operational windows strategy at pemex - … · window (ow) that for pemex access “wehave...

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Presented by

Operational Windows

Strategy at PEMEX

Improving Operational

Safety & Reliability

Mr. Carlos Alberto Guevara Díez

© Copyr i gh t 2014 O SIs o f t , LLC .

Agenda

• Pemex at a Glance

• The Journey to Operational Windows (OW)

• PEMEX’s Operational Window Portal

• Examples & Video

• Results

• Next Steps

• Conclusion

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About PEMEX

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E&PGas & Pasic

Petrochemicals

Petro

ChemicalsRefiningCorporate

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• Single Operational Window (OW) for

all PEMEX refining

• Web- based, simple, prioritized

information presented in context

• Consistent KPIs to support continuous

improvement of efforts

• Improved yields, production, reliability,

and safety of refineries

Solution Results and Benefits

Implementing a Standardized Operational

Window (OW) at PEMEX Refining

Business Case

• Low performance in refinery

utilization, reliability, and yield

• Inability to share best practices

across refining division

• Inability to view entire PEMEX

refining value chain in real-time

• Expanded current PI System to

provide integration & applications

infrastructure elements

• Used PI AF and PI WebParts as

foundational components

• Developed web based Operational

Window (OW) that for PEMEX access

“We have implemented a proof of concept for a web based

Operational Window (OW) that provides system wide KPIs and

operational windows for critical assets and refineries. The initial

results have been indicate “game changing” potential for improving

asset reliability, safety, and performance with positive impact of

yield and production. The use of PI Asset Framework (PI AF) and

PI WebParts was foundational”.

Mr. Carlos Alberto Guevara Díez

Dirección Corporativa de Tecnología de Información

y Procesos del Negocio, DCTIPN. Pemex

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The Road to Improving Operational

Safety & Reliability

• Issues with Rising Maintenance and Safetycosts – 30% Avoidable Errors

• December 2012 – Launch of the OperationalWindows (OWs):

– Establish the proper operation of the main equipment

– Improve operational reliability.

• Issue of the PEMEX Reliability Manual

– Best Practices to prevent & eliminate defects throughproper use of the OWs

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An Operational Window – What is it?

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Upper

Operational

Limit

Lower

Operational

LimitS

ec

ure

op

era

tio

na

l R

an

ge

Operation is

in Steady

Stable, secure

and profitable

limits

Safe Range

Normal operational Range

Unsafe

Operation Unsafe

Operation

Operational Limits of a process variable

Risk

Level

Risk Level vs. Process Variable Limits

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Process for a Successful OWs Implementation

Critical

Equipment

Selection

Operational

Variables to be

monitored

Definition of the

OW limits

Management and

improvement

process

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Challenges to implement a OWs strategy

• Allowing Accountability of the operational staff in each sector and as a result allows the execution of preventive and corrective actions.

• Monitoring in an standardized manner at all refineries so all displays of the status of critical OWs for all different levels of equipment are the same.

• Conduct analysis showing the percentage of time that critical equipment is inside and outside safe ranges to help prioritize the require corrective action.

• Visibility. Show critical equipment which are constantly operating out of safe range and record why corrective actions have not been made to them or means to determine the cause of deviations.

• To have an approved platform, that is simple to operate, which contains uniform rules across the organization to determine the progress in the implementation and improvement of the OWs system.

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The strategy of OWs should have a tool that allows proper monitoring by:

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Operational Window Solution

The "Approved Display Platform for Operational Windows at Pemex" was created which was designed using the following products:

• PI Server

• PI Asset Framework (PI AF)

• Microsoft Visual Studio 2005 (To Implement Rollups)

• PI WebParts

• Microsoft SharePoint

Let’s take a look of the application….

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Standardized Real Time Portal at PEMEX

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All 4 PEMEX

Companies'

Metrics are

in a single

Portal

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Simple solution to standardize all KPI

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Process Variables

and all KPI

are presented &

calculated

in a standard

way using PI AF

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Use of Rollups for standard KPI aggregation

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“One ring portal to have them all…”

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A single detailed view for all equipment

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The Heart -- the OW Calculation

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360 solution – mobile included!!

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Demo video here…..

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ResultsThis project has allowed us to explore new solutions, ways to attack a problem in a holistic way, looking at all the possible angles that make life easier for operations personnel and has resulted in:

• Doubling the percentage of process variables "green" in less than 3 weeks of operation

• Building a system to monitor process conditions of over 2,600 variables

• A solution capable of monitoring process variables from operations, quality, power generation and any other areas to come in the future

• A certified, simple, easy ability to transport and adapt to other production processes

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Next Steps…..While we have achieved significant benefits we still have goals to achieve:

• Strengthen the use of the solution through internal marketing, video conferences and

constantly monitor the operating windows on field in conjunction with the business area.

• Improve the quality of information contained in the model (operating limits, setpoints,

text descriptions).

• Quantify the benefits obtained through the strategy OWs.

• Increase the functionality of the solution integrating some additional graphics detail

pages, setting response times and some other improvements to the navigation between

the different pages.

• Replicate this solution to all petrochemical complexes, gas processing complexes,

pumping stations, storage and distribution stations and generally to all centers where

there Pemex processes require monitoring and control.

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Carlos Alberto Guevara Díez

• carlos.alberto.guevara@pemex.com

• Mtro.

• PEMEX

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