intergrated asset planning, scheduling and reporting ppt
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Integrated Asset Planning, Scheduling, and Reporting
Randy KauffmanBP Texas City Refinery
Speaker Bio
Randy KaufmanLead Scheduler
10 years at BP Texas City Refinery
Expertise in:
Scheduling
Integrated work management
Maintenance processes
SAP and Primavera scheduling system experience
BP Texas City History
Texas City RefineryBPLocated in Texas City, Texas
Third largest refinery in the USProduces 3% of nation’s gas supply
BP’s largest refinery worldwideProcesses 475kbdCan process over 54 different types of crude oil
Texas City Refinery Site
Texas City Refinery Summary
Crude Distillation Capacity
475,000 bpdReceives approximately 70% of its crude oil via marine terminalSends out approximately 75% of its products via pipelineUnleaded gasoline- from crude tank to product pipeline- produced in approximately 12 hours
Texas City Environment
Texas City Complexity
Refined ProductsLiquefied petroleum gas
(LPG)
Kerosene (paraffin)
Lubricating oils
Heavy fuel oils
Bitumen
Waxes
Maintenance Focus
Routine maintenance was the original area of focus
Schedule update frequency is once, twice, or as needed
per day
Involves entire regular plant staff
All maintenance occurring on a permitting area is
scheduled in Primavera
Contractor staff can add 2000‐4000+ staff during Tar's
Maintenance Facts
Daily, Preliminary weekly, and a locked weekly schedule
is produced
Routine maintenance resources are leveled once a week
and scheduled daily.
Typical schedule look ahead is 4 weeks
P6 Project Model contains 400,000+ activities
Integrated scheduling and planning is an ongoing effort
year ‘round
Integrated Scheduling & Planning
Routine Maintenance and Programs: Plan in SAP – Transport daily to Primavera.
Consists of Routine and Area Groups.
TAR:Plan in SAP – Transport when needed to Primavera.
Projects:Plans and schedules in Primavera, incorporates
mandatory activity codes in construction schedule to be included in site wide integrated schedule.
All 3 groups data is approved by the permitting areas in the refinery on a weekly and daily basis.
Integrated Scheduling & Planning
Integrated Asset Planning: A holistic approach to planning and scheduling that
centralizes all asset-impacting work activities from all sources into a single integrated plan.
Technical OverviewSoftware Systems (SAP)
SAP implementation started October 2003 at Texas City.
Current Texas City SAP version is ECC 6
Prior system was a custom in‐house client/server system
Implemented SAP PM for asset management
SAP system includes Texas City and various BP Chemical sites
Pipeline Maxavera (SAP PM <‐> Primavera P6 integration)
Primavera P6 for scheduling (release 7 SP 2)
Technical Overview
Software Systems (Maxavera)
Pipeline Maxavera (SAP PM <‐> Primavera P6 integration)
Pipeline Maxavera system includes 2 SAP systems, and 5
Primavera instances from the same system.
Syntempo for schedule viewing, schedule updating, and
collective confirmation in SAP
Pipeline Maxavera has data feeds to project reporting
systems
Technical Overview
Software Systems (Primavera)
Primavera P6 for scheduling (release 7 SP 2)
Primavera data base includes 5 refineries, 3 chemical
plants and pipelines.
Each group has own instance in Primavera.
Technical Overview
Software Systems (SAP, Maximo)
Different versions of SAP are used at different sites.
Maximo 4.1 and 7.0 are being used at other sites.
Pipeline Maxavera move the data from SAP or Maximo to the
different instances of Primavera.
Texas City Business GroupsBusiness Groups
Routine Scheduling team
Area Group that works on PPMs, troubleshooting and LDar.
Routine Group that works on maintenance repairs.
Projects Scheduling team
TAR Scheduling team
Execution team
Operations team
Contractors
Solution Approach
Solution
Maxavera integration solution from Pipeline Software
Integrated planning approach
High performance for data volumes
Preferred a packaged solution approach
Support for key systems ‐ SAP and Primavera
Scenario templates for online maintenance, outages, TAR.
Texas City Scenarios
Texas City example for data fields and round trip process
Scenario #1: SAP PM – Primavera P6
Scenario #2: Primavera P6 – SAP PM
Work Orders updated to Primavera
Scenario ‐
Planner creates and plans and assigns resources in SAP Work Orders,
Schedulers send them to Primavera for scheduling.
SAP PM PRIMAVERA
Operations Activities- Schedule Data - Durations, Dates- Effort - Planned Work, Remaining Work- Work Center - Resource Assignment- Relations - Relationships- Confirmations - Actual Work / Time
Sub-Operations Resource Assignments - Work Center - Resource- Schedule Data - Durations, Dates
Work Centers Resources- Descriptions - Descriptions- Capacities - Calendar & Availability
P6 Schedule Data updated to SAP
Scenario ‐
Scheduler schedules activities and resources with
dates in Primavera and sends back to SAP
Sub-Operations Resource Assignments- Duration - Duration- Work Center - Resource- Number of Capacities - Planned Units Per Time
Operations Activities- Early Start - Planned Start Date- Early Finish - Planned Finish Date- Work Center - Resource- Number of Capacities - Planned Units Per Time
SAP PM
PRIMAVERA
Schedule ReportingData Cube
Primary Feed
Secondary Feed
Schedule Reporting
Dashboard KPI’s
Gantt
Data object linking
(integration) with EPM/ EAM
data sources enables
comprehensive multi‐
dimensional analytics!!
Pert
Tabular
Schedule Reporting
Syntempo Work Collaboration
Composite of other systems!You need information from all of these systems in a combined view in order to make the right decisions.
Syntempo Key Aspects
Supervisor
Craft
Foreman
Syntempo
Enterprise SystemsMaintenance & Operations
Work Execution ManagementOutage Visibility and Collaboration
Syntempo Benefits
• Syntempo Enables• Real‐time outage schedule• Real‐time progress collection• Real‐time alerts & communications• Single universally accessible system
• Benefits• Decision making based on real‐time information• Improved communications across teams• Increased visibility of outage execution• Simplified business processes• Reduced personnel training costs
Solution Rollout Process
Delivery Process
Structured methodology to each rollout from Pipeline‐
positive, predictable results
Pipeline onsite solution blueprint workshop
Offsite configuration by Pipeline
Close coordination between Texas City and Pipeline
teams
Shared testing activities before go‐live
Integrated scheduling, planning, and maintenance can save time, money, and resources for maintenance processes
High performance processing
Automate data transfers
Establish common processes
Reduce (or eliminate) manual data steps
Reduce (or eliminate) double data entry
Integrated Scheduling & Planning
Business process improvements that customers can use to provide accurate forecasting across the organization
Reduce (or eliminate) data quality mistakes and errors
Better align planning team to establish the approved work with scheduling team
Leverage key systems such as SAP as system of record
Reduce miscommunications
Integrated Scheduling & Planning
Best practices for improving resource utilization during routine and STO work types
Comprehensive project view with integrated dataComposite view including work, costs, and detailed schedulesReduce un-needed meetings, calls, emails, etc.Better data enables better decisions
Integrated Scheduling & Planning
Summary
Key Take‐Aways
Integrated scheduling and reporting can be improved and risks reduced with an integrated system approach
SAP PM – Primavera P6 integration can be delivered well, using the right solution, Pipeline Software
Save time and effort by using a packaged system for planning and scheduling integration
Integrated Asset Planning, Scheduling, and Reporting
Randy KauffmanBP Texas City Refinery
Justin TylerPipeline Software
jtyler@PipelineSoftware.com
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