Leveraging PI System for Real-Time Operation Monitoring

Transcription

1 Leveraging PI System for Real-Time Operation Monitoring Presented by: Musreen Azwan Mustafa Nurhazlin Mat Musak 2013 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner. 10 June 2014 PETRONAS

2 Agenda About PETRONAS Business Challenges Solution Way Forward and Next Steps Conclusion and Summary 10 June 2014 PETRONAS

3 About PETRONAS PETRONAS

4 Where are we? Malaysia 10 June 2014 PETRONAS

5 Our presence Source: PETRONAS Annual Report 2012:2 ( 10 June 2014 PETRONAS

6 What we do Source: PETRONAS Annual Report 2012:2 ( 10 June 2014 PETRONAS

7 The facts.. MALAYSIA NOC E&P GAS & POWER DOWNSTREAM Incorporated on 17 th August ,860 employees worldwide USD 87 billion 2012 revenue E&P USD 147 billion of assets PEX PDP PMU Production 2,015 kboe per day 32.6 Bboe discovered resources 10 June 2014 PETRONAS

8 Business Challenges PETRONAS

9 Why do we need PI System? Diverse operational facilities Inhomogeneous sources of operational data Real-time process data locked within isolated control systems Technical performance & business intelligence reliant on offline data 10 June 2014 PETRONAS

10 Slow response by engineers due to stagnant data at sites Optimization Engineers Day 1-30: Plug data manually from process data database into excel and make trending for one month. Needs to call operation engineers at sire for data not available in ODC. Normally, operation not able to cater request due to busy activities at site. Day 31: Key in aggregated/calculated operating data and parameters in simulation software. Reliability Engineers Day 1: Receive notification from offshore. Day 2-10: Clarify with operation personnel at site. Request for relevant data for affected operating parameter for one week. Day 10 : See trending and do analysis. If see abnormality, arrange for offshore trip during next mobilization day (Tuesday/ Saturday only) 10 June 2014 PETRONAS

11 Previous information flow took weeks to obtain data Event / Incident Generate Report & Review Perform Analysis & Investigation Management Endorsement Implementation Management Review Report incident by OT Report verify by OIM Report review by FE / RE Request support from HQ Investigation report & finding Equipment investigation Identify investigation report Yes 2 3 weeks to obtain the relevant data from site Engineers in office take up to three weeks to get the info and provide support (including travel time) Further investigation No Recommended action Implementation of recommended action Management Review 10 June 2014 PETRONAS

12 Solution: Deployment of PI System & Architecture PETRONAS

13 Current PI System status in PETRONAS E&P PMO16 PMO17 PMO18 PMO24 PMO15 PMO19 PMO23 PMO20 PMO22 PMO21 PMO14 PMO13 PMO12 PMO10 PMO11 PMO9 PMO7 PMO8 PMO1 PMO2 PMO6 PMO3 PMO4 PMO5 SBO8 SBO9 SBO7 SBO6 Completed Due to complete in 2014 After 2015 SBO1 SKO1 SBO3 SBO 2 SKO11 SKO2 SKO10 SKO12 SKO3 SKO9 SKO4 SKO13 SKO8 SKO14 SKO5 SKO20 SKO19 SKO7 SKO15 SKO6 SKO18 SKO17 SKO16 SBO4 SBO5 10 June 2014 PETRONAS

14 Overall PI System Architecture PI WebParts PI WebParts 10 June 2014 PETRONAS

15 Site PI System Architecture PI WebParts 10 June 2014 PETRONAS

16 Cyber Security Architecture One Way Communication Only data from control network to flow to corporate network and not vice versa DMZ Zone (Layer 3.5) Communication from both layers are not directly but via PI Server Port 5450 Only port 5450 is allowed, for PI Server communication Security Security is advised, audited and approved by PETRONAS ICT Group Security 10 June 2014 PETRONAS

17 OSIsoft Products and Services Employed PI Interface PI Interface for OPC DA PI Interface for Modbus Ethernet PI to PI Interface PI Notifications PI Server PI System Management Tools (PI SMT) OSIsoft vcampus OSIsoft YouTube Learning Channel OSIsoft Users Community 10 June 2014 PETRONAS

18 Solution: How PI System addressed business challenges PETRONAS

19 Turning stagnant data into flow of profitable information We want to manage operational data and take control of them Plant 0Systems? PLCs Control Systems 10 June 2014 PETRONAS

20 New information flow; data is available anytime, anywhere Real / Near Time Equipment Monitoring Perform Analysis & Investigation Management Endorsement Implementation Management Review Earliest Warning or Failure can be detected before the equipment failure and the mitigation action can be planned. To avoid unplanned equipment/shutdown at the offshore platform Investigation report & finding Equipment investigation Indentify investigation report Yes Data is available in office in realtime Eng. at VO & CHO closely monitor the equipment from onshore Eng. take action when the equipment trending are not as per agreed parameter Further investigation No Recommended action Implementation of recommended action Management Review 10 June 2014 PETRONAS

21 Safety Operating Limit and Critical Operating Limit using PI WebParts The objective of SOL and COL real-time monitoring is to detect, record and monitor instances when operating near or beyond Safe operating limit range. 10 June 2014 PETRONAS

22 Critical Operating Limit Monitoring using Excel PI DataLink Business Challenge Critical Operating Limit (COL) only available in P&ID No proper monitoring tools on any COL excursion. Solution Trending of main equipment Critical Operating Limit (COL) Alert on any COL excursion for the day using conditioning feature of Excel PI DataLink. Results and Benefits Remote monitoring of process instrumentation, power generation and rotating equipment at offshore platform from office become easier. 10 June 2014 PETRONAS

23 Troubleshooting made easy and accurate! PI System is a vital tool for every engineers to properly perform their role in the dynamic oil & gas world. C Sathya Murthi, Staff Engineer (Process) Historical data for PT 1000 from April 2012 to May 2013 was extracted from PI System Business Challenge Troubleshooting based on limited technical data as no proper historian system for process parameters Not able to predict potential problem to the critical equipment or process instrumentation as no real-time monitoring system available Solution PZAHH 101A has been put on bypass due to several platform Process Shutdown (PSD) Reduced 5 unplanned shutdowns in 2013 Implemented the PI System as process data infrastructure and historian Connecting critical systems to the remote PI System Established PI to PI connection between remote PI System and main PI System in the office Results and Benefits Technical reference easily accessible from PI System Reduce troubleshooting/ diagnostic period which will improve the overall equipment mean time to restore well Minimizing unplanned shutdown and production loss 10 June 2014 PETRONAS

24 Future Plans and Next Steps PETRONAS

25 PI System deployment status PI System: Number of Assets Deployed Number of PI Tags Installed Pre Pre June 2014 PETRONAS

26 High Level Roadmap Phase 1 FY13 Phase 2 FY14 Phase 3 FY15 onward Establishment of PI System Blueprint PI System Implementation of several assets following proposed standard Establishment MSSA PI System Implementation for more assets following proposed standard and lesson learnt Implementation of PI Asset Framework, PI ACE and PI Coresight Study on the design and propose enhancement 10 June 2014 PETRONAS

27 PI System Maturity Chart Mobile and Calculation Automation Reporting, Asset Framework and Web Reporting and Graphics 2012 Asset Implementation PI ProcessBook PI ProcessBook PI Coresight PI Asset Framework PI Asset Framework PI WebParts PI WebParts PI DataLink PI DataLink PI ACE PI DataLink 10 June 2014 PETRONAS

28 Conclusion PETRONAS

29 Automate the information flow to give engineers more time to make the world! 10 June 2014 PETRONAS

30 Musreen Azwan Mustafa Instrumentation Engineer PETRONAS Nurhazlin Mat Musak Instrumentation Engineer PETRONAS 10 June 2014 PETRONAS

31 The End PETRONAS