overview of the pi system enabled integrated refinery...
TRANSCRIPT
© Copyright 2015 OSIsoft, LLC
Mr. Mahmoud M. Madani – IRIS Lead Project Engineer, YASREF
Mr. Alex Brodskiy - Manager, Solution Architect, Accenture
Presenters:
Overview of the PI System Enabled Integrated Refinery Information System (IRIS) at
YASREF
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
YASREF- Most Advanced Refinery in The World
• Yanbu Aramco Sinopec Refining Company - Ltd
• JV Signed in late 2012 – 62.5% 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, 2013
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© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
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
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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
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*OME – Operations, Maintenance and Engineering
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
IRIS – Architecture Principles
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• 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
Basic guiding architecture principles were agreed upon in the beginning of the project:
© Copyright 2015 OSIsoft, LLC
IRIS Overview – Applications Architecture
11
Common Applications Engineering Applications Operations Applications Enabled by OSIsoft PI System Components
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Integration of a Portfolio of Applications
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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
SSRS, SSAS, MDS, SSIS
PI Asset Framework
PI Asset Based Analytics
Integration Platform Microsoft BizTalk
Collaboration platform, including Document Management System,
Alerts and Notifications, Workflow ManagementMicrosoft SharePoint
Mass Balance & Energy Accounting Belsim Vali
© Copyright 2015 OSIsoft, LLC
Secure real-time data acquisition from DCS
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Fully redundant architecture with interface, network, and server level failover
Strict rules and traffic control across firewalls
High Availability PI Collectives at all levels
Buffering data at all levels to ensure no data loss in case of network or server outages
High frequency data collection from the source
Leverage best practices in securing control systems
Exa OPC ServerOperation Area 01
Exa OPC ServerOperation Area N
DAHS OPC ServerCentral Control Room
3rd Party OPC Server 1..NCentral Control Room
OPC Interface Node A OPC Interface Node B
FailoverInterface
Hot standby
PA
ND
MZ
PI Primary Server PI Secondary Server
PI Collective SyncOnline High Availability
PI-to-PI Interface Node A PI-to-PI Interface Node B
FailoverInterface
Hot standby
WA
N C
orpo
rate
Net
wor
k
PI Primary Server PI Secondary Server
PI Collective SyncOnline High Availability
Remote OPC connections over DCOM
Unidirectional PINet connection over TCP/IP port 5450
Multiple instances of PI OPC Interface
running on each node
Unidirectional PINet connection over TCP/IP port 5450
PI-to-PI Interfacesconfigured in the
“Push” mode
© Copyright 2015 OSIsoft, LLC
Integrated Notifications Engine
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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
Collects and distributes Notifications from all source applications
© Copyright 2015 OSIsoft, LLC
Leveraging Microsoft BI on SharePoint
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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
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
Asset Framework – Data Federation
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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)
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
© Copyright 2015 OSIsoft, LLC
Multi-step Data Quality Assurance
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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%)
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
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
© Copyright 2015 OSIsoft, LLC
• 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
Solution Results and Benefits
PI System Enabled Integrated Refinery
Information System (IRIS)
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
• 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
“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”.
Mahmoud M. Madani, IRIS Lead Project Engineer
31
PI Coresight 2014
© Copyright 2015 OSIsoft, LLC
Mahmoud M. Madani
IRIS Lead Project Engineer, YASREF
32
Alex Brodskiy
Solution Architect, Accenture
© Copyright 2015 OSIsoft, LLC 33
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