Reduce Maintenance Cost - OSIsoft

© 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

Reduce Maintenance Cost - OSIsoft

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