas to Action

33. Demonstration – Collaboration in Action Ideas to Action

34. Approach / Status Strategy – Phase 1 • Implemented Proof of Concept at Centralia ACM • Expand xVIP with Portal Team • IT Plan to Support IT Strategy • Integrating with SAP Enterprise Portal, EDM, FORCE – SAP R/3 Enterprise Upgrade, BW, TOP – Real Time Ideas to Action

35. Steps to Enabling Maintenance • Maintenance Strategy • Community Pages for Maintenance • KPI’s – Turning on BW Content • Document Mgmt (getting your data in order) • SAP Simplication (Portal, iViews for ALM) • Realtime Info (bringing in PI) • Bringing it all together (xVIP) • Rollout across Fleet in Sync with Other Projects and Opportunities (eg, New Plants, Upgrades, etc) Key - IT Strategy Linked to Maintenance Strategy Ideas to Action

36. Operations Ideas to Action

37. Specification or Limit Average Average Current Variations Move Average Operation Reduced with Closer to Advanced Control Specification or Limit Optimization leads to Continuous Improvement Minimize operational variances enabling the units to “push” the constraints Ideas to Action

38. Goal: Integrate, Optimize all Areas True Controlled Operating Region Economic Optimum Unit Generation Output Emissions Fuel Costs Operator's Preferred Operating Region Unit heat & ramp rates Operational Values Ideas to Action

39. Existing GT Performance Trends Ideas to Action

40. Optimization in Action ####### Yellow = differential between current operation and model based optimal operation Ideas to Action

41. TOP – Pilot Expected Benefits • Production Increases • Avoid trips caused by process upsets • Soot-blower Optimization = less boiler stress • Steam Temperature Control improvements • Reduced Startup times via HM monitoring • Improved Heat rates due to improved pressure control, derived from Historical Data. • Improved operation of unit due to control system improvements via APC • Above results in less operator intervention of process, allowing operator to focus on more details of optimizing the unit operation. Ideas to Action

42. TOP – Efficiency Benefits • Improved Energy Marketing communication - less missed trades, etc. • High level summary available from any networked PC with drill down capabilities to details (plant/unit/device level) • One source of Plant operational data for corporate decision making • Financial and non Financial information sharing for defined KPI's • Applications sharing Information with acceptable performance. • Implementation must be repeatable at reduced costs and using more TA resources Ideas to Action

43. TOP – Current State • Initiated Pilot – Jan ‘03 • Award contract to vendor – April ’03 • Develop project plan, scope and firm Pilot costs – March ‘03 • Define the Standard Reference Model and KPI’s - IP • Implementation of Vendor tools (Pilot) – April ‘03 • Integration of non-Vendor tools (Pilot) – May ‘03 • Program – 3rd quarter • Confirm DCS, Fit-Gap of existing plants • Develop deployment plan > turnaround schedules Ideas to Action

44. Ideas to Action

45. Plant Operations • Generation schedule execution • Unit capability and availability • Unit performance and optimization decisions • Shift management • Resource allocation (O&M) • Energy Marketing • Balancing marginal costs and market prices • Generation risk and market commitment decisions • Scheduling generation units • Power reserves for handling of forced outages • Maintenance & Repair • Diagnostics of deratings and component failures • Maintenance and repair scheduling decisions • Equipment isolation and occupational safety requirements • Performance Reporting & Bench Marking • Collection and prediction of performance data • Benchmarking of units and operation modes • Environmental monitoring Integrated Decision Support Areas Operations Ideas to Action

46. Ideas to Action

47. Conclusions • PI is the glue between process and Enterprise • Exploit Technologies like xVIP, OSISoft and SAP NetWeaver to leverage your existing investments – bring it all together • TOP is another step in integration and standardization: • “The Integrated Enterprise” • Vertical and horizontal integration and optimization • Thank you! Ideas to Action

48. Q& A Keith_Christianson – Keith_Christianson@TransAlta.com Paul Kurchina – Paul_Kurchina@TransAlta.com Ideas to Action