Reduce Maintenance Cost - Sigmafine€¦ · Pimsoft WCF Service –SAP/PM Asset synchronization Pimsoft SAP/XI Asset Synch. WCFService IT Supporting Business Process SAP-PM PI System

© 2008 OSIsoft, Inc. | Company Confidential

Reduce Maintenance Cost connecting AF, RLink and Sap

PM in Erg

G. Conigliaro - ErgG. DiBartolo - Visiant

3© 2008 OSIsoft, Inc. | Company Confidential

Agenda

Erg Group

Erg Power & Gas Assets

Maintenance

The Project

IT Erg Architecture

IT supporting business process

Results

Next Steps


Erg Group

Italy’s main independent energy and petroleum group

Works in

– Crude refining

– Petroleum product distribution

– Electric energy production


Erg 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 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


Maintenance

The Standard Process

MAINTENANCE

STRATEGIES

DEFINITION

ANNUAL

PLANNINGSCHEDULING

ACTIVITY

EXECUTING

AND

CHECKING

COMPUTING

DATA

AND

FEED-BACK

CONSISTENT UNIT MANAGEMENT

PLANNED

SHUTDOWN

PLANNED

ACTIVITIES

MANAGEMENT

UNPLANNED

ACTIVITIES

MANAGEMENT


Maintenance

Improvement

MAINTENANCE

STRATEGIES

DEFINITION

ANNUAL

PLANNINGSCHEDULING

ACTIVITY

EXECUTING

AND

CHECKING

COMPUTING

DATA

AND

FEED-BACK

CONSISTENT UNIT MANAGEMENT

PLANNED

SHUTDOWN

PLANNED

ACTIVITIES

MANAGEMENT

UNPLANNED

ACTIVITIES

MANAGEMENT


Maintenance

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


Maintenance

PLANNED

SHUTDOWN

PLANNED

ACTIVITIES

MANAGEMENT

UNPLANNED

ACTIVITIES

MANAGEMENT

More Expensive

… ?

Process Optimization


Maintenance

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


Maintenance

Do we need this big event


Maintenance

PLANNED

SHUTDOWN

PLANNED

ACTIVITIES

MANAGEMENT

UNPLANNED

ACTIVITIES

MANAGEMENT

This is What We Want


Maintenance - 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 - 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 - 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 - Timings

5 Months Feasibility Study + Analysis

– As Is

– To Be

8 Months Prototypal Phase

– 1 Unit

6 Months Project Completion


The 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 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 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 Architecture

LOCAL AREA NETWORK

DDCN DDCNMETERINGPDA

SHAREPOINT

DATA CENTER

SAP

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

PI

US

ER

S

RE

PO

SIT

OR

Y

&

PR

ES

EN

TA

TIO

N

RE

AL

- T

IME

EN

TR

YA

SS

ET

. . . . . . . .

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 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 PM

PI-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


PI

System

NETWORK

INFRASTRUCTURE

OLEDB

PROVIDER

PI

System

`

`

Pimsoft SOA AF

Data Reference

PI

SystemPI-AF

System

WCF

Server

SOA Remote System

-Web Service

- SOA Server

`

Microsoft SharePoint

+ OSIsoft RtWebParts and RtBaselineServices

(Presentation Layer)

Data Entry

WebParts

SOA 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 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

Pimsoft SAP/XI

Asset Synch.

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

Pimsoft SAP/XI

Asset Synch.

WCFService

PI-AF

Maintenance

Model

Trigger

for notification


Results

Change maintenance culture

Now Managers have measurable objectives

KPI

New 2009 Budget Structure

Reducing Cost and Time will be measured along the 2009


Next 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


Documents

Reduce Maintenance Cost - Sigmafine€¦ · Pimsoft WCF Service –SAP/PM Asset synchronization Pimsoft SAP/XI Asset Synch. WCFService IT Supporting Business Process SAP-PM PI System