Transcript Slide 1

Our Journey with
The New Zealand
REFINING COMPANY LTD
Company Introduction
• New Zealand’s only Oil Refinery
• Publicly traded Company
– 75% owned by the four major oil company’s
(BP, Caltex, Mobil, Shell)
– 25% owned by public
• Approximately 300 staff
• Tolling operation - do not own any Hydrocarbon Stock
• Income is generated via a processing fee
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
2
Company Introduction
• Located 150kms north of Auckland
Marsden Point
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
3
Company Introduction
Regional Petroleum Product Demand
Japan
5.0 mbd
East Asia
15.1 mbd
Australia
0.85 mbd
New Zealand
0.15 mbd
South Asia
3.2 mbd
Total Regional Demand 24.3 mbd
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
4
What was before PI?
• PROSS II (Process Supervisory System) – Shell Oil USA
• 5 * Digital VAX/VMS mini-computers
• VT220 Terminals & Ramtek Touch Screens
• History retention was very limited
• Needed a team of 3 staff to maintain it
• All Configuration of Tags, Reports and Graphics had to be
done by PROSS team.
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
5
Why PI?
• PROSS II was hard to maintain and getting old
• Maintenance on the PROSS system $250K pa
• Replacement parts for Ramtek monitors hard to source
• Very hard to get data from PROSS to Excel
• Graphics only available in Control Room
• User friendly Interface
• History retention was excellent
• Without PI the HIP Project would not proceed
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
6
What is HIP?
• Hydrocarbon Integration Project
• NZD $11.5 Million
• >60,000 person hours
• 25 Individual projects
• 36 months duration
• Its aim was for information to be freely available instantly
to all parties in the supply chain
• We needed a single source of Data
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
7
What is HIP?
Refinery Steering Instructions
Economics
Crude Assay Library
Data Generation
GEMMS
Nominations
IMPRESS
Oil Accounts
BLISS
Receive
HDIS
Refinery Steering Instructions
MPMP (Blend Optimiser)
Economics
Nominations
BLISS
Produce
Blend
Business Objects
PI
Distribute
Site Balancing
Information Architecture
BLISS
Rigorous Models
IMPRESS (Refinery Schedule)
Refinery Steering Instructions
Nominations
RAPsody (II)
Oil Accounts
Refinery Steering Instructions
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
8
IT Architecture
420+
P4 PCs
30 * Servers
(Win 2k & 2k3)
Internet
RIN
Other Databases
•Staff Administration
•Incident Analysis
•Maximo
•Oracle Financials
PI
BLISS
HDIS
Hydrocarbon Databases
OPC Scanners
PIN
TDC3000 LCN(s)
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
9
Our Original Configuration
• PI-Server 3.0 Installed early 1996
• Digital AlphaServer 1000 4/200 Mhz
• Operating on Digital Unix 3.2C
• 128MB Ram
• Data storage 16 GB (RAID 5)
• Application space 2 GB (RAID 0)
• 20,000 Point License
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
10
Going Live Experiences
• We were bleeding edge
• Acceptance testing failed due to performance problems
• Tech Support used, put straight on to Developers
• Problems solved very quickly
• Once rolled out, Very fast User Acceptance
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
11
Our Big Move from Unix
• Easier that expected as we did not know what to expect 
• Installed PI-Server on new Win2K Server
• Copied PI Archives from Unix Server
• Copied PI Configuration files from Unix Server
• Started System on different platform
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
12
Our Current Configuration
• PI-Server UDS 3.4.364
• Windows Server 2000 SP4
• Dual 933Mhz CPUs
• 512Mb RAM
• Data storage 200 GB (RAID 5)
• O/S & Application space 8 GB (RAID 0)
• 50,000 Point License
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
13
Our Future Configuration
(Currently in test – go live next 6 - 8 weeks )
• PI-Server UDS 3.4.364
• Windows Server 2003 SP2
• 3.2Ghz CPUs
• 2Gb RAM
• Data storage 200 GB (RAID 5)
• O/S & Application space 30 GB (RAID 0)
• 50,000 Point License
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
14
Current Standing
• 26873 tags in system, made up of
• 2649 Calculations / Totaliser / PI-MCN
• 6058 Laboratory / Manual Entry Data
• 17820 Scanned Process Data
•
352 Download Tags
• Scanning 1 minute with 15 & 30 Seconds
• Some downloading of Data to Honeywell DCS
• > 1000 PI-ProcessBook files
• > 150 Corporate Excel reports using PI-Datalink
• 11 Years On-line Data (76 GB Storage)
• Archives growing at a rate of 1.2GB per month
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
15
Current Standing (Con’t)
•
•
•
•
•
•
•
PI-ProcessBook 3.0.15
PI-Datalink 3.1.5
PI-ODBC 1.2
PI-OPC Scanners
PI-SQC
PI-Batch
PI-SMT
• PI-MCN
• PI-Perfmon
• PI-Ping
• PI-SNMP
• PI-TCPResponce
• PI-Interface Status
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
16
Graphics
Graphics in the early Days
Current Graphics
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
17
Graphics
One of our most important Graphics
if you are a boatie
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
18
Reporting / Manual Data entry
Operator Manual Data Entry
Laboratory results
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
19
Plans for the Future
• PI-ACE
• PI-Maximo Interface
• New Plant being built so more Tags, Graphics &
Reports required
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
20
User Comments
“The problem with assessing the usefulness of PI, is that it is so
embedded, we would find it hard to imagine life without it. “
D. Keat - Refinery Manager
“Very powerfull Online viewing window into the
process from our desktops. ”
R. Patterson - Asset Manager
“Very powerful tool, allowing us to make informed
and quick decisions. ”
B. McRae – Processing Planner
“PI is now an integral part of our work process,
not only to view historical data but also as a data provider to most
business applications."
P. Smit – Head of Process Control
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
21
Conclusions
• Use Tech Support they know their stuff
• Best Customer Service I have come across
• Stable Products 
• Friendly Staff
• Value for Money
• Use the Tools!
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
22
Questions
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
23
Contact Details
[email protected]
www.nzrc.co.nz
The New Zealand
REFINING COMPANY LTD
Copyright © 2007 OSIsoft, Inc. Company Confidential. All rights reserved.
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