Openo&M Oil & Gas Industry Use Cases with Scenarios and Enabling
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OpenO&M Oil & Gas Industry Use Cases with Scenarios and Enabling Technology Ken Bever MIMOSA CTO [email protected] +1 (513) 276-4105 1 Use Cases 1 Handover Information from EPC to O/O 2 Engineering Upgrades to O&M 3 Field Changes to Plant/Facility Engineering 4 Up-to-Date Product Data Library (from On-line RDL) 5 O&M Asset Configuration Updates 6 Preventive Maintenance Triggering 7 (Semi-) Automatic Triggering of Condition Based Maintenance (CBM) 8 Early Warning Notifications 9 Incident Management/Accountability 10 Information Provisioning of O&M Systems 2 Systems Requiring Interoperability AHMS Asset Health Management System MES Manufacturing Execution System CIR Common Interoperability Registry MMS Maintenance Management System CMS Condition Monitoring System OPM Operational Performance Modelling & Optimization System DCS Distributed Control System ORM Operational Risk Management System DMS Document Management System PDM Product Data Management System EAM Enterprise Asset Management System PLC Programmable Logic Controller ENG Engineering Schematic Topology and PORT Enterprise KPI/Event Portal Instrumentation Tag Configuration Management System ERM Enterprise Risk Management System PSMS Process Safety Management System ERP Enterprise Resource Planning System QMS Quality Management System HMI Human-Machine Interface (Operator Console) REG O&M Product, Structure, Asset Registry with System Standardised Data Dictionary and Taxonomy ISBM Information Service Bus Model SCADA Supervisory Control and Data Acquisition LIMS Lab Information Management System SHES Safety, Health, and Environmental System 3 OpenO&M Systems Landscape Data Flow Diagram with Use Case Scenarios Open Standards Which Define Data Content for Information Exchange OAGIS, CIDX OpenO&M Common Interop. Registry ISO 15926 / iRING B2MML B2MML & PRODML MIMOSA, B2MML & PRODML NOTE: Arrows with Do Not MIMOSA Connect Directly to Another System Publish Information OPC Which Can Be Subscribed to Fieldbus (Foundation, Profibus, etc.) By Multiple Systems 4 2 28 3 6 9 1 27 23 24 19 21 4 5 20 22 11 31 14 15 16 12 10 17 18 13 29 30 8 26 7 25 Scenarios No. Method Data From System To System As-Designed/As-Built Engineering 1 Publish ENG REG-STRUCTURE Network/Segment/Tag As-Designed/As-Built Engineering 2 Publish REG-STRUCTURE O&M Network/Segment/Tag 3 Publish As-Maintained Engineering Network/Segment/Tag O&M O&M ENG, 4 Publish As-Built Engineering Asset REG-ASSET CONSTRUCT 5 Publish As-Built Engineering Asset REG-ASSET O&M 6 Publish As-Maintained Engineering Asset O&M O&M 7 Pull OEM Model OEM PDM REG-PRODUCT 8 Pull OEM Model REG-PRODUCT O&M 9 Publish OEM Model O&M O&M 10 Push Asset Removal/Installation CMS MMS 11 Publish Asset Removal/Installation MMS O&M 7 Scenarios (cont.) No. Method Data From System To System 12 Pull Usage Readings CONTROL MMS, ORM 13 Publish Usage Readings CONTROL MMS, ORM 14 Push CBM Advisories ORM MMS 15 Pull Maintenance Work Status/Work History MMS O&M 16 Publish Maintenance Work Status/Work History MMS O&M ERP, ERM, PORT, 17 Pull Maintenance KPIs MMS MES, OPM ERP, ERM, PORT, 18 Publish Maintenance KPIs MMS MES, OPM ERP, ERM, PORT, 19 Pull Performance KPIs ORM OPM ERP, ERM, PORT, 20 Publish Performance KPIs ORM OPM ERP, ERM, PORT, 21 Pull Significant ORM Events ORM OPM ERP, ERM, PORT, 22 Publish Significant ORM Events ORM OPM 8 Scenarios (cont.) No. Method Data From System To System ERP, ERM, PORT, 23 Pull OPM KPIs OPM MES ERP, ERM, PORT, 24 Publish OPM KPIs OPM MES 25 Publish Product/Part Engineering Change Advisories OEM PDM REG-PRODUCT 26 Publish Product/Part Engineering Change Advisories REG-PRODUCT O&M 27 Publish Plant/Process Change Advisories ENG REG-STRUCTURE 28 Publish Plant/Process Change Advisories REG-STRUCTURE O&M CONTROL, ORM, 29 Pull Current Operating Data and Events CMS OPM CONTROL, ORM, 30 Publish Current Operating Data and Events CMS OPM 31 Pull Historical Operating Data and Events HIST ORM, OPM 9 OpenO&M Systems Landscape Data Flow Diagram with Use Case 1 scenarios 1 4 10 Use Case 1 – Handover EPC to O/O • Handover of As-Designed, As-Engineered and As-Built Information from Engineering, Procurement, and Construction (EPC) Contractor(s) to Owner/Operator – A core problem for Owner/Operators (O/O), vendors and systems implementers is the lack of good mechanisms for managing the needed information exchanges between EPC activities and the O&M related systems, applications and technologies. • Information to Be Exchanged: Information is needed to properly bootstrap O&M systems with as-designed functional segment data (including P&ID diagram information of network topologies, breakdown structures and process/equipment data sheets), and asset and installation data. Need to have access to “tag” databases which identify where sensors have been installed for control and monitoring, related to the process equipment they are monitoring, and the meta-data about them (tag ID, update frequency, engineering unit, etc.). • Scenarios Activated: 1, 4 11 Use Case 1 – Handover EPC to O/O Scenarios • The first scenario is (2) Publish As-Designed / As-Built Engineering Network / Segment / Tag data from REG- STRUCTURE to O&M . This scenario details the batch exchange of structural design information that forms part of the registry master data required by most O&M systems. This information originates from the Structural Registry (which stores Plant Breakdown Structures, Logical P&IDs and PFDs) and is sent to all applicable O&M systems. • The second scenario is (5) Publish As-Built Engineering Asset data from REG-ASSET to O&M . This scenario is similar to the previous, but details the exchange of asset and installation information. This information originates from the Asset Registry and is sent to all applicable O&M systems. 12 Use Case 2 – Engineering Upgrades • Recurring Updates – Send Open Engineering Upgrades to O&M: Once a site is operational, plant or facility engineering and design organizations may continue to make changes to the as-designed information models on a recurring basis . These changes can be driven by the need to operate more efficiently or with greater safety in support of the originally intended process supporting the same product mix or they can be associated with the need to change the process to yield new products, not envisioned in the original design. Once the new design information is developed it may be managed in several different ways depending on the driver for the change and the associated priority it will be assigned. Depending on the nature and scale of the changes involved, the actual work may be performed by the maintenance staff, a maintenance contractor or a construction contractor. In all cases, some type of appropriate feedback loop must be provided to ensure that the status is known and shared by Engineering Reference Databases and O&M systems. • Information to Be Exchanged: Need to propagate changes to functional segment data, including P&ID diagram information related to process/equipment data sheets with guaranteed delivery despite network hiccups. • Scenarios Activated: 1, 2, 4, 5 13 Use Case 3 – Field Changes • Field Engineering – Changes Sent To Plant or Facilities Engineering: In a perfect world, fully leveraging best practices, all engineering changes would flow through the enterprise design engineering and approval systems on a “waterfall” basis, even if the actual design work is done locally or through an independent contractor. All such engineering changes would be fully reconciled and rationalized before the work was actually done and the integrity of the Engineering Reference Databases would be ensured as a specialization of use case 2. Unfortunately, there are many situations where this does not occur (and may be impractical). This frequently results when a centralized plant or facilities engineering organization is overwhelmed by emergent situations and the plant or facilities manager must take responsibility for the situation without the ideal level of centralized support. Lack of proper synchronization of this work can result in anomalies with respect to the system of record for the engineering information, since in this case, the most up-to-date as-designed information is flowing from the field to the enterprise, rather than the other way around. • Information to Be Exchanged: The information is very similar to that which is contained in Use Case 2, but it now needs to flow from the field to the Engineering Reference Database so that the systems can be kept in sync. Need to propagate changes to functional segment data, including P&ID diagram information related to process/equipment data sheets with guaranteed delivery despite network hiccups. • Scenarios Activated: 3, 6 14 Use Case 4 – Online Product Data • Open On-line Product Data Library: All of the Use Cases contained in this document anticipate the on-line availability of appropriate product data libraries containing the detailed engineering reference information for makes and models of important classes of physical assets . Critical elements of ERM including both Operational Risk Management (ORM) and EH&S depend on the Enterprise Asset Management (EAM), Reliability Management (RM), Condition Based Maintenance (CBM) and ORM systems leveraging the most current product data. Manufacturers are often reluctant to publish some quality and reliability data about their products which is extremely important and this information needs to be gathered from trusted third parties and/or internal operating experience. As this new experience-based information becomes available, it also needs to be properly persisted and synchronized. • Information to Be Exchanged: For all key originally installed and replaced equipment, ORM and EAM systems need on-line access to motor/pump/gear/bearing/valve/sensor OEM cut-sheet specification data in order for ORM systems to perform equipment diagnostics, validate current configurations meet the required process requirements, and for EAM systems to display to maintenance personnel.