Title : OSIsoft PI System Pilot Project for PETRONAS Group Technical Solutions (GTS) Name : Ng Tong Wu Matric ID : 13513 Course : ICT UTP Supervisor : En. Saipunidzam b. Mahamad Intern Supervisor : En Faiz H. Hussin
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
TABLE OF CONTENTS 1. PROJECT BACKGROUND i. Introduction ... 1 ii. Problem Statement . 1 iii. Feasibility of Project 2 2. LITERATURE REVIEW i. Literature Review . 3 3. METHODOLOGY i. Project Activities ... 4 ii. Gantt Chart .. 5 4. RESULTS AND DISCUSSION i. Data Gathering and Analysis 6 5. PROJECT ACHIEVEMENT AND PROGRESS i. Project Achievement and Progress .. 7
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
1. PROJECT BACKGROUND Introduction Oil and gas industry relies on real time and reliable data to engage precise process control in order to regulate risks associated in its upstream and midstream activities.
OSIsofts PI System is a plant information system that can help oil and gas companies to maximize their process and production efficiency in order to face extremely high production costs.
OSIsoft PI System deploys an architecture that provide real time data infrastructure and collaboration tools to maximize asset performance through real time monitoring, periodical reporting, and also historical trend analysis.
This project aims to develop and install the OSIsoft PI System in a pilot project to show to the client, PETRONASs Group Technical Solutions, Technology and Engineering Department its capabilities and advantages. PETRONAS Penapisan (Melaka) Sdn. Bhd. which is an existing OSIsoft PI System user will be the host to allow our team to read and extract real time data from their PI AF Server. iPerintis which is the technical team of PETRONAS will be the supporting arm to handle all the connectivity and security issues between all parties.
All of the PETRONAS production facilities or plants have existing plant information systems, either Honeywell or Aspentech. However, none of these existing PI systems provide the extensive capabilities and features offered by OSIsoft.
As a system integrator and / or agent to OSIsoft, Consurv Technic (M) Sdn. Bhd. notices the business opportunity. We decided to establish a team of IT staffs and made a proposal to the Technology and Engineering Department of GTS to kick start this pilot project in order to demonstrate the capabilities and features of the OSIsoft PI System.
Problem Statement Conventional plant information systems lacked in terms of reporting features as offered by OSIsofts PI System. It has the capability to generate reports and custom views in its PI Process Book component. Trends and 2D Plant and Instrumentation Diagram (PNI Diagram) with real time data can be generated.
OSIsofts PI System allows sharing of data across platform and data availability in real time. The OSIsoft PI Web Parts allows content provider to build Microsoft Sharepoint System to share information across the enterprise while PI Coresight allows user to generate custom data views through Silverlight enabled browser.
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
PI Notification has the capability to deliver real time desktop alert, alarm, and / or email notification upon breaching of parameters. This will allow for immediate and accurate decisions to control and mitigate the risks.
Also, existing plant information system has been in used for a long time and is getting compatibility issues with newer equipment. OSIsofts PI system promises new features while maintaining backward compatibility for older equipment. It can easily replace obsolete and / or aging plant information technology.
Another feature of current plant information systems is they lacked the ability to integrate with Microsoft Office applications. Whereas OSIsofts PI System is built around Microsoft Office components to allow user take advantage of features they already familiar with.
Feasibility of Project The project will be conducted over a period of six (6) months, which is from June 2012 to December 2012.
As this is a pilot project, trial licenses for each of OSIsoft PI System components have been issued and expiry date is 31 st December 2012.
This project has been proposed since the month June 2011 to PETRONAS GTS and was kick started in the month of May 2012.
Consurv Technic (M) SDn. Bhd. aimed to gain not just monetary profit from this pilot project but also the recognition from client as the preferred vendor for OSIsoft PI System. However, all costs and fees involved in the process of the project will be carried by the client.
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
2. LITERATURE REVIEW John Baier, Director of Project Management from OSIsoft said: Wish you knew how to predict the future? The answer lies in the past.
Many incidents in a production facility are repeating and / or happening after certain symptoms. Maintenance work or mitigation process should be made when symptoms that have history of leading to an incident occurs. Comparative analysis of current equipment status with historical data is beneficial to predict incidents and prevent them.
According to The Role of Predictive Analytics in Asset Optimization for the Oil and Gas Industry published by R. Nicholson, C. Madden, J. Flebowitz, and R. Bigliani (2001), an analysis on the financial statements of the 5 major oil and gas companies in the USA reveals the 51% of their assets consist of plants, equipments, and properties. Therefore, it can be deduced that proper asset management will help to optimize the cost of production in the industry.
This is supported by the ERG Group, a clientele of OSIsofts PI System. The ERG Group is Italys main independent energy and petroleum group. They reported to have achieved reduction in downtime and cost saving by shifting to condition based maintenance, which means maintenance done based on early detected symptoms instead of periodical maintenance. ERG: Driving out unnecessary costs by shifting ot Condition Based Maintenance and reducing downtime.
OSIsofts PI System is a comprehensive asset monitoring tool that is able to help the user to optimize the production and increase efficiency in the value chain, especially in the Oil and Gas industry where production costs is extremely huge and downtime is crucial.
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
3. METHODOLOGY Project Activities 1. Planning - Discussion with GTS (client) to identify business requirements. - Discussion with iPerintis and PPMSB to identify technical requirements. - Discussion with OSIsoft (Singapore) to acknowledge and acquire trial licenses. 2. Analyze & Design - Project feasibility study and costing (internal). - Submission of project feasibility report to GTS. - Submission of commercial impact (quotation) report to GTS. - Submission of finalized Terms of Reference (TOR) to GTS. 3. Building - Procurement and initial set up of PI System components on a server. - Set up networking to access PPMSB PI Server through PETRONAS intranet. - Build AF Tree in PI System Explorer. - Build customized dashboard view in PI Process Book. - Export PI Process Book entry to Microsoft Office Excel file. - Build Microsoft Sharepoint System based on PI Web Parts. - Build web portal based on PI Coresight. - Progress report for each session at GTS office. 4. Testing - Test planning. - System Integration Testing. - Application Testing. - User Acceptance Testing. 5. End - Project completion / termination meeting. - Submission of final project report. - Submission of invoice. - Discussion on future collaborations / procurement.
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
Gantt Chart
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
4. RESULT AND DISCUSSION Data Gathering and Analysis Data gathered in this project is in terms of values of each tag. Each monitored equipment will have a sensor that is reporting values to the Data Collector Server (DCS), this sensor will have a specific tag name. The values of the tags will be stored in the PI Server and can be retrieved using any OSIsoft PI System component. The fundamental of the OSIsoft PI System is reading the tag values using any components in a real time manner.
Using the PI System Explorer, we can generate and organize a tree view of all the equipment in a hierarchical manner. The status of each equipment can be viewed from its attributes.
Using the PI Process Book, we can generate a role based dashboard that can view data in a graphical way corresponding to the levels of the user. Each user will only need to see the data regarding his / her own department; no unnecessary data will be distracting the knowledge worker.
PI Process Book will also be used as a tool to perform data analysis using its trend building features that can include historical data from the start of record.
Using PI Web Parts, information can be shared over the Microsoft Sharepoint platform to all connected users.
PI Coresight is used to create a web portal that will allow end user to view data from any place using browser that support the Silverlight platform. The web portal is highly customizable by the end user. End user will be able to use drag-and-drop gesture to create a customized view for needed data views.
Consurv Technic (M) Sdn Bhd Lot C12A-4 Jalan Ampang Utama 1/1 68000 Ampang, Selangor, Malaysia Tel.: 03 4256 4254 Fax: 03 4256 5254
5. PROJECT ACHIEVEMENT AND PROGRESS The project team is now in the Building phase where we are focusing on the task: Building dashboard using PI Process Book.
The project team had encountered several issues during the Analyze and Design phase where the security certificate for the intranet connection is being delayed. Also the tag configuration from the host server was not released during the Analyze and Design phase. These two (2) issues had caused a certain delay, but with proper control and support from the client, iPerintis, and PPMSB, the Building phase is in progress as scheduled.
NO TASK STATUS Planning 1.1 Discussion with GTS to identify business requirement DONE 1.2 Discussion with iPerintis and PPMSB to identify technical requirement DONE 1.3 Discussion with OSIsoft (Singapore) to acknowledge and acquire trial licenses. DONE Analyze & Design 2.1 Project feasibility study and costing (internal) DONE 2.2 Submission of project feasibility report to GTS DONE 2.3 Submission of commercial impact (quotation) report to GTS DONE 2.4 Submission of finalized Terms of Reference (TOR) to GTS DONE Building 3.1 Procurement and initial set up of PI System components on a server DONE 3.2 Set up networking to access PPMSB PI Server through PETRONAS intranet DONE 3.3 Build AF Tree in PI System Explorer DONE 3.4 Build customized dashboard view in PI Process Book WORKING 3.5 Export PI Process Book entry to Microsoft Office Excel file WORKING 3.6 Build Microsoft Sharepoint System based on PI Web Parts WORKING 3.7 Build web portal based on PI Coresight WORKING 3.8 Progress report for each session at GTS office WORKING Testing 4.1 Test planning PENDING 4.2 System Integration Testing PENDING 4.3 Application Testing PENDING 4.4 User Acceptance Testing PENDING End 5.1 Project completion / termination meeting PENDING 5.2 Submission of final project report PENDING 5.3 Submission of invoice PENDING
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