overview of the pi system enabled integrated refinery...

© 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


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

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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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– EMS

– Visualization


• Best Practices


4


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


Project Time Lines

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– EMS

– Visualization


• Best Practices



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:


IRIS – Integration Platform

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IRIS Overview – Applications Architecture

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Common Applications Engineering Applications Operations Applications Enabled by OSIsoft PI System Components


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


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


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


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








– EMS

– Visualization


• Best Practices


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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

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AF Extensively Used for Asset Analytics

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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 20

Asset Analytics for Emission Monitoring


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%)








– EMS

– Visualization


• Best Practices


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Performance Management System

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Performance Management System

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Emission Monitoring System

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Self Serve BI with Ad-hoc Dashboards

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Leveraging PI Coresight 2014 for Visualization

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– EMS

– Visualization


• Best Practices



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

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Agenda

• YASREF at a Glance







– EMS

• Best Practices



• 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


Mahmoud M. Madani

[email protected]

IRIS Lead Project Engineer, YASREF

32

Alex Brodskiy

[email protected]

Solution Architect, Accenture

mailto:[email protected]

mailto:[email protected]


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overview of the pi system enabled integrated refinery...

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