PI Introduction on ERP Project in KHNP

Sangyoung Mo, et al.1

PI Introduction on ERP Project

in KHNP

May 13, 2003

Sangyoung Mo1 and Taegheon Kwag2

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

Headquarters,

KOREA HYDRO & NUCLEAR POWER CO., LTD.


Outline

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)

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)

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)

PWR

PWR

PHWR

Ulchin

⚫ # 1, 2, 3 & 4

◼ # 5 & 6

Wolsong

⚫ # 1, 2, 3 & 4

Kori

⚫ # 1, 2, 3 & 4

PWRYonggwang

⚫ # 1, 2, 3, 4, 5 & 6

⚫ In Operation : 18 (15,716MW)

◼ Under Construction : 2 (2,000MW)


Background 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 & ERP

Management

Transparency/Implement

ation of profit oriented

business system

Gain Comparative Advantage in Power Generation

Project

Background

Innovation

Program

Project

Objective

Changes in Utility Industry Business Environment

→ Graduate Dispersion of Demand & Open Competition

Introduce Advanced

Business Mgt.

Technique

Integrate/Implement

developed information

system


Brief 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 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 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 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

Buffer

Nodes

Nuclear Div.- Kori

- Wolsong

- Yonggwang

- Ulchin

PI-API

PM

Head Office

DREAMS

(SAP)PI R-Link

Han RiverBuffer

Nodes

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

Buffer

Node

Client Tools- PI DataLink

- PI ProcessBook


Interface 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 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 Input

Dummy Value(-1)

Manually Input

Actual Value

Set

Alarm Tag

Create Measurement

Doc. In SAP

Return Doc. No.

SAP → PI

Reset

Alarm Tag

In case of Manual Input Data

Delete

Dummy Value


Interface with SAP and Legacy systems

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

Generation

Monitoring System

SAP R/3

PI System

(API App.)

Power Trading

System

①

②

②

②①

▪Power Sales

▪Prices

▪Power Generated

▪Power Purchased

▪In-Site Consumption

▪Operating Time

Sharing data with

other companies

CO, PP, FI, SEMAuto./Manual

Input


Web Screen Shot – Main page


Web Screen Shot – Unit summary page


Web Screen Shot – Primary system


Web Screen Shot – Secondary system


Web Screen Shot – TBN-GEN


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)

Original Expression

Truncated Expression

after being copied


Trouble Shooting on DataLink

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

(DL version 2.1)

SolutionUse 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)

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 .






Conclusions

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.

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PI Introduction on ERP Project in KHNP

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