ESKOM’S CENTRALISED PDS INFORMATION HISTORIAN

1. ESKOM’S CENTRALISED PDS INFORMATION HISTORIAN John Viljoen Corporate Consultant Generation Business Engineering Vicki Naudé Senior Advisor Generation Information Management

2. Background Project Solution Benefits Agenda Considerations Summary

3. 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 MONITORINGINFORMATION • 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 USEABLEINFORMATION is not easily accessable

4. 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. • ITARCHITECTURE landscape is fragmented. • ITSECURITY a continuous challenge. • IT INFRASTRUCTURE outsourced.

5. Background THE CHALLENGE How can Generation manage the escalating complexity of merging its PLANTINFORMATION world with its INFORMATION TECHNOLOGY environment

6. Setting the Scene The Current Eskom Power Generation Fleet

7. Setting the Scene The South African Power Network Coal Fired Hydro Pump Storage Nuclear OCGT

8. Palmiet Power Station Koeberg Power Station Tutuka Power Station Matimba Power Station Typical Plant

9. 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.

10. 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

11. Background Project Solution Benefits Agenda Considerations Summary

12. 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.

13. 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

14. 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

15. 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

16. 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.

17. Topology

18. Interfacing • The mechanism of obtaining data is via OPC. PDS provides a standard interface to the Generation Fleet Historians irrespective of the underlying technology

19. 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.

20. PDS S-95 Galaxy

21. 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.

22. PDS Screenshots

23. PDS Screenshots

24. PDS Screenshots

25. Active Factory Screenshots Typical Light up of a unit MW Load

26. Daytime highs Nightime lows Active Factory Screenshots Typical load profile over 7 days

27. Background Project Solution Considerations Agenda Benefits Summary

28. 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)

29. Background Project Solution Considerations Agenda Benefits Summary

30. 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.

31. 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

32. Primary Energy Plant Environment Performance Production GRID Outage Statistics Finance Keeping the lights burning – the IGCC • Manipulated Data • Lower Granularity • Business Relevant • Strategic Decisions IGCC Wonderware Data enrichment PDS • Detailed Data • High Granularity • Function Relevant • Operational Decisions SAS Prism Oracle SAP Phoenix Oracle Primavera Oracle Wonderware

33. 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

34. Integrated Generation Control Centre

35. Integrated Generation Control Centre

36. Integrated Generation Control Centre

37. IGCC Screen Shots

38. 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.

39. PRiSM Screen Shots

40. Background Project Solution Benefits Agenda Considerations Summary

41. 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!

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

43. Project summary ? Questions ? ? ? ? ? ? ? ?