from tactical to strategic the continuous journey of the...

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© Copyr i gh t 2013 OSIso f t , LLC.

From Tactical to Strategic

The Continuous Journey of the PI

System in Support of Corporate

Sustainability

“The Language of PI”

Tibor Komróczki

Head of Process Information & Automation


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

2


MOL Plc.

3

© Copyr i gh t 2013 OSIso f t , LLC. 4

MOL’s Fuels Value Chain Overview


Outline






• Q&A

5


MO

L G

RO

UP

ST

RA

TE

GY

Climate Change

Environment

Health & Safety

Communities

Human Capital

Economic

sustainability

So

cia

l Aw

are

ne

ss

Pro

fita

bili

ty

Hu

ma

n C

ap

ita

l O

ptim

iza

tion

Sustainability in Oil & Gas

Information Management & Governance S

afe

ty &

Ris

k M

an

ag

em

en

t

En

viro

me

nta

l S

tew

ard

sh

ip

Co

mp

lian

ce

Alignment of Sustainability Frameworks


Outline






• Q&A

7


The PI System Converges: Time & Space All Data – Any Time – Any Location – In Context

8


With the PI System

Enabling a Collaborative Work Environment


The Value of an Enterprise Real-Time Infrastructure

10


Outline






• Q&A

11


I Keep Getting to Come Back …???

12

2011 2012

2014+ ??

2013


Outline






• Q&A

13


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.

14

Asset

management

Resource and

process

efficiency

Market

management

Value chain

optimization

Focus areas


Process Information

PI 1998

SIGMAFINE

1998

NICE

2007

LIMS

1998

OPRALOG

2011

SEMAFOR (KPI

monitoring)

2008

• PI System based

• Native PI System interfaces

• PI System reports,dashboards

• PI System calculation

• Strong integration

PI System Centric…Beginning of the Journey


Process

Automation

DCS

1983

APC

1995

OTS

2006

Energy monitoring

2012

Alarm management

CPM

2011

Industrial Network

2012

• Only a small PI System in the Industrial Network

• Initiative Integration

• PI System provides systems with data

Limited Exposure to the PI System


1+1=3….Realizing the Synergies of the New

Department .. “The Language of PI”

17

Process Information

PI

1998

SIGMAFINE

1998

NICE 2007

LIMS 1998

OPRALOG 2011

SEMAFOR (KPI

monitoring)

2008 Process

Automation

DCS

1983

APC

1995

OTS

2006

Energy monitoring

2012

Alarm management

CPM

2011

Industrial Network

2012

&


Outline






• Q&A

18


Opralog

Weekly Production Program

(WPP)

APC Energy

Monitoring

NDSP Support Solutions


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)


PI Coresight visualizes the measured quality

regarding quality specifications

• 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

Support to reduce quality give-away


Opralog Industrial

PI System


Safety Solutions

23

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.

EN 61511 SIL Implementation of SIL safety standard, based on the Seveso II directive.

Interlock logbook Tracking MOS-POS switches status

Operation

Management

Staff

Competence

Technical Risk

Management

Alarm &

Instrument

Management

Hazards

Accidents


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

24

Industrial Network


Opralog PI

Notification PI AF


Electronic Shift Logbook

26

Consequent, event based logging

Information Sharing

Support audits

(PSM, Behavior, IIR, etc.)

Easier incident investigation

Highlights problematic fields Opralog


Interlock Logbook Migration into Opralog

27

Information about the switch (name, description)

Information about the status (new state, event time)

Who turned on/off?

Who permitted?

What was the reason? Opralog


Notification on control room temperature

SMS

Fast reaction

Reporting of outages

Interlock events to Opralog

Webservice

System to system

Problem with escalation

Analyze technology

Technogy card

Statistical methods

Other algorythms

PI AF Notification

PI AF


Energy monitoring

PI AF


Energy Monitoring

30

On-line, open loop model based control system. Detects excess energy consumption, and advices corrective interventions to the operators.

Data-mining, Reports Evaluations.

Unit level control system (DCS)

Energy Monitoring

System

PI System

Unit control level

HMI

Alarms

Interventions

furnace columns Energy

monitoring


Aim of the project

1-3% energy saving from the total energy

consumption

Real-time energy information

Technological approach

Engineer level (PI data and client

application)

Manager level (KPI dashboards)

Model based support system for energy efficient operation

Target and real value data comparison for manual manipulation

of the operator.

Focus area: energy as electrical power,

utilized and produced steam, fuel oil and

gas

Main goal: generate good operator intervention

Result in energy saving – operational

cost saving

31

Energy monitoring


Energy monitoring

Easy Overview in PI Webparts


PI AF – Integration and Data Abstraction

33

Email, SMS, Webservice

Easier, Quicker Appl. Development

Real-time data

Benchmarking Cloud

New solutions Maintenance

of PI

Asset management

Learning

PI AF


APC PI System Reports

PI

AF ARGUS


2013-05-01 2013-05-02 2013-05-03 2013-05-04 2013-05-05 2013-05-06 2013-05-07

Thursday Friday Saturday Sunday Monday Tuesday Wednesday

DARED 101 -1,11623

DCDU3 105 N/A N/A N/A 0,02135

DGFRU 112 0,86768

DGFRU 118 N/A 0,00938

DGFRU 123 0,71449

DAEDB 1/101 -0,31899

DAEDB 2/108 0,30235

DAEDB K1 0,15184

DFCC 840V2 -0,75675

DETBE 450V2 0,46290

DETBE 450V3 0,01197

DETBE 450V4 0,33566

DMHCK K803 1,14934

DGHT3 K501 -0,03649

DGHT3 K803 -0,34319

DSRU6 T501 -0,38648

DSRU6 T801 0,45209

DDCKU T106 0,58097

DDCKU T109 -0,56480

DDCKU T201 0,28825

TGOK C10 -0,30423

TMTB C104 N/A N/A N/A N/A N/A N/A N/A N/A

Total -: -1,67239

Total +: 3,18412

SubTotal: 1,52111

Deviation from target [mHUF/week]

Motorfuel

Tisza Refinery

Distillation

Aromatics

Residue

ColumnUnit

DETBE 450V2 Unit start-up, minimum throughput

DMHCK K803 Amine regeneration troubles

DDCKU T106 APC upgrade

PI

DataLink


Column Dashboard

PI

Webparts First month was totally red!


Unit Sample Point Analysis 2013.02.28 2013.04.25 2013.05.02 2013.05.13

DARB 101FJKI Benzene Precise, but not Accurate

Precise, but not

Accurate

Precise, but not

Accurate Precise, but not Accurate

DARB 101FJKI Non aromatic Valid

Precise, but not

Accurate Not enough data Valid

DARB 101FJKI Toluene Valid

Precise, but not

Accurate

Precise, but not


DARB OXILOLKI C9 Precise, but not Accurate

Precise, but not

Accurate

Precise, but not


DARB OXILOLKI Cumene Precise, but not Accurate

Precise, but not

Accurate

Precise, but not


DARB OXILOLKI

Meta-xylene

Precise, but not Accurate

Precise, but not

Accurate

Precise, but not


DARB OXILOLKI Non aromatic Valid Valid Valid Valid

DARB OXILOLKI Ortho-xylene Precise, but not Accurate

Precise, but not

Accurate

Precise, but not


DARB TOLUOLKI Benzene Precise, but not Accurate

Precise, but not

Accurate Valid Valid

DARB TOLUOLKI Non aromatic Valid

Precise, but not

Accurate Valid Precise, but not Accurate

DARB TOLUOLKI Toluene Precise, but not Accurate

Precise, but not

Accurate

Precise, but not


DARB XILOLKI Etil-benzol Valid

Precise, but not

Accurate

Precise, but not


DARB XILOLKI Meta-xylene Precise, but not Accurate Valid Valid Valid

DARB XILOLKI Non aromatic Valid

Precise, but not

Accurate

Precise, but not


DARB XILOLKI Ortho-xylene Valid Not Valid Not Valid Valid

DARB XILOLKI Para-xylene Precise, but not Accurate Valid

Precise, but not


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

Analysers Validity Report

ARGUS

DBK5: sulphur analyser could have helped to recognise product contamination

Comment:

Based on PI solutions (ProcessBook and DataLink) ARGUS

Regular report in every week

Continuous monitoring


APC OPERATION OVERVIEW

PI AF

Switched status

Constrained status



Checking Control MODES

Import Data from CPM to PI

Regular report in every week


PI AF


PI AF

CPM

Checking Control MODES

Detailed Plant view

Includes all important controller


Structure represent

technology

Assets solves business problems

Bottom-up approach

Real-time visualisation

Datalink summaries

Visualisation of time

summaries

Notification issues

Process safety

management

OSISoft Portfolio & Refining


Outline






• Q&A

43


Tibor Komróczki

[email protected]

H-2443

Százhalombatta

P.O.Box:1.

44

mailto:[email protected]


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