case: virtual mill - aalto virtual mill timo syrjänen 11.10.2006 t-86.5141 enterprise systems...
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CASE: Virtual Mill
Timo Syrjänen
11.10.2006
T-86.5141 Enterprise Systems Architecture
timo.syrjanen@poyry.com3
Content
• Pöyry Group
• Mill Life-cycle
• Document management
• Virtual mill
timo.syrjanen@poyry.com4
Pöyry - Global consulting and engineering
• Client- and technology-oriented globally operating consulting and engineering firm
• Core operations based on three know-how clusters: energy, forest industry, and infrastructure & environment
• Global market leader in forest industry
• Strong international position in energy, and infrastructure & environment
• Office network in 45 countries
timo.syrjanen@poyry.com5
0
100
200
300
400
500
600
1985 1991 1997 2003 2004 2005
Infrastructure &Environment
Energy
Forest Industry
Forest Industry, newinvestments
12% annual growth
EUR million
Pöyry - Net sales 1985-2005
timo.syrjanen@poyry.com6
Approval of InvestmentProposal
Plant take-overBusinessIdea
Implementation ProductionDevelopment Rationalization
Life-cycle engagement
timo.syrjanen@poyry.com7
Commissioning
Disturbance report
Installation ProductionEngineering
Maintenance
Mill Lifecycle – Operating mill
timo.syrjanen@poyry.com8
Info
rmat
ion
valu
e
(com
plet
enes
s, c
orre
ctne
ss, a
cces
sibi
lity)
1000’s
Path of evo
lution
Document management
Information legacy
Generation 1: Camp fire stories
100’s 10’s years ago
Generation 2: Filing cabinet
Generation 3: ‘DocHotel’
Information management evolution
timo.syrjanen@poyry.com9
Consultant
Operations
Engineering
Maintenance
Suppliers
Projects
Document management
timo.syrjanen@poyry.com10
100 %
0 %
Document are “as-built”after project
Time
Doc
umen
t com
plet
enes
s an
d ac
cura
cy Modifications at the mill
The bigger the gap, the higherthe risks for errors, additional costs, slow response -even accidents
And yet, typically…
timo.syrjanen@poyry.com11
Why ?
• No clear strategy on how to manage technical information
• Chaotic co-existence of Generation 1,2 and 3 information management
• Unofficial, personal files are built and kept ‘because it’s handy’
• Updating documents after a modification has too low a priority
• All document based systems (paper or electronic documents) have one GREAT weakness: By definition, the same information appears in several documents. This means that keeping the information up to date is difficult, bordering to impossible
timo.syrjanen@poyry.com12
50 electrical and automation maintenance people answered this question.
22
13
9 9 98
54
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What are the problems in automation maintenance ?
timo.syrjanen@poyry.com13
Info
rmat
ion
valu
e
(com
plet
enes
s, c
orre
ctne
ss, a
cces
sibi
lity)
1000’s
Path of evo
lution
Document management
Information management
Information legacy
Generation 1: Camp fire stories
100’s 10’s 1 years ago
Generation 2: Filing cabinet
Generation 3: ‘DocHotel’
Generation 4: ‘Virtual Mill’
The evolution continues
timo.syrjanen@poyry.com14
E-browser
WebPub
Data base
Information
3D Model
Documents
Virtual mill User interfaceFast and easy access to information, excellent support for projects, operations and maintenance
Links
The Jaakko Pöyry Virtual Mill concept
timo.syrjanen@poyry.com15
E-browser
Data base
Electronic data transfer
3D Model
Documents
Virtual Mill
Change engineering
Electronic documents
3D Scan
Mobile applications
Virtual Mill for existing plants
timo.syrjanen@poyry.com16
E-browser
Data base
Documents to DMS
3D Model
Documents
Virtual Mill
MTO’s to SAP
4 & 5 D animation
Technical data to MMS
Mobile applications
Virtual Mill System integration
timo.syrjanen@poyry.com17
Cos
t of i
nfor
mat
ion
mai
nten
ance
No manual handling, copying, distribution
Information stored only once
Value of information
Information management costs
timo.syrjanen@poyry.com18
100 %
0 %
Document are “as-built”after project
Time
Doc
umen
t com
plet
enes
s an
d ac
cura
cy STRATEGY
PROCEDURES
TOOLS
RESOURCES
2000
Modifications at the mill
Pöyry information management services
Information management improvement
timo.syrjanen@poyry.com19
Now we are building virtual mill
timo.syrjanen@poyry.com20
Integrated Virtual Mill Concept Tools
timo.syrjanen@poyry.com21
COMPA2000
InternDocumentmanagement
MILL DATA MODEL
2D & 3D
Models and drawings
Piping material
ProElina
• process- and mechanical• electrical- and automation
-engineering
Jalina
LoopwiseFunctional descriptions
JPDoc
WebPub
WWW-publishing
MODE – Model Driven Engineering
timo.syrjanen@poyry.com22
Process andMechanicalEngineering
ElectricalEngineering
Electrificationtasks
AutomationEngineering
Instrumentationtasks
Plant Model
It all started from work process
timo.syrjanen@poyry.com23
Plant Portal
Data ModelProElina
ProductionControl
Maintenance
Documentation
ProcessControl
Information repositories at a mill
Business SystemsERP
3-D model
VIRTUAL MILL
timo.syrjanen@poyry.com24
Engineering and Maintenance Data Flow
Transactional Business System ( ERP)
Maintenance System
Engineering Design System Document Management S.
Plant Monitoring Systems, eg. DCS
Asset InfoAsset Info NotificationsNotifications Work HistoryWork History
Overall DesignOverall Design
Diagnostics and HistoryDiagnostics and History
Document LinksDocument Links
Document LinksDocument Links
Common User Interface :Common User Interface :Plant Web PortalPlant Web Portal
timo.syrjanen@poyry.com25
Virtual Mill applications
• ProElina database (Oracle)– process-, mechanical-, electrical- and automation engineering– = mill datamodel, = virtual mill
• Mode AutoCad applications– flow sheets– electrical and automation diagrams
• Jalina– web-based tool for loopwise functional descriptions
• WebPub• dynamic view to mill model• documents generated with changes in database • dynamic views to other information sources
• 3D-modelling application• Remote engineering possibility
timo.syrjanen@poyry.com26
Business paybacks
• Engineering tool
• Effective and fast engineering with integrated tool (process, mechanical, electrical, automation and instrumentation)
• Guaranteed quality of engineering
• Standard templates, solutions and models
• Guarantied quality of content
• Wide user base assures good support and continuous development
• Used in all Pöyry projects and also in local offices
• Used at many pulp and paper mills
timo.syrjanen@poyry.com27
• Mill model management system
• Real mill/virtual mill
• Information on the mill always up to date
• Lifecycle management of mill processes and data: Supports futureengineering
• Integration to other mill systems: less work, less data exchange costs, timed data exchange
• Optimization of work processes
• Enables e-commerce
Business paybacks
timo.syrjanen@poyry.com28
• Online publishing of the mill model information and documents
• The same up-to-date information is available everywhere at the mill
• Easy navigation with links based on functional and physical relations between mill objects (pumps, motors, instr. loops etc.)
• Right information is fast and easily available
• Unpredicted downtime can be shortened
Business paybacks
timo.syrjanen@poyry.com29
Virtual Mill demo
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