Alstom Environmental Control Systems Presenter - Scott Warnke
POWER SYSTEMS
Scott Warnke Alstom Environmental Control Systems: Global Applications Manager − Program Director aligning 10 offices for global execution. 15 years industry experience − Previous: • Intel technology development manager • Intel project controls group
New Mexico State University, BBA Arizona State University, MBA
ECS – Partnering Industry Leaders Worldwide Air Pollution Control systems for − − − −
Power Generation Business Industry Sectors Incineration Plants C02 Removal
Built to customer requirements
Fossil Fueled Power Plant NOx Control
-SCR Systems -SCONOx
Burner NOx Retrofits - RSFC™ Burner Systems - P2™ - LNCFS - TFS 2000TM - Fuel Switching
Research and Development - Air Modeling Capabilities - CFD Modeling
Boiler Steam Turbine and Generator Isolated Phase Bus Substation Systems
Pulverizer Ash Handling
Air Preheater
Particulate Control – Fabric Filter – Electrostatic Precipitator
Electrical & Control Systems - ALSPA P320 - Optiplant + – Power Distribution Systems
Flue Gas Desulfurization – Wet FGD – Dry FGD – FDA
Construction
Global Execution
P3DM - Alstom To make integrated engineering lifecycle information available globally across ALSTOM Power’s value chain – Efficiently, Economically, Easily P1
Project Engineering
Design, implement, deploy and maintain project management solutions
P2
Plant Engineering
Design, implement, deploy and maintain plant engineering solutions (e.g., PDMS,Comos,) in ALSTOM Power
P3 Product Engineering
Design, implement, deploy and maintain product engineering solutions
Production Systems Operations Provide stable, reliable end-to-end service, training and support for all P3DM solutions
Changing the ECS Business Model Value Category Information Framework
Value Added Solutions
Growth Operational Compliance Nuisance Type Category
(Data Centric Integration) Processes
Remove Duplication, complexity Standardize processes and tools
Policies
Tools Conver gence
Main Entities
Business as it is: Complex, regionalized and segmented
Knoxville
Milan
Vaxjo Oslo Kolkata Kobe Beijing
Sao Paulo
Bucharest
Moscow
ECS Landscape Oslo
Multiple Suppliers/
V창xjo
Beijing
Knoxville
Sao Paulo
Milan
Kolkata
Multiple Databases
ECS Multi-Site Operations
Plant Integration
ECS Product Portfolio
EP3DM Program Overview • Program Objective:
RE-INVENT THE GLOBAL DESIGN ENGINEERING PROCESS • Program Scope: • Global Process Definitions • Tool application • Integration with Sector plant integration initiatives (P3DM / Plant) • Tool methodologies and templates (configuration) • Multisite project governance and processes • Cats & Specs − Global Administration of all applications • Hardware / Database Architecture • Connectivity / bandwidth • User support • Training • Ongoing development, support and maintenance − Database Integration − Group 1 Offices: Knoxville, Milano, Oslo, Vaxjo, Kolkata − Group 2 Offices: Moscow, Beijing, Kobe, Sao Paulo.
EP3DM:
The Game Plan
Three Phases – Overlapping Activities Balance the needs of the business
Phase 1 Phase 2
Design 3D 2D Document, Data mgt. Std. Licensing Admin and Support Current Scope
Phase 3
Enhanced Data Base SAP integration Structural Analysis FEED
Engineering Database with Full change management And Supplier interfaces
Functional delivery – support global design ECS Units Cross sites Work Sharing capabilities enabled by a multi site architecture WEB Portal Server + Web Vault
SITE 1
Desk Top Client
Desktop Clients LAN
SITE 2
LAN
External WEB User
SITE 3 LAN
Third party WEB access WEB User
You are here
Current issues
Multiple software platforms internally and multiple systems required by customers and suppliers in collaboration. Joint venture development on C02 removal technology. No system or standard alignment.
Must support sharing between the engineering Offices and Subcontractors on multiple platforms. ECS will never refuse contracts for CAD reasons No standard WBS, data standards or master documents are defined. ECS approach starts at tender stage to identify the potential discrepancy between internal standards and customer expectation
Interoperability Many systems, many deliverables
Activities
Sotware Name
Software editors
P3DM Standard
According to P3DM standard
Process schematic SMF/ SMD AXSYS2D P&ID
SP PID
P&ID
2D Pipe
EDF
Not applicable 2D Pipe / SP Intergraph PID 2D Pipe / SP Asuni CAD PID
Not applicable Yes Yes
Pipe specification Piping classes
Paragon and Specon
Aveva
SECAD
No
Piping classes
PDS
Intergraph
SECAD
No
ROHR2
SIGMA
ROHR2
Yes
Eqp, piping, piping supports, light steel structure Modeling
PDMS
Aveva
PDMS
Yes
Drawings extractions
Plan-C
EDF
PDMS
No
Pipe calculation Piping stress calculation Installation – 3D
Engineering Example
Turbine Equipment
Alstom Alst om
Alternateur Purchase Purc
Heat Exchanger
Schematic
Handovers
Basic Design
Equipment Schematic
Installation engineering
Equipment Schematic
Designed
Pumps
PI&D process engineering
Mechanical engineering
Equipment
Schematic
Instrumentation engineering
Purchase
Electrical engineering
Cable trays
rd Party 3TNU
3D Model
PTP
Project Reviews
Detailed Design
Issues Faced by ECS Legacy: Every office has the best standard. The pressure from customers to use their data/naming coding, has been high.
Alstom has had to adapt its own systems and procedures to this requirement. The KKS System is mainly a material / maintenance oriented System and does not lend itself to project delivery. Require a more open standard. The ECS System is mainly a functional process oriented System. Deliverables include model transfers on various formats but still must protect Alstom ECS IP
The Future • Dedicated tool for the EPCs organisations (Changes management & Workflow features). − Many tools require data exchange and notification − Standardise on ISO 15936 internally • CAD neutral solution (ISO 15 926) to support customers and suppliers. • Flexible regarding the codification of the projects ECS, KKS and leverage Fiatech standards. • Stable, reliable and well-known IT solutions. Ride the technology curve and move away from custom developed systems. − Moore’s Law − Grove’s Law − Vendor sponsored development
Future standards Standard ISO 15926 The ISO 15926 is titled: "Industrial automation systems and integration—Integration of life-cycle data for process plants including oil and gas production facilities“ This standard developed a generic data model and Reference Data Library for process plants Data Exchanges should be based on the standard ISO 15926 dedicated for data integration, sharing, exchange, and hand-over between computer systems
Future Based on Data and standards Stress calculation
Cost calculation
SECAD Archive
Simulation ALSTOM Standard
3D Design PDMS
P&ID
New EDB
ALSTOM Standard
ALSTOM Standard
Electrical
Electrical
I&C
Workflow, Data and Document Management Access Control, Revision Management, Baselining Change Management, Configuration Management Input-Output Management (Reporting & Interfaces) Catalogue & Specification Management / MTO
Engineering Database (EDB)
Primavera
Powermax
Project Tool Suite
APC-RPDM
Project Mgmt
Product Mgmt
External Suppliers / Partners
Customer tools / standards
Improvements A standard compass to sail to Support of the entire life cycle.
Improved plant information management CAD neutral position maintained with customers and suppliers Reduction of geography specific issues and software
EP3DM : SPF-DMS1 (Smart Plant Foundation) Overview
POWER SYSTEMS