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© 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
4© 2008 OSIsoft, Inc. | Company Confidential
Erg 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 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 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
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
8© 2008 OSIsoft, Inc. | Company Confidential
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
9© 2008 OSIsoft, Inc. | Company Confidential
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
10© 2008 OSIsoft, Inc. | Company Confidential
Maintenance
PLANNED
SHUTDOWN
PLANNED
ACTIVITIES
MANAGEMENT
UNPLANNED
ACTIVITIES
MANAGEMENT
More Expensive
… ?
Process Optimization
11© 2008 OSIsoft, Inc. | Company Confidential
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
12© 2008 OSIsoft, Inc. | Company Confidential
Maintenance
Do we need this big event
13© 2008 OSIsoft, Inc. | Company Confidential
Maintenance
PLANNED
SHUTDOWN
PLANNED
ACTIVITIES
MANAGEMENT
UNPLANNED
ACTIVITIES
MANAGEMENT
This is What We Want
14© 2008 OSIsoft, Inc. | Company Confidential
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
15© 2008 OSIsoft, Inc. | Company Confidential
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
16© 2008 OSIsoft, Inc. | Company Confidential
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
17© 2008 OSIsoft, Inc. | Company Confidential
The 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 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 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 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 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
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 Process
RLINK – gateway for SAP-PM
PI Cluster
23© 2008 OSIsoft, Inc. | Company Confidential
IT 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 Process
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
25© 2008 OSIsoft, Inc. | Company Confidential
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
26© 2008 OSIsoft, Inc. | Company Confidential
IT 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 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 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
Results
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 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