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Reduce Maintenance Cost connecting AF, RLink and Sap PM in Erg

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.

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Reduce Maintenance Cost connecting AF, RLink and Sap PM in Erg

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  1. Reduce Maintenance Cost connecting AF, RLink and Sap PM in Erg G. Conigliaro - ErgG. DiBartolo - Visiant

  2. Agenda • Erg Group • Erg Power & Gas Assets • Maintenance • The Project • IT Erg Architecture • IT supporting business process • Results • Next Steps

  3. Erg Group Italy’s main independent energy and petroleum group Works in Crude refining Petroleum product distribution Electric energy production

  4. 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

  5. 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

  6. Maintenance The Standard Process

  7. Maintenance Improvement

  8. 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

  9. Maintenance More Expensive Process Optimization … ?

  10. 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

  11. Maintenance Do we need this big event

  12. Maintenance This is What We Want

  13. 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

  14. 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

  15. 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

  16. The Project - Timings 5 Months Feasibility Study + Analysis As Is To Be 8 Months Prototypal Phase 1 Unit 6 Months Project Completion

  17. 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

  18. 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

  19. IT Erg Architecture • PI System in ERG Power & Gas from 2000 • 2 years ago ERG Power & Gasdecided to implement OSIsoft Enterprise Infrastructure • Support business with all OSIsoft product suite • RLINK • Sigmafine • RtWebParts and Microsoft SharePoint • AF • Scalability, security,reliability • Blade technology

  20. IT Erg Architecture

  21. IT Supporting Business Process • RLINK – gateway for SAP-PM SAP-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-RLINK PM PI System PI Cluster

  22. IT Supporting Business Process • PI-AF Plant Maintenance Model SAP-PM • 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 PI-AF Maintenance Model PI System

  23. IT Supporting Business Process • Pimsoft WCF Service – SAP/PM Asset synchronization SAP-PM • 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 Pimsoft SAP/XI Asset Synch. WCFService PI-AF Maintenance Model PI-RLINK PM Trigger for notification PI System

  24. Pimsoft SOA Concepts Pimsoft SOA Configurator • Dynamic Input Definition Pimsoft SOA Configurator • SOA Server B Microsoft SharePoint + OSIsoftRtWebParts and RtBaselineServices (Presentation Layer) SOA web Configurator Data Entry WebParts Data Transformation Utility (Code) • Features: • Recasting to dataset • Regular Expression NETWORK INFRASTRUCTURE OLEDB PROVIDER WCF Server • SOA Data Sources PI System PI System WCF Client Configurator PI System PI-AF System Pimsoft SOA AF Data Reference • SOA Remote System • Web Service • SOA Server • AF Database Synchronizer Definition • SOA Server A

  25. IT Supporting Business Process • User Front End – Web page SAP-PM • 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 PI-AF Maintenance Model Pimsoft RtWebParts AF WEB Service PI System

  26. IT Supporting Business Process • Update Asset  PI-Notification SAP-PM Mail Message • Pimsoft Asset Synch. Manage a trigger tag to notify SAP-PM configuration update Pimsoft SAP/XI Asset Synch. WCFService • PI-Notification send mail message to the end user • Manual operation • Standard PI-Notification feature PI NOTIFICATION Trigger for notification PI System

  27. IT Supporting Business Process • Architecture schema SAP-PM Pimsoft SAP/XI Asset Synch. WCFService PI-AF Maintenance Model Pimsoft RtWebParts AF Web Service PI NOTIFICATION PI-RLINK PM Trigger for notification RtPM PI System

  28. Results • Change maintenance culture • Now Managers have measurable objectives • KPI • New 2009 Budget Structure • Reducing Cost and Time will be measured along the 2009

  29. 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

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