Integrated Asset Planning,  Scheduling, and Reporting

Randy KauffmanBP Texas City Refinery

Speaker Bio

Randy KaufmanLead Scheduler

10 years at BP Texas City Refinery

Expertise in:

Scheduling

Integrated work management

Maintenance processes

SAP and Primavera scheduling system experience

BP Texas City History

Texas City RefineryBPLocated in Texas City, Texas

Third largest refinery in the USProduces 3% of nation’s gas supply

BP’s largest refinery worldwideProcesses 475kbdCan process over 54 different types of crude oil

Texas City Refinery Site

Texas City Refinery Summary

Crude Distillation Capacity

475,000 bpdReceives approximately 70% of its crude oil via marine terminalSends out approximately 75% of its products via pipelineUnleaded gasoline- from crude tank to product pipeline- produced in approximately 12 hours

Texas City Environment

Texas City Complexity

Refined ProductsLiquefied petroleum gas

(LPG)

Kerosene (paraffin)

Lubricating oils

Heavy fuel oils

Bitumen

Waxes

Maintenance Focus

Routine maintenance was the original area of focus

Schedule update frequency is once, twice, or as needed 

per day

Involves entire regular plant staff

All maintenance occurring on a permitting area is 

scheduled in Primavera

Contractor staff  can add 2000‐4000+  staff during Tar's

Maintenance Facts

Daily, Preliminary weekly, and a locked weekly schedule 

is produced

Routine maintenance resources are leveled once a week 

and scheduled daily.

Typical schedule look ahead is 4 weeks

P6 Project Model contains 400,000+ activities

Integrated scheduling and planning is an ongoing effort 

year ‘round

Integrated Scheduling & Planning

Routine Maintenance and Programs: Plan in SAP – Transport daily to Primavera.

Consists of Routine and Area Groups.

TAR:Plan in SAP – Transport when needed to Primavera.

Projects:Plans and schedules in Primavera, incorporates

mandatory activity codes in construction schedule to be included in site wide integrated schedule.

All 3 groups data is approved by the permitting areas in the refinery on a weekly and daily basis.

Integrated Scheduling & Planning

Integrated Asset Planning: A holistic approach to planning and scheduling that

centralizes all asset-impacting work activities from all sources into a single integrated plan.

Technical OverviewSoftware Systems (SAP)

SAP implementation started October 2003 at Texas City.

Current Texas City SAP version is ECC 6

Prior system was a custom in‐house client/server  system

Implemented SAP PM for asset management

SAP system includes Texas City and various BP Chemical sites

Pipeline Maxavera (SAP PM <‐> Primavera P6 integration)

Primavera P6 for scheduling (release 7 SP 2)

Technical Overview

Software Systems (Maxavera)

Pipeline Maxavera (SAP PM <‐> Primavera P6 integration)

Pipeline Maxavera system includes 2 SAP systems, and 5 

Primavera instances from the same system.

Syntempo for schedule viewing, schedule updating, and 

collective confirmation in SAP

Pipeline Maxavera has data feeds to project reporting 

systems

Technical Overview

Software Systems (Primavera)

Primavera P6 for scheduling (release 7 SP 2)

Primavera data base includes 5 refineries, 3 chemical 

plants and pipelines.

Each group has own instance in Primavera.

Technical Overview

Software Systems (SAP, Maximo)

Different versions of SAP are used at different sites.

Maximo 4.1 and 7.0 are being used at other sites.

Pipeline Maxavera move the data from SAP or Maximo to the 

different instances of Primavera.

Texas City Business GroupsBusiness Groups

Routine Scheduling team

Area Group that works on PPMs, troubleshooting and LDar.

Routine Group that works on  maintenance repairs.

Projects Scheduling team

TAR Scheduling team

Execution team

Operations team

Contractors

Solution Approach

Solution

Maxavera integration solution from Pipeline Software

Integrated planning approach

High performance for data volumes

Preferred a packaged solution approach

Support for key systems ‐ SAP and Primavera

Scenario templates for online maintenance, outages, TAR.

Texas City Scenarios

Texas City example for data fields and round trip process

Scenario #1: SAP PM – Primavera P6

Scenario #2: Primavera P6 – SAP PM

Work Orders updated to Primavera

Scenario ‐

Planner creates and plans and assigns resources in SAP Work Orders, 

Schedulers send them to Primavera for scheduling.

SAP PM PRIMAVERA

Operations Activities- Schedule Data - Durations, Dates- Effort - Planned Work, Remaining Work- Work Center - Resource Assignment- Relations - Relationships- Confirmations - Actual Work / Time

Sub-Operations Resource Assignments - Work Center - Resource- Schedule Data - Durations, Dates

Work Centers Resources- Descriptions - Descriptions- Capacities - Calendar & Availability

P6 Schedule Data updated to SAP

Scenario ‐

Scheduler schedules activities and resources with 

dates in Primavera and sends back to SAP

Sub-Operations Resource Assignments- Duration - Duration- Work Center - Resource- Number of Capacities - Planned Units Per Time

Operations Activities- Early Start - Planned Start Date- Early Finish - Planned Finish Date- Work Center - Resource- Number of Capacities - Planned Units Per Time

SAP PM 

PRIMAVERA

Schedule ReportingData Cube

Primary Feed

Secondary Feed

Schedule Reporting

Dashboard KPI’s

Gantt

Data object linking 

(integration) with EPM/ EAM 

data sources enables 

comprehensive multi‐

dimensional analytics!!

Pert

Tabular

Schedule Reporting

Syntempo Work Collaboration

Composite of other systems!You need information from all of these systems in a combined view in order to make the right decisions.

Syntempo Key Aspects

Supervisor

Craft

Foreman

Syntempo

Enterprise SystemsMaintenance & Operations

Work Execution ManagementOutage Visibility and Collaboration

Syntempo Benefits

• Syntempo Enables• Real‐time outage schedule• Real‐time progress collection• Real‐time alerts & communications• Single universally accessible system

• Benefits• Decision making based on real‐time information• Improved communications across teams• Increased visibility of outage execution• Simplified business processes• Reduced personnel training costs

Solution Rollout Process

Delivery Process

Structured methodology to each rollout from Pipeline‐

positive, predictable results

Pipeline onsite solution blueprint workshop

Offsite configuration by Pipeline

Close coordination between Texas City and Pipeline 

teams

Shared testing activities before go‐live

Integrated scheduling, planning, and maintenance can save time, money, and resources for maintenance processes

High performance processing

Automate data transfers

Establish common processes

Reduce (or eliminate) manual data steps

Reduce (or eliminate) double data entry

Integrated Scheduling & Planning

Business process improvements that customers can use to provide accurate forecasting across the organization

Reduce (or eliminate) data quality mistakes and errors

Better align planning team to establish the approved work with scheduling team

Leverage key systems such as SAP as system of record

Reduce miscommunications

Integrated Scheduling & Planning

Best practices for improving resource utilization during routine and STO work types

Comprehensive project view with integrated dataComposite view including work, costs, and detailed schedulesReduce un-needed meetings, calls, emails, etc.Better data enables better decisions

Integrated Scheduling & Planning

Summary

Key Take‐Aways

Integrated scheduling and reporting can be improved and risks reduced with an integrated system approach

SAP PM – Primavera P6 integration can be delivered well, using the right solution, Pipeline Software

Save time and effort by using a packaged system for planning and scheduling integration

Integrated Asset Planning,  Scheduling, and Reporting

Randy KauffmanBP Texas City Refinery

Justin TylerPipeline Software

jtyler@PipelineSoftware.com