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Reduce Maintenance Cost connecting AF, RLink and Sap PM in Erg. G. Conigliaro - Erg G. DiBartolo - Visiant. Agenda. Erg Group Erg Power & Gas Assets Maintenance The Project IT Erg Architecture IT supporting business process Results Next Steps. Erg Group. - PowerPoint PPT Presentation
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© 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
4© 2008 OSIsoft, Inc. | Company Confidential
Erg GroupErg Group
Italy’s main independent energy and petroleum group
Works in – Crude refining– Petroleum product distribution– Electric energy production
5© 2008 OSIsoft, Inc. | Company Confidential
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
6© 2008 OSIsoft, Inc. | Company Confidential
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
7© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
The Standard Process
MAINTENANCESTRATEGIESDEFINITION
ANNUALPLANNING
SCHEDULING
ACTIVITYEXECUTING
ANDCHECKING
COMPUTINGDATAAND
FEED-BACK
CONSISTENT UNIT MANAGEMENT
PLANNED SHUTDOWN
PLANNEDACTIVITIESMANAGEMENT
UNPLANNEDACTIVITIESMANAGEMENT
8© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
Improvement
MAINTENANCESTRATEGIESDEFINITION
ANNUALPLANNING
SCHEDULING
ACTIVITYEXECUTING
ANDCHECKING
COMPUTINGDATAAND
FEED-BACK
CONSISTENT UNIT MANAGEMENT
PLANNED SHUTDOWN
PLANNEDACTIVITIESMANAGEMENT
UNPLANNEDACTIVITIESMANAGEMENT
9© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
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
10© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
PLANNED SHUTDOWN
PLANNEDACTIVITIESMANAGEMENT
UNPLANNEDACTIVITIESMANAGEMENT
More Expensive
… ?
Process Optimization
11© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
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
12© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
Do we need this big event
13© 2008 OSIsoft, Inc. | Company Confidential
MaintenanceMaintenance
PLANNED SHUTDOWN
PLANNEDACTIVITIESMANAGEMENT
UNPLANNEDACTIVITIESMANAGEMENT
This is What We Want
14© 2008 OSIsoft, Inc. | Company Confidential
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
15© 2008 OSIsoft, Inc. | Company Confidential
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
16© 2008 OSIsoft, Inc. | Company Confidential
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
17© 2008 OSIsoft, Inc. | Company Confidential
The Project - TimingsThe Project - Timings
5 Months Feasibility Study + Analysis– As Is– To Be
8 Months Prototypal Phase– 1 Unit
6 Months Project Completion
18© 2008 OSIsoft, Inc. | Company Confidential
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
19© 2008 OSIsoft, Inc. | Company Confidential
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
20© 2008 OSIsoft, Inc. | Company Confidential
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
21© 2008 OSIsoft, Inc. | Company Confidential
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
22© 2008 OSIsoft, Inc. | Company Confidential
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
23© 2008 OSIsoft, Inc. | Company Confidential
IT Supporting Business ProcessIT Supporting Business Process
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
24© 2008 OSIsoft, Inc. | Company Confidential
Pimsoft WCF Service – SAP/PM Asset synchronization
Pimsoft SAP/XI Asset Synch.
WCFService
IT Supporting Business ProcessIT Supporting Business Process
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
25© 2008 OSIsoft, Inc. | Company Confidential
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
26© 2008 OSIsoft, Inc. | Company Confidential
IT Supporting Business ProcessIT Supporting Business Process
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
27© 2008 OSIsoft, Inc. | Company Confidential
IT Supporting Business ProcessIT Supporting Business Process
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
28© 2008 OSIsoft, Inc. | Company Confidential
IT Supporting Business ProcessIT Supporting Business Process
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
29© 2008 OSIsoft, Inc. | Company Confidential
ResultsResults
Change maintenance culture Now Managers have measurable objectives
KPI New 2009 Budget Structure Reducing Cost and Time will be measured
along the 2009
30© 2008 OSIsoft, Inc. | Company Confidential
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
31© 2008 OSIsoft, Inc. | Company Confidential