The PI System as a Strategic Integration and Applications Infrastructure. Process Information Leader

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2 The PI System as a Strategic Integration and Applications Infrastructure Presented by Tibor Komróczki Process Information Leader

3 AGENDA MOL Overview Business Challenge System Results/Benefits Q&A 3

4 AGENDA MOL Overview Business Challenge System Results/Benefits Q&A 4

5 Leading European Integrated Company Integrated Portfolio based on 3 Pillars 5

6 Fuels Value Chain Overview Crude pipelines Friendship I Capacity: 20 Mtpa D Refineries DANUBE Capacity: 8.1 Mtpa NCI: 10.6 Friendship Il Capacity: 7.9 Mtpa BRATISLAVA Capacity: 6.1 Mtpa NCI: 11.5 Adria JANAF Capacity: 10 Mtpa Mantua - IES Capacity: 2.6 Mtpa NCI: 8.4 Bratislava Danube RIJEKA Capacity: 4.5 Mtpa NCI: 5.8 SISAK Capacity: 2.2 Mtpa NCI: 6.1 Mantua Sisak Rijeka MOL Refinery MOL Own depot MOL Rented depot 6

7 HS&E ENTERPRISE RESOURCE PLANNING (ERP) Quality Mgmt. Accounting Planning SCM Asset Management HR SAFETY SMS Safety Management / Expert System ENVIRON. CEMS Continuous Emissions Monitoring System QUALITY PT/QM Production Tracking / Quality Monitoring SQC Statistical Quality Control ARM Analyzer Reliability Monitoring PRODUCTION & OPERATION MANAGEMENT PADR Production Accounting & Data Reconc. PERFORMANCE MANAGEMNT Site Performance Monitoring & Accounting SCO Production Planning & Scheduling OMS OIS Solutions Operations and Applications Operational Monitoring & Reporting P&CA Procedure & Control Exec. Analysis Intelligence RTO Plant & Wide Area Optimization ASSET AVAILABILITY & REL. RBA Risk Based Analysis & Evaluation OEE Overall Equipment Effectiveness CBM Condition Based Monitoring EHM Asset Reliability / Availability Monitoring PEOPLE OTS/LMS Operator Training / Learning Management Unified Real-time Integration and Applications Infrastructure SAFETY CONTROL LIMS PROCESS ANALYZERS DCS PLC/SCADA ADVANCED CONTROL HISTORIAN DIAGNOSTIC SYSTEMS MANUAL DATA PLANT DATABASE OTHER COLUMNS FURNACES PUMPS HEAT EXCHANGERS TURBINES COMPRESSORS MOTORS VALVES TRANSMITTERS ACTUATORS TRANSFORMERS OTHER

8 MOL REFIS (Refinery Information System) Corporate systems ERP BI ( SEM BW ) Maintenance Planning / Scheduling Planning Scheduling Blending Expert systems Applications E_LogBook Architecture Reports Daily / Monthly Process Control ( Instrument infrastructure ) DCS SEMAFOR (KPI) PI Workflows DER / ICA / MOC HUMOR / DACAR All System with Native PI connection Sigmafine LIMS NICE PI WebParts Blenders Movement application TGS ARGUS Implement same modules at every site Standardization is important All systems and programs at Applications and Architecture layer provides with PI System data 8

9 AGENDA MOL Overview Business Challenge System Results/Benefits Q&A 9

10 Business Challenge Closing the gap between process control and business governance Providing real-time information for tighter control of operations Action to reach these goals: Improve information flow among departments & shifts Establishing a unified data model of refining for all refineries Overall monitoring of operations to fulfill strategic objectives Closer to planned operations, scheduled activities, events Improve the flow of information between the shifts Real-time-based electronic shift report system Minimize the loss of information 10

11 Areas of Improvement Reliability Safety Human Profitability 11

12 AGENDA MOL Overview Business Challenge System Results/Benefits Q&A 12 12

13 Integration Bratislava Refinery Mantua Refinery Rijeka Refinery Danube Refinery Sisak Refinery Applications PI System Sigmafine SEMAFOR (KPI) LIMS E-logbook Opralog 13

14 Laboratory Information System - LIMS Before q Many analysis interfaces from and to everywhere Now q Only one standard PI System interface q PI System provides all system with analyses data PIMS 14

15 KPI System SEMAFOR q Daily operation monitoring through KPIs q Consolidated information and reporting system q Increase performance transparency q Sharing Group resources (productive/developer system) 15

16 Knowledge sharing PI WebParts q Upload PI ProcessBook flow sheets q System checking q Organize training q Workflows q Share important information and documentations q Task lists 16

17 Health monitor 17

18 In-House Education Training mandatory all new plant manager shift leader, operator. Prerequisite of appointment PI System advanced PI System beginner Tank monitoring Rotating equipment Advanced report PI DataLink report PI ProcessBook drawing Shift leaders PI DataLink report PI ProcessBook drawing 18

19 PI Coresight Ac5ons Develop screen parallel with PI AF Corrosion monitoring Unit reflux Pumps Replace PI ProcessBook trends Unit Benchmarking Change Requests More properties Bold colors at gauges (for building KPI dashboards) Present min, max, avg at calculated points and PI AF elements PI ACE, PI NOTIFICATIONS PI AF SERVER PI CORESIGHT SERVER PI CORESIGHT DATABASE 19

20 Mass of reports & logbooks Seal register Shift logbook Blind register Daily deviation list Rapport logbook Daily report Deoiler logbook Odour logbook Deodorant logbook Safety interlock logbook Sample register Area operator s logbook Steam-trap register List of Work permissions Furnaces logbooks Safety interlock logbook Loading-pouring ticket Task manager Certificate of quality Dispatcher s logbook 20

21 E-logbook MAINTENANCE DIRECTOR QUALITY CONTROL ENERGY HSE DISPATHCHER OPM & PE AREA & PLANT MANAGERS SECURITY SERVICE 21

22 Benefits Improve q Data accuracy q Data model q Communication between SCM & Refining q Plant reliability q Decision making q Safety operations 22

23 Maintenance Rotating equipment Online analyzers Lubricating Calibration Running time vs. laboratory Timebased Conditionbased 23

24 Equipment Lubricating Program 24

25 AGENDA MOL Overview Business Challenge System Results/Benefits Q&A 25 25

26 Summary Integrated System & Interfaces & E - LogBook Knowledge sharing Communications LogBooks Shift-handover KPI Earlier Shared folders, local computers Poor communication between departments Paper based logbooks without retrieval functions Missing information, dangerous Local KPI-s,different rules Now PI Webparts and Portal Effective information sharing E_LogBook with searching & reporting functions Effective & safety Global KPI-s,same rules,good house-keeping 26

27 Benefits Tangible Reliability Safety q Improves productivity q Ensures reliability q Reduces downtime / numbers of shutdowns q Supports cost-efficient decision making q Enables statistic-based models and controls Intangible q Enhanced communications & information flow q Heighten customer satisfaction q Saves enormous time and effort q Delivers instant, company-wide access to data Human Profitability 27

28 Conclusion q Optimized operational performance requires unified information and applications infrastructure and system hierarchy q Using the PI System as an integration and applications infrastructure supports: q Consistency of information and applications q Evolutionary way to replace existing applications q Effective means to address cyber security q A best of breed approach to the integration of technology q Modification of the historical applications and solutions approach q A foundation for the value now, value over time vision q Sharing knowledge and experience between the different units and organizations using a well-defined application pool is essential. 28

29 Brought to you by

30 Tibor Komróczki H-2443 Százhalombatta P.O.Box:1. 30

31 Backup slides 31

32 Plan vs Actual Compare daily plan/actual data Differences Plan Yields Actual Yields 32

33 New E_LogBook Reports Collects different data type q Accounting figures q PI System data q Events q Staff data q Controller data 33