leveraging pi system for real-time operation monitoring · slow response by engineers due to...

© 2013 PETROLIAM NASIONAL BERHAD (PETRONAS)

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Leveraging PI System for Real-Time Operation

Monitoring

Presented by:

Musreen Azwan Mustafa

Nurhazlin Mat Musak

10 June 2014 © PETRONAS 2014 1

Agenda


• About PETRONAS

• Business Challenges

• Solution

• Way Forward and Next Steps

• Conclusion and Summary

About PETRONAS

© PETRONAS 2014 3

Where are we?


Malaysia

Our presence


Source: PETRONAS Annual Report 2012:2 (http://www.petronas.com.my/investor-relations/Pages/annual-report.aspx)

What we do


Source: PETRONAS Annual Report 2012:2 (http://www.petronas.com.my/investor-relations/Pages/annual-report.aspx)

The facts..


E&PGAS &

POWERDOWNSTREAM

USD 87 billion 2012 revenue

USD 147 billion of assets

43,860 employees worldwide

Incorporated on 17th August 1974

MALAYSIA NOC

Production 2,015 kboe per day

32.6 Bboe discovered resources

E&P

PEX PDP PMU

Business Challenges

© PETRONAS 2014 8

Why do we need PI System?


Diverse operational facilitiesInhomogeneous sources of

operational data

Real-time process data locked

within isolated control systems

Technical performance & business

intelligence reliant on offline data

Slow response by engineers due to ‘stagnant’ data at

sites

10 June 2014 © PETRONAS 2014 10

Reliability Engineers Day 1: Receive notification from offshore.Day 2 - 10: Clarify with operation personnel at site. Request for relevant data for affected operating parameter for one week.Day 10 :See trending and do analysis. If see abnormality, arrange for offshore trip during next mobilization day (Tuesday/ Saturday only)

Optimization Engineers Day 1 - 30: Plug data manually from process data database into excel and make trending for one month.Needs to call operation engineers at sire for data not available in ODC. Normally, operation not able to cater request due to busy activities at site. Day 31: Key in aggregated/calculated operating data and parameters in simulation software.

Previous information flow took weeks to obtain data

10 June 2014 © PETRONAS 2014 11

Management

ReviewImplementation

Management

Endorsement

Report

incident by

OT

Perform Analysis

& Investigation

Identify investigation

report

Equipment

investigation

Investigation report &

finding

Further

investigation

Yes

Recommended

actionNo

Request

support from

HQ

Management

Review

Implementation of

recommended

action

Engineers in office take up to three weeks to get

the info and provide support (including travel time)

Generate Report &

ReviewEvent / Incident

Report review

by FE / RE

Report

verify by

OIM

2 – 3 weeks

to obtain

the

relevant

data from

site

Solution: Deployment of

PI System & Architecture

© PETRONAS 2014 12

Current PI System status in PETRONAS E&P

10 June 2014 © PETRONAS 2014 13

PMO13

PMO20

PMO15

PMO21 PMO14

PMO12

PMO11

PMO7

PMO9

PMO8

PMO10

PMO1

PMO2

PMO3

SKO10

SKO8

SKO14 SKO5

SKO3 SKO9

SKO1

SKO2

SKO4

SKO7 SKO6

SKO20

SKO12

SKO19 SKO15

SKO18

SKO17

SKO16

SBO8 SBO7

SBO6

SBO4

SBO5

SBO3

SBO1

SBO 2

SBO9

PMO22

PMO23 PMO19

PMO18 PMO24

PMO6

PMO4 PMO5

PMO16

PMO17

SKO11

SKO13

Completed

Due to complete in 2014

After 2015

Overall PI System Architecture

10 June 2014 © PETRONAS 2014 14

PI WebParts

PI WebParts

Site PI System Architecture

10 June 2014 © PETRONAS 2014 15

PI WebParts

Cyber Security Architecture

10 June 2014 © PETRONAS 2014 16

DMZ Zone (Layer 3.5)

Communication from both layers are not

directly but via PI Server

Port 5450

Only port 5450 is allowed, for PI Server

communication

One Way Communication

Only data from control network to flow to

corporate network and not vice versa

Security

Security is advised, audited and

approved by PETRONAS ICT Group

Security

OSIsoft Products and Services Employed

10 June 2014 © PETRONAS 2014 17

• PI Interface

• PI Interface for OPC DA

• PI Interface for Modbus

Ethernet

• PI to PI Interface

• PI Notifications

• PI Server

• PI System Management Tools

(PI SMT)

• OSIsoft vCampus

• OSIsoft YouTube Learning

Channel

• OSIsoft Users Community

Solution: How PI System addressed

business challenges

© PETRONAS 2014 18

Turning stagnant data into flow of profitable

information

10 June 2014 © PETRONAS 2014 19

1

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0 1

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Control Systems

PLCs

Plant Systems

We want to manage operational data and take control of them…

http://www.google.com.my/imgres?imgurl=http://cdn1.iconfinder.com/data/icons/SOPHISTIQUE/construction/png/256/civil_engineer.png&imgrefurl=http://www.iconfinder.com/icondetails/45086/128/engineer_icon&usg=__NBVLVsVLAl0cs4pVEkCdgpaZrq8=&h=256&w=256&sz=41&hl=en&start=3&zoom=1&um=1&itbs=1&tbnid=RQGlW0-6hWQrhM:&tbnh=111&tbnw=111&prev=/search?q=engineer+icon&um=1&hl=en&sa=N&biw=1259&bih=846&tbm=isch&ei=SRopTpfAKozprQfDw_jUBg

New information flow; data is available anytime,

anywhere

10 June 2014 © PETRONAS 2014 20

Management

ReviewImplementation

Management

Endorsement

Eng. at VO & CHO closely

monitor the equipment

from onshore

Perform Analysis

& InvestigationReal / Near Time Equipment Monitoring

Indentify investigation

report

Equipment

investigation

Investigation report &

finding

Further

investigation

Yes

Recommended

actionNo

Eng. take action when the

equipment trending are not

as per agreed parameter

Management

Review

Implementation of

recommended

action

• Earliest Warning or Failure can be detected before the

equipment failure and the mitigation action can be

planned.

• To avoid unplanned equipment/shutdown at the

offshore platform

Data is

available

in office

in real-

time

Safety Operating Limit and Critical Operating Limit

using PI WebParts

10 June 2014 © PETRONAS 2014 21

The objective of SOL

and COL real-time

monitoring is to

detect, record and

monitor instances when

operating near or

beyond Safe operating

limit range.

Critical Operating Limit Monitoring using Excel

PI DataLink

10 June 2014 © PETRONAS 2014 22

Remote monitoring of process

instrumentation, power

generation and rotating

equipment at offshore

platform from office become

easier.

• Critical Operating Limit

(COL) only available in

P&ID

• No proper monitoring tools

on any COL excursion.

Trending of main equipment

Critical Operating Limit

(COL)

Alert on any COL excursion

for the day using

conditioning feature of

Excel PI DataLink.

Solution Results and BenefitsBusiness Challenge

Troubleshooting made easy and accurate!

10 June 2014 © PETRONAS 2014 23

• Technical reference easily

accessible from PI System

• Reduce troubleshooting/

diagnostic period which will

improve the overall equipment

mean time to restore well

• Minimizing unplanned shutdown

and production loss

Troubleshooting based on

limited technical data as no

proper historian system for

process parameters

Not able to predict potential

problem to the critical

equipment or process

instrumentation as no real-time

monitoring system available

Solution Results and BenefitsBusiness Challenge

PZAHH 101A has been put on

bypass due to several platform

Process Shutdown (PSD)

Historical data for PT 1000

from April 2012 to May 2013

was extracted from PI System

Implemented the PI System as

process data infrastructure

and historian

Connecting critical systems

to the remote PI System

Established PI to PI

connection between remote

PI System and main PI System

in the office

“PI System is a vital tool for every

engineers to properly perform their role

in the dynamic oil & gas world.”C Sathya Murthi, Staff Engineer

(Process)

Reduced 5 unplanned

shutdowns in 2013

PI System deployment status

10 June 2014 © PETRONAS 2014 25

Pre2010

2011 2012 2013 2014 2015

2 35

8

31

46

Number of PI Tags Installed

Pre2010

2011 2012 2013 2014 2015

10000 15000 3500085000

500000

800000

PI System: Number of Assets Deployed

High Level Roadmap

10 June 2014 © PETRONAS 2014 26

Phase 1

FY13

Phase 2

FY14

Phase 3

FY15 onward

• Establishment of

PI System Blueprint

• PI System

Implementation of

several assets following

proposed standard

• Establishment MSSA

• PI System

Implementation for

more assets following

proposed standard and

lesson learnt

• Implementation of

PI Asset Framework,

PI ACE and

PI Coresight

• Study on the design and

propose enhancement

PI System Maturity Chart

10 June 2014 © PETRONAS 2014 27

Asset Implementation

Reporting and Graphics

Reporting, Asset Framework and Web

Mobile and Calculation Automation2015

2014

2013

2012

PI ProcessBookPI ProcessBook

PI WebParts

PI WebParts

PI DataLink

PI DataLink

PI DataLink

PI Asset Framework

PI Asset FrameworkPI ACE

PI Coresight

10 June 2014 © PETRONAS 2014 30

Musreen Azwan Mustafa• [email protected]

• Instrumentation Engineer

• PETRONAS

Nurhazlin Mat Musak• [email protected]

• Instrumentation Engineer

• PETRONAS

mailto:[email protected]

mailto:[email protected]

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