Overview of the PI System Enabled Integrated Refinery Information System (IRIS) at YASREF

Transcription

1 Overview of the PI System Enabled Integrated Refinery Information System (IRIS) at YASREF Presenters: Mr. Mahmoud M. Madani IRIS Lead Project Engineer, YASREF Mr. Alex Brodskiy - Manager, Solution Architect, Accenture

2 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management EMS Visualization Business Intelligence Best Practices Concluding Remarks 2

3 YASREF- Most Advanced Refinery in The World Yanbu Aramco Sinopec Refining Company - Ltd JV Signed in late % Aramco, 37.5% Sinopec By 2020 YASREF will be among the most recognized pacesetter enterprises in the world 400K BPD full conversion facility Located in Yanbu Industrial City on the Red Sea Commissioning completed in September 2014 PI System Selected as strategic element of IRIS Enterprise Agreement (EA) signed in October,

4 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management EMS Visualization Business Intelligence Best Practices Concluding Remarks 4

5 Objective of IRIS Enable Data Based Decision Making Provide Quality Data One version of the truth Implement 23 Engineering and Industrial Applications Provide interface between PAS and ERP (SAP) Enable collaboration with near real-time data in context Support self serve Business Intelligence Support Refinery startup plan 5

6 Foundation for YASREF Operational Excellence by: Align production goals with business objectives Improve Process Units availability and Utilization Facilitate a responsive decision making process for OME* Ensure data availability and minimum discrepancy Providing OME users with robust analytical tools for data aggregation and process calculations Avail business / process to all company layer *OME Operations, Maintenance and Engineering 6

7 Project Time Lines 7

8 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management EMS Visualization Business Intelligence Best Practices Concluding Remarks

9 IRIS Architecture Principles Basic guiding architecture principles were agreed upon in the beginning of the project: Business process driven approach Maximum functionality coverage Proven technology and standard packages (easy to upgrade and maintain, reduce customization) Flexible architecture to manage future needs and changes in the business Single version of the truth across the value chain and make relevant information available in time for effective decision making. Role based KPIs aligned with organizational strategy and drill up/drill down based on roles Data federation approach and avoid unnecessary data replication Capitalize on Microsoft and OSIsoft technologies and maximize use of Enterprise Agreements 9

10 IRIS Integration Platform 10

11 IRIS Overview Applications Architecture Common Applications Engineering Applications Operations Applications Enabled by OSIsoft PI System Components 11

12 Integration of a Portfolio of Applications APPLICATION VENDOR PRODUCT Data Acquisition & Historization (DAHS) OSIsoft PI Data Archive Emissions Monitoring OSIsoft PI Asset Framework PI Asset Based Analytics PI Notifications Laboratory Information Management Labware LIMS Crude Assay Management Haverly H-CAMS LP Planning Tool Aspentech PIMS Production Scheduling Aspentech ORION Operations Management Portal, including Operating Instructions, Blending, Movement and Shipping, Alarms Visualization, Process Displays Honeywell Microsoft OSIsoft OMPRO, MM SharePoint PI ProcessBook PI Coresight PI WebParts Operations Logbook Honeywell OMPRO Reporting, Performance Management & KPIs (Including Calculation Engine) Microsoft OSIsoft Integration Platform Microsoft BizTalk Collaboration platform, including Document Management System, Alerts and Notifications, Workflow Management Microsoft SharePoint Mass Balance & Energy Accounting Belsim Vali SSRS, SSAS, MDS, SSIS PI Asset Framework PI Asset Based Analytics 12

13 PAN DMZ WAN Corporate Network Secure real-time data acquisition from DCS Leverage best practices in securing control systems PI Collective Sync Online High Availability PI Primary Server PI Secondary Server Fully redundant architecture with interface, network, and server level failover Strict rules and traffic control across firewalls High Availability PI Collectives at all levels Unidirectional PINet connection over TCP/IP port 5450 PI-to-PI Interfaces Failover configured in the Interface Push mode Hot standby PI-to-PI Interface Node A PI-to-PI Interface Node B Unidirectional PINet connection over TCP/IP port 5450 Buffering data at all levels to ensure no data loss in case of network or server outages PI Primary Server PI Collective Sync Online High Availability PI Secondary Server High frequency data collection from the source Multiple instances of PI OPC Interface running on each node OPC Interface Node A Failover Interface Hot standby OPC Interface Node B Remote OPC connections over DCOM Exa OPC Server Exa OPC Server DAHS OPC Server 3 rd Party OPC Server 1..N Operation Area 01 Operation Area N Central Control Room Central Control Room 13

14 Integrated Notifications Engine Collects and distributes Notifications from all source applications Self-managed subscription on event types Common definition of events across all applications Escalation workflow OSIsoft PI Server / Notifications as a source of real-time events BizTalk / SQL Server as a middleware to deliver events from other systems Unified view of all Notifications on SharePoint 14

15 Leveraging Microsoft BI on SharePoint Integrated Refinery Portal based on Microsoft SharePoint 2013 is at the heart of the system, delivering key functionality with the following components: Dashboards and KPI- Microsoft Power View Real-time Displays, Trends, and KPV - OSIsoft PI Web Parts and PI Coresight Reports - Microsoft SSRS Multidimensional Data Cube - Microsoft SSAS ETLs - Microsoft SSIS Cross References and Dimension management Microsoft MDS Data Store for some facts Microsoft SQL Server 15

16 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management EMS Visualization Business Intelligence Best Practices Concluding Remarks 16

17 PI System an Integration & Applications Infrastructure PI Server Data Archive: Data Acquisition and Historization System (DAHS) Data quality assurance Asset Framework (AF): Detailed asset based object model for context Asset based calculations and analytics Data Federation (data lookup from other systems) Notifications: Notifications for operational data feed to notifications engine PI ProcessBook, PI Coresight and PI WebParts Visualization Mobility Real-time monitoring, Alerting, and ad-hoc Analysis PI OLEDB Enterprise: Integration method to Business Intelligence and Interfaces 17

18 AF Extensively Used for Asset Analytics 18

19 Asset Framework Data Federation External data required for real-time calculations and visualization in PI Process Book / PI Coresight is brought into Asset Framework as Linked Tables and connected to Element Attributes No data replication Data is refreshed directly from the source and is always in sync. Relational Data Sets can be treated as Time Series data in AF as long as values correspond to timestamps. Use cases in IRIS are Laboratory data (LIMS) Mass & Energy Balance (Vali) 19

20 Asset Analytics for Emission Monitoring 20

21 Multi-step Data Quality Assurance Data Quality is particularly important for regulatory and compliance reporting parameters. Users must be aware of the quality of the data they are basing their decisions on. Cleanse Raw Data Remove Spikes Check range Detect flat line Use alt source for bad data Calculate confidence level based on percent of good data of all input parameters Reject Calculated results with the Confidence level below a threshold (e.g. 80%) 21

22 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management EMS Visualization Business Intelligence Best Practices Concluding Remarks 22

23 Performance Management System 23

24 Performance Management System 24

25 Emission Monitoring System 25

26 Self Serve BI with Ad-hoc Dashboards 26

27 Leveraging PI Coresight 2014 for Visualization 27

28 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management EMS Visualization Business Intelligence Best Practices Concluding Remarks

29 Best Practices 1. Early decision to Use the PI System Strategically 2. Leveraged the EA early to support design, installation, training, testing, and commissioning 3. Focus on secure data acquisition and cleansing 4. Use of AF for asset based calculations and integration framework 5. Leverage of Microsoft BI for self serve analytics and KPIs 29

30 Agenda YASREF at a Glance Objectives of IRIS Architecture Overview The Role of PI System Components Application Examples: Performance Management Business Intelligence EMS Best Practices Concluding Remarks

31 PI System Enabled Integrated Refinery Information System (IRIS) Selecting the PI System and EA early in the grass roots project cycle enabled us to develop, install, and commission IRIS on time, reduce costs, support the refinery start up, and set the foundation for an integrated, data based decision making, collaborative culture that supports YASREFs vision of Operational Excellence. PI Coresight 2014 Mahmoud M. Madani, IRIS Lead Project Engineer Business Challenge Grassroots Refinery JV Complex Business Processes Aggressive schedule 23 applications & requirement of a single integrated system Collaborative, data based decision making in context Solution PI System selected as a strategic element of IRIS early in the project Enterprise Agreement selected as best way to support IRIS goals Asset Framework and PI Coresight 2014 key to IRIS platform Microsoft BI and BizTalk leveraged Results and Benefits Integrated quality data with business process workflow Integrated applications environment Enabled smooth start-up Foundation for vision of a collaborative, data based operational excellence culture 31

32 Mahmoud M. Madani IRIS Lead Project Engineer, YASREF Alex Brodskiy Solution Architect, Accenture 3 2

33 Questions Please wait for the microphone before asking your questions State your name & company 33

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