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Presented by
Operational Windows
Strategy at PEMEX
Improving Operational
Safety & Reliability
Mr. Carlos Alberto Guevara Díez
© Copyr i gh t 2014 O SIs o f t , LLC .
Agenda
• Pemex at a Glance
• The Journey to Operational Windows (OW)
• PEMEX’s Operational Window Portal
• Examples & Video
• Results
• Next Steps
• Conclusion
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About PEMEX
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E&PGas & Pasic
Petrochemicals
Petro
ChemicalsRefiningCorporate
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• Single Operational Window (OW) for
all PEMEX refining
• Web- based, simple, prioritized
information presented in context
• Consistent KPIs to support continuous
improvement of efforts
• Improved yields, production, reliability,
and safety of refineries
Solution Results and Benefits
Implementing a Standardized Operational
Window (OW) at PEMEX Refining
Business Case
• Low performance in refinery
utilization, reliability, and yield
• Inability to share best practices
across refining division
• Inability to view entire PEMEX
refining value chain in real-time
• Expanded current PI System to
provide integration & applications
infrastructure elements
• Used PI AF and PI WebParts as
foundational components
• Developed web based Operational
Window (OW) that for PEMEX access
“We have implemented a proof of concept for a web based
Operational Window (OW) that provides system wide KPIs and
operational windows for critical assets and refineries. The initial
results have been indicate “game changing” potential for improving
asset reliability, safety, and performance with positive impact of
yield and production. The use of PI Asset Framework (PI AF) and
PI WebParts was foundational”.
Mr. Carlos Alberto Guevara Díez
Dirección Corporativa de Tecnología de Información
y Procesos del Negocio, DCTIPN. Pemex
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The Road to Improving Operational
Safety & Reliability
• Issues with Rising Maintenance and Safetycosts – 30% Avoidable Errors
• December 2012 – Launch of the OperationalWindows (OWs):
– Establish the proper operation of the main equipment
– Improve operational reliability.
• Issue of the PEMEX Reliability Manual
– Best Practices to prevent & eliminate defects throughproper use of the OWs
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An Operational Window – What is it?
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Upper
Operational
Limit
Lower
Operational
LimitS
ec
ure
op
era
tio
na
l R
an
ge
Operation is
in Steady
Stable, secure
and profitable
limits
Safe Range
Normal operational Range
Unsafe
Operation Unsafe
Operation
Operational Limits of a process variable
Risk
Level
Risk Level vs. Process Variable Limits
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Process for a Successful OWs Implementation
Critical
Equipment
Selection
Operational
Variables to be
monitored
Definition of the
OW limits
Management and
improvement
process
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Challenges to implement a OWs strategy
• Allowing Accountability of the operational staff in each sector and as a result allows the execution of preventive and corrective actions.
• Monitoring in an standardized manner at all refineries so all displays of the status of critical OWs for all different levels of equipment are the same.
• Conduct analysis showing the percentage of time that critical equipment is inside and outside safe ranges to help prioritize the require corrective action.
• Visibility. Show critical equipment which are constantly operating out of safe range and record why corrective actions have not been made to them or means to determine the cause of deviations.
• To have an approved platform, that is simple to operate, which contains uniform rules across the organization to determine the progress in the implementation and improvement of the OWs system.
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The strategy of OWs should have a tool that allows proper monitoring by:
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Operational Window Solution
The "Approved Display Platform for Operational Windows at Pemex" was created which was designed using the following products:
• PI Server
• PI Asset Framework (PI AF)
• Microsoft Visual Studio 2005 (To Implement Rollups)
• PI WebParts
• Microsoft SharePoint
Let’s take a look of the application….
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Standardized Real Time Portal at PEMEX
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All 4 PEMEX
Companies'
Metrics are
in a single
Portal
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Simple solution to standardize all KPI
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Process Variables
and all KPI
are presented &
calculated
in a standard
way using PI AF
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Use of Rollups for standard KPI aggregation
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“One ring portal to have them all…”
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A single detailed view for all equipment
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The Heart -- the OW Calculation
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360 solution – mobile included!!
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Demo video here…..
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ResultsThis project has allowed us to explore new solutions, ways to attack a problem in a holistic way, looking at all the possible angles that make life easier for operations personnel and has resulted in:
• Doubling the percentage of process variables "green" in less than 3 weeks of operation
• Building a system to monitor process conditions of over 2,600 variables
• A solution capable of monitoring process variables from operations, quality, power generation and any other areas to come in the future
• A certified, simple, easy ability to transport and adapt to other production processes
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Next Steps…..While we have achieved significant benefits we still have goals to achieve:
• Strengthen the use of the solution through internal marketing, video conferences and
constantly monitor the operating windows on field in conjunction with the business area.
• Improve the quality of information contained in the model (operating limits, setpoints,
text descriptions).
• Quantify the benefits obtained through the strategy OWs.
• Increase the functionality of the solution integrating some additional graphics detail
pages, setting response times and some other improvements to the navigation between
the different pages.
• Replicate this solution to all petrochemical complexes, gas processing complexes,
pumping stations, storage and distribution stations and generally to all centers where
there Pemex processes require monitoring and control.
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© Copyr i gh t 2014 O SIs o f t , LLC .
Carlos Alberto Guevara Díez
• Mtro.
• PEMEX
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