reduce maintenance cost connecting af, rlink and sap pm in erg

© 2008 OSIsoft, Inc. | Company Confidential

Reduce Maintenance Cost Reduce Maintenance Cost connecting AF, RLink and Sap connecting AF, RLink and Sap

PM in ErgPM in Erg

Reduce Maintenance Cost Reduce Maintenance Cost connecting AF, RLink and Sap connecting AF, RLink and Sap

PM in ErgPM in Erg

G. Conigliaro - ErgG. Conigliaro - ErgG. DiBartolo - VisiantG. DiBartolo - VisiantG. Conigliaro - ErgG. Conigliaro - Erg

G. DiBartolo - VisiantG. DiBartolo - Visiant

3© 2008 OSIsoft, Inc. | Company Confidential

AgendaAgenda

Erg GroupErg Power & Gas AssetsMaintenanceThe ProjectIT Erg ArchitectureIT supporting business processResultsNext Steps


Erg GroupErg Group

Italy’s main independent energy and petroleum group

Works in – Crude refining– Petroleum product distribution– Electric energy production


Erg GroupErg Group

Coastal Refining and Integrated Downstream :– Accounts for about 19% of total Italian

refining capacity– 320 thousand barrels/day– Second largest refiner in Italy– Sales of petroleum products on the

domestic market cover about 9% of Italian consumption


Erg Power & Gas AssetsErg Power & Gas Assets

Power Generation:– ISAB Energy generates electricity at a 528 MW

capacity power plant fuelled by syngas– ERG NuCe currently has an operating capacity of

about 150 MW, 480 MW after repowering– ERG Renew, generates electricity from renewable

sources, mainly wind farms, has an installed capacity of over 164 MW and another 200 MW of capacity that has already been authorised

– ERG sales of electric power account for about 2% of the domestic market


MaintenanceMaintenance

The Standard Process

MAINTENANCESTRATEGIESDEFINITION

ANNUALPLANNING

SCHEDULING

ACTIVITYEXECUTING

ANDCHECKING

COMPUTINGDATAAND

FEED-BACK

CONSISTENT UNIT MANAGEMENT

PLANNED SHUTDOWN

PLANNEDACTIVITIESMANAGEMENT

UNPLANNEDACTIVITIESMANAGEMENT



Improvement

MAINTENANCESTRATEGIESDEFINITION

ANNUALPLANNING

SCHEDULING

ACTIVITYEXECUTING

ANDCHECKING

COMPUTINGDATAAND

FEED-BACK

CONSISTENT UNIT MANAGEMENT

PLANNED SHUTDOWN





Maintenance Strategies definition– Transform those strategies in a shared asset database– Every Equipment has its own criticalities

• Experience• Operation / Performance• Hse

– Create parameters that give the right priority between items

Computing Data and Feedback– Close the Loop– Improve the strategies– We have data– Use data instead of experience



PLANNED SHUTDOWN



More Expensive

… ?

Process Optimization



Shut-Down …. Few Numbers

– 2 Years– 16 Million Euros– 30 Days– 1400 Employees– 300000 working hours– 10000 Work Permits– 4000 Highly-skilled Jobs– 600 Thousand Euros– Logistic



Do we need this big event



PLANNED SHUTDOWN



This is What We Want


Maintenance - Business GoalsMaintenance - Business Goals

Reduce maintenance cost– Give the right Priority in Cost Reduction.

What Remove ? Increase life of equipment Avoid Equipment failure

– Early failure detection Reduce downtime Give measurable objectives

to the managers Keep the higher levels

of unit performance


The Project - ObjectivesThe Project - Objectives

As Is / To Be: Process design and consolidation Objective

– Maintenance Optimization through strategic KPI definition and analysis

– Pass from corrective maintenance to a calendar-based and condition-based maintenance

– Shut down optimization reducing preparation time• Standard cycle definition in SAP

– Budget Structure Review• Coherent with maintenance strategies and KPI• Correct Cost Plan and Check

– Synchronize company asset databases


The Project - KPIThe Project - KPI

General Index– Total Maintenance Cost / Asset Value– Total Maintenance Cost / Production Volume

Efficacy Index– Unit Availability– Mean Time Between Failure– Mean Time to Repair

Efficiency Index– Medium Stock Value / Asset Value– Unit Maintenance Cost


The Project - TimingsThe Project - Timings

5 Months Feasibility Study + Analysis– As Is– To Be

8 Months Prototypal Phase– 1 Unit

6 Months Project Completion


The Project: The Prototypal phaseThe Project: The Prototypal phase

Integration with SAP/PM achieved with standard RLINK gateway installation management system

Test on three SAP environment Development, Test and Production

Manual Configuration 1 Unit / 100 Measurement Point

Critical equipment Engines and Pumps, Counters

Data integration From DCS to SAP


The Project: A new ApproachThe Project: A new Approach

Maintenance Model Creation in AF SAP/PM acts EAMS holding equipment hierarchy

– Plants– Units– Equipment– Functional locations

SAP Hierarchy charged in Production Repository AF

On Line Analysis on the model


IT Erg ArchitectureIT Erg Architecture

PI System in ERG Power & Gas from 2000– 2 years ago ERG Power & Gas decided to implement

OSIsoft Enterprise Infrastructure– Support business with all OSIsoft product suite

RLINK Sigmafine RtWebParts and Microsoft SharePoint AF

– Scalability, security,reliability– Blade technology


IT Erg ArchitectureIT Erg Architecture

LOCAL AREA NETWORK

DDCN DDCNMETERINGPDA

SHAREPOINT

DATA CENTER

SAP

PI-OPC PI-OPC PI-OPC PI-OPC

PI

US

ER

SR

EP

OS

ITO

RY

&

PR

ES

EN

TA

TIO

NR

EA

L -

TIM

EE

NT

RY

AS

SE

T

. . . . . . . .

SQLORACLERLINK AF

PI-INTERFACE

NU.CE ISAB ENERGY


SAP-PM

PI-RLINK PM

RLINK for SAP-PM standard installation - Send measurement values to SAP - Measurement document creation- Equipment definition from SAP

(automatic configuration) PI Server Cluster installation

PI System

IT Supporting Business ProcessIT Supporting Business Process

RLINK – gateway for SAP-PM

PI Cluster



PI-AF Plant Maintenance Model

SAP-PM

PI System

PI-AF

Maintenance Model

PI-AF Model- Plant Maintenance Model- Subset of SAP-PM configuration- Hierarchical model

AF DataReference Formula and/or PI Point to associate measured valued to the SAP Counter

AF Attribute for the equipment to manage InService and OutOfService


Pimsoft WCF Service – SAP/PM Asset synchronization

Pimsoft SAP/XI Asset Synch.

WCFService


SAP-PM

PI System

PI-RLINK PMPI-AF

Maintenance Model

Trigger

for notification

Pimsoft WCF Service (SOA Service)- PM Asset synchronization with

SAP /XI protocol- Manage hierarchical PI-AF Model- Update PI-RLINK Table - Load PI-AF PM Model (Massive /

On Demand) Tag Trigger management for

Notification


PISystem

NETWORKINFRASTRUCTURE

NETWORKINFRASTRUCTURE

OLEDBPROVIDER

PISystem

`

`

Pimsoft SOA AF Data Reference

Pimsoft SOA AF Data Reference

PISystem

PI-AFSystem

WCF Server

SOA Remote System-Web Service- SOA Server

`

Microsoft SharePoint+ OSIsoft RtWebParts and RtBaselineServices

(Presentation Layer)

Microsoft SharePoint+ OSIsoft RtWebParts and RtBaselineServices

(Presentation Layer)

Data EntryWebParts

Data EntryWebParts

SOA webConfiguratorSOA web

Configurator

WCF Client Configurator

`

Features:

-Recasting to dataset

-Regular Expression

Dynamic Input Definition

SOA Data Sources

SOA Server A

SOA Server B

Pimsoft SOA Configurator

AF Database Synchronizer

Definition

Data Transformation Utility (Code)

Pimsoft SOA Configurator

Pimsoft SOA ConceptsPimsoft SOA Concepts



User Front End – Web page

SAP-PM

PI System

Pimsoft

RtWebParts

AF

WEB Service

PI-AF

Maintenance Model

Web Data presentation:- Microsoft SharePoint (Portal)- OSIsoft RtWebParts- Pimsoft AFtoWeb : web service to show PI-AF data in the portal Web page integrated in the Enterprise Portal



Update Asset PI-Notification

SAP-PM

PI System

PI

NOTIFICATION


WCFService

Trigger

for notification

Pimsoft Asset Synch. Manage a trigger tag to notify SAP-PM configuration update

PI-Notification send mail message to the end user Manual operation Standard PI-Notification

feature

Mail Message



Architecture schema

SAP-PM

RtPM PI System

PI-RLINK PMPimsoft

RtWebParts

AF

Web Service

PI

NOTIFICATION


WCFService

PI-AF

Maintenance Model

Trigger

for notification


ResultsResults

Change maintenance culture Now Managers have measurable objectives

KPI New 2009 Budget Structure Reducing Cost and Time will be measured

along the 2009


Next StepsNext Steps

Increase monitored equipment– Heat exchanger

Translate maintenance engineer’s experience in AF plug-in leveraging the PI-AF PM model automatically created

Develop Maintenance Simulation– What if Analysis– Scenarios

reduce maintenance cost connecting af, rlink and sap pm in erg

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