1. science

From Tactical to Strategic
The Continuous Journey of the PI
System in Support of Corporate
Sustainability
“The Language of PI”
Presented by Tibor Komróczki
Head of Process Information & Automation
© Copyri g h t 2013 OSIso f t , LLC.
Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
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MOL Plc.
© Copyri g h t 2013 OSIso f t , LLC.
3
MOL’s Fuels Value Chain Overview
© Copyri g h t 2013 OSIso f t , LLC.
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Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
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Alignment of Sustainability Frameworks
Human Capital
Economic
sustainability
Social Awareness
Compliance
Enviromental Stewardship
Communities
Safety & Risk Management
Health & Safety
Profitability
MOL GROUP STRATEGY
Environment
Human Capital Optimization
Sustainability in Oil & Gas
Climate Change
Information Management & Governance
© Copyri g h t 2013 OSIso f t , LLC.
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Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
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The PI System Converges: Time & Space
All Data – Any Time – Any Location – In Context
© Copyri g h t 2013 OSIso f t , LLC.
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Enabling a Collaborative Work Environment
With the PI System
© Copyri g h t 2013 OSIso f t , LLC.
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The Value of an Enterprise Real-Time Infrastructure
© Copyri g h t 2013 OSIso f t , LLC.
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Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
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I Keep Getting to Come Back …???
2014+ ??
2011
2012
2013
© Copyri g h t 2013 OSIso f t , LLC.
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Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
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New Down Stream Program (NDSP)
•
To give an effective response to the current unfavorable global economic and Downstream
industry environment, with restoring MOL Plc. top position in efficiency and profitability in
Europe, utilizing all synergies of the integrated Downstream operation.
Focus areas
Value chain
optimization
Market
management
Asset
management
Resource and
process
efficiency
© Copyri g h t 2013 OSIso f t , LLC.
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PI System Centric…Beginning of the Journey
PI
1998
SEMAFOR
(KPI
monitoring)
2008
SIGMAFINE
1998
•
•
•
•
•
PI System based
Native PI System interfaces
PI System reports,dashboards
PI System calculation
Strong integration
Process
Information
NICE
OPRALOG
2011
2007
LIMS
1998
© Copyri g h t 2013 OSIso f t , LLC.
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Limited Exposure to the PI System
•
•
•
DCS
1983
Industrial
Network
APC
2012
1995
Only a small PI System in the Industrial Network
Initiative Integration
PI System provides systems with data
Process
Automation
Alarm
management
CPM
2011
OTS
2006
Energy
monitoring
2012
© Copyri g h t 2013 OSIso f t , LLC.
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1+1=3….Realizing the Synergies of the New
Department .. “The Language of PI”
DCS
1983
PI
1998
SEMAFOR
(KPI
monitoring)
2008
Industrial
Network
2012
SIGMAFINE
1998
&
Process
Information
NICE
2007
OPRALOG
2011
LIMS
1998
APC
1995
Process
Automation
Alarm
management
CPM
2011
OTS
2006
Energy
monitoring
2012
© Copyri g h t 2013 OSIso f t , LLC.
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Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
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NDSP Support Solutions
Weekly
Production
Program
(WPP)
Opralog
APC
Energy
Monitoring
© Copyri g h t 2013 OSIso f t , LLC.
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Support to reduce quality give-away
•
Modifying the lab-PI interface to filter out
off-spec qualities automatically based
on registered specifications
and collecting off-specs automatically
•
„Flask colouring” happened automatically
(good -> green ,
off-spec ->red ,
laboratory limit ->yellow)
© Copyri g h t 2013 OSIso f t , LLC.
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Support to reduce quality give-away
• Lab results and product’s specifications can be
found in the PI database
• All matched data were gathered in Asset
Framework for easier examination:
• lab result
• WPP minimum specification
• WPP maximum specification
• APC calculation (if exists)
• on-line analyzer value (if exists)
WPP
PI Coresight visualizes the measured quality
regarding quality specifications
© Copyri g h t 2013 OSIso f t , LLC.
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Industrial
PI
System
Opralog
© Copyri g h t 2013 OSIso f t , LLC.
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Safety Solutions
Electronic Shift Logbook
Refinery wide central logbook database which
is easily accessible, and reduces the loss of
information. Handles shift handover, contains
condition checks and plant limitations
Training
Regular & ad-hoc trainings for engineers, shift
leaders,operators etc.
Operation
Management
Staff
Competence
Accidents
Hazards
EN 61511 SIL
Implementation of SIL safety
standard, based on the Seveso II
directive.
Technical Risk
Management
Alarm &
Instrument
Management
Interlock logbook
Tracking MOS-POS switches status
© Copyri g h t 2013 OSIso f t , LLC.
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Industrial Network
Increase the safety and security of
Danube Refinery
Process Control Systems
Separate Process Control Network
and MOL Business Network
Implement an
“independent Industrial Network”
Central supervision
– network intrusion and virus attack
detection and prevention
Redundant servers
Industrial PI server
Industrial
Network
© Copyri g h t 2013 OSIso f t , LLC.
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PI
Notification
Opralog
PI AF
© Copyri g h t 2013 OSIso f t , LLC.
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Electronic Shift Logbook
Consequent, event based logging
Information Sharing
Support audits
(PSM, Behavior, IIR, etc.)
Easier incident investigation
Opralog
Highlights problematic fields
© Copyri g h t 2013 OSIso f t , LLC.
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Interlock Logbook Migration into Opralog
Information about the switch (name,
description)
Information about the status (new
state, event time)
Who turned on/off?
Who permitted?
Opralog
What was the reason?
© Copyri g h t 2013 OSIso f t , LLC.
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PI AF Notification
Notification on
control room
temperature
Interlock
events to
Opralog
Analyze
technology
SMS
Webservice
Technogy
card
Fast reaction
System to
system
Statistical
methods
Reporting of
outages
Problem with
escalation
Other
algorythms
PI AF
© Copyri g h t 2013 OSIso f t , LLC.
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PI AF
Energy
monitoring
© Copyri g h t 2013 OSIso f t , LLC.
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Energy Monitoring
On-line, open loop model based control system. Detects excess energy consumption, and advices corrective
interventions to the operators.
PI System
Data-mining, Reports
Evaluations.
Energy
Monitoring
System
Alarms
Interventions
Unit control
level
HMI
Unit level control system (DCS)
Energy
monitoring
furnace
columns
© Copyri g h t 2013 OSIso f t , LLC.
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Aim of the project
1-3% energy saving
from the total energy
consumption
Real-time energy
information
Main goal: generate
good operator
intervention
Focus area: energy
as electrical power,
utilized and produced
steam, fuel oil and
gas
Technological
approach
Manager level (KPI
dashboards)
Target and real value
data comparison for
manual manipulation
of the operator.
Engineer level (PI
data and client
application)
Model based support
system for energy
efficient operation
Result in energy
saving – operational
cost saving
Energy
monitoring
© Copyri g h t 2013 OSIso f t , LLC.
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Easy Overview in PI Webparts
Energy
monitoring
© Copyri g h t 2013 OSIso f t , LLC.
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PI AF – Integration and Data Abstraction
Benchmarking
Cloud
New solutions
Maintenance
of PI
Asset
management
Learning
Email, SMS, Webservice
Easier, Quicker Appl.
Development
Real-time data
PI AF
© Copyri g h t 2013 OSIso f t , LLC.
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PI System
Reports
APC
PI
AF
ARGUS
© Copyri g h t 2013 OSIso f t , LLC.
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Unit
Distillation
Aromatics
Motorfuel
Residue
Tisza Refinery
PI
DataLink
2013-05-01
Thursday
Column
DARED 101
DCDU3 105
DGFRU 112
DGFRU 118
DGFRU 123
DAEDB 1/101
DAEDB 2/108
DAEDB K1
DFCC 840V2
DETBE 450V2
DETBE 450V3
DETBE 450V4
DMHCK K803
DGHT3 K501
DGHT3 K803
DSRU6 T501
DSRU6 T801
DDCKU T106
DDCKU T109
DDCKU T201
TGOK C10
TMTB C104
DETBE 450V2
DMHCK K803
DDCKU T106
N/A
2013-05-02
Friday
2013-05-03
Saturday
N/A
N/A
N/A
N/A
2013-05-04
Sunday
2013-05-05
Monday
2013-05-06
Tuesday
N/A
N/A
Unit start-up, minimum throughput
Amine regeneration troubles
APC upgrade
N/A
N/A
N/A
2013-05-07
Deviation from target [mHUF/week]
Wednesday
-1,11623
0,02135
0,86768
0,00938
0,71449
-0,31899
0,30235
0,15184
-0,75675
0,46290
0,01197
0,33566
1,14934
-0,03649
-0,34319
-0,38648
0,45209
0,58097
-0,56480
0,28825
-0,30423
N/A
N/A
Total -:
-1,67239
Total +:
3,18412
SubTotal:
1,52111
© Copyri g h t 2013 OSIso f t , LLC.
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Column Dashboard
PI
Webparts
First month was totally red!
© Copyri g h t 2013 OSIso f t , LLC.
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© Copyri g h t 2013 OSIso f t , LLC.
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Analysers Validity Report
Unit
Sample Point
Analysis
DARB
101FJKI
Benzene
DARB
101FJKI
Non aromatic
DARB
101FJKI
Toluene
DARB
OXILOLKI
C9
DARB
OXILOLKI
Cumene
2013.02.28
Precise, but not Accurate
Precise, but not
Accurate
Precise, but not Accurate
Valid
Precise, but not
Accurate
Not enough data
Valid
Valid
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Precise, but not Accurate
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Precise, but not Accurate
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Precise, but not Accurate
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Valid
Valid
Valid
Valid
Precise, but not Accurate
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Precise, but not Accurate
Precise, but not
Accurate
Valid
Valid
Valid
Precise, but not
Accurate
Valid
Precise, but not Accurate
Precise, but not Accurate
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Valid
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
Meta-xylene
DARB
OXILOLKI
DARB
OXILOLKI
DARB
DARB
DARB
OXILOLKI
TOLUOLKI
TOLUOLKI
Non aromatic
Ortho-xylene
Benzene
Non aromatic
2013.04.25 2013.05.02 2013.05.13
Precise, but not
Accurate
DARB
TOLUOLKI
Toluene
DARB
XILOLKI
Etil-benzol
DARB
XILOLKI
Meta-xylene
Precise, but not Accurate
Valid
Valid
Valid
DARB
XILOLKI
Non aromatic
Valid
Precise, but not
Accurate
Precise, but not
Accurate
Precise, but not Accurate
DARB
XILOLKI
Ortho-xylene
Valid
Not Valid
Not Valid
Valid
Precise, but not Accurate
Valid
Precise, but not
Accurate
Precise, but not Accurate
DARB
XILOLKI
Para-xylene
DARB
XILOLKI
Toluol
Pt Created
Not enough data
Valid
Precise, but not Accurate
DBK5
COMBPROD
Sulphur content
Out of operation
Out of operation
Out of operation
Valid
DBTK
MOTBEN
Vapour pressure
Valid
Valid
Valid
Valid
Based on PI solutions (ProcessBook
and DataLink) ARGUS
Regular report in every week
Continuous monitoring
Comment:
ARGUS
DBK5: sulphur analyser could have helped to recognise product contamination
© Copyri g h t 2013 OSIso f t , LLC.
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APC OPERATION OVERVIEW
Switched status
Constrained status
Continuous monitoring
PI AF
© Copyri g h t 2013 OSIso f t , LLC.
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Checking Control MODES
Import Data from CPM to PI
Regular report in every week
Continuous monitoring
PI AF
© Copyri g h t 2013 OSIso f t , LLC.
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Checking Control MODES
Detailed Plant view
Includes all important
controller
PI AF
CPM
© Copyri g h t 2013 OSIso f t , LLC.
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OSISoft Portfolio & Refining
Structure
represent
technology
Assets solves
business
problems
Datalink
summaries
Visualisation
of time
summaries
Bottom-up
approach
Real-time
visualisation
Notification
issues
Process
safety
management
© Copyri g h t 2013 OSIso f t , LLC.
42
Outline
•
Information as the Foundation for MOL’s Sustainability Strategy
•
O&G in the 21st Century—the Collapse of Time and Space
•
From Tactical to Strategic – The continuous Evolution of the PI System
•
The “Language of PI”- IT and OT Integration
•
Illustrative Examples of the PI System and Sustainability
•
Q&A
© Copyri g h t 2013 OSIso f t , LLC.
43
Tibor Komróczki
tkomroczki@mol.hu
H-2443
Százhalombatta
P.O.Box:1.
© Copyri g h t 2013 OSIso f t , LLC.
44
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