Data involved in capital projects. Data Quality Symposium Clem Swanepoel

Data involved in capital projects Data Quality Symposium Clem Swanepoel Agenda     Sasol Context Sasol Challenges ISO standards Cataloguing at ...
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Data involved in capital projects Data Quality Symposium Clem Swanepoel

Agenda    

Sasol Context Sasol Challenges ISO standards Cataloguing at source

The Sasol Business . . . Sasol Limited is an innovative and competitive global energy company. World-leading technology for the commercial

production of synthetic fuels and chemicals. A workforce of 30 000 in exploration, mining, science, technology R&D and business development. Listed on the Johannesburg Securities Exchange (JSE), symbol SOL and the New York Stock Exchange (NYSE), symbol SSL. Almost 50 entities in The Americas, Australasia, Europe and Africa

A code of shared values that mould Sasol into one powerful global brand Total Turnover FY 2008: > R 110 billion

3

Secunda Complex

Sasol’s Diversification strategy has pushed Sasol into new Geographies and Businesses … Growth focus in 3 areas through JVs Commercialise and expand our gas&coal-to-liquids (GTL&CTL) conversion technologies Exploit upstream hydrocarbon opportunities Grow our chemicals portfolio Relative size

Key Characteristic

1998

2003

2008

5

Sasol at a glance – Significant Capital expansion Russia

Alaska

Russia

China

Qatar USA

Trinidad and Tobago

Qatar Trinidad and Tobago

Nigeria

China

India India

Malaysia Malaysia

Nigeria

South Africa

South Africa

Papua N Papua NewGuinea Guinea

GTL GTL GTL CTL CTL

GTL GTL GTL CTL CTL

investigation construction operation investigation operation

investigation construction operation investigation operation

Australia

Australia

Leveraging Operational data for Capital Projects FINANCIALS

ANALYTICS

MATERIALS & SERVICES MANAGEMENT

BILL OF MATERIALS

OPERATIONS SUPPORT

WAREHOUSE MANAGEMENT

Existing Plant Operations

Re-use past performance standards

EPC

Logistics Information System

Production Planning & Scheduling System

Plan Plan

Plant Information Management System

Design Design

Build Build

Customers

Suppliers

Enterprise Resource Planning

Maintenance Management System

Commission Commission

New Expansion

Capital Projects EQUIPMENT LISTS

P&ID

SPIR LISTS

BOM’S

START-UP SPARES

STEP

Information Architecture: Information equip lists

schemas

Benefits

spec’s

P&ID

DATA

bom’s

that is complete, reliable, accurate and timely

inventory mr preventative maint

shut downs

perf hist

critical spares

sr stock levels

vendor performance

Appropriate stock levels ? Maintenance schedules ?

Improved Raw Material Selection Improved Process Operations Improved Strategic Sourcing Reduced time to Operate

when integrated turns to

that when easily accessed in the required form at the right time

INFORMATION provides

KNOWLEDGE which leads to

WISDOM

regarding what is happening and why it is happening

to solve operating problems, improve operations and make better operating and business decisions

Defining International Data requirements ISO 15926; 13584; 10303 Oil and Gas Production facilities - ISO 15926

STandard for the Exchange of Product model data (STEP) - ISO 10303







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The purpose of ISO 15926 is to facilitate integration of data to support the lifecycle activities and processes of production facilities (Oil & Gas). It is a representation of information associated with engineering, construction and operation of oil and gas production facilities, supporting: Information requirements in all life-cycle phases sharing and integration of information Each participating computer system maps its data from its internal format to such ISOstandard Node and Template instances. Data can be "handed over" from one Façade to another in cases where data custodianship is handed over





 –

Parts Library (PLib) - ISO 13584

 The STEP exchange protocol 13584-102 specifies how various representations of the parts defined in a PLib-compliant library may be represented, and exchanged, as STEP AP conforming files. Examples of AP’s include Plant Spatial Configuration (AP227) and Product Life Cycle Support (AP 239: PLCS). It specifies how such STEP files may be referenced from the PLib library file. Thus, each part of a family of parts defined in a PLib library may be associated with explicit representations defined by any STEP Application Protocol. Exchange data between Cax applications. Native Source to Neutral ISO 10303 ASCII to Native Receiving system

 – – –  – – 

The goal of the PLib standard is to define a neutral format for the representation of pre-existing components, thus providing for exchanging parts libraries between heterogeneous systems. Description of supplier part library structure Information hierarchy Supporting automatic integration into user libraries Supplier codes Representations of lists of “similar parts” - related by geometry, part of same product, etc defined explicitly or implicitly dictionary data exchange (developed jointly with IEC) Multiple information views

Use of ISO 10303 AP227: Plant Spatial Configuration

Plant Item • Type • Connections • Functional/Physical • Definition/Occurrence

Plant Layout • Location of Plant-items • Site Description • Change Control

Shape

Plant Systems • Line Definitions • Composition • Capabilities • Component Connectivity

Functional/Analysis • Interference • Performance Requirements • Requirement Satisfaction

• Explicit Shape • Brep • CSG

Defining International Data requirements ISO 8000; 22745 Industrial Data Quality – ISO 8000

 – –

–  – –

– – –  – – – – – – – –

Open Technical Dictionary (OTD) - ISO 22745

ISO 8000 is concerned with:  ISO 22745, Open technical dictionaries and their application to master data, is a system of the principles of data quality; descriptive technology used to create unambiguous, the characteristics of data that determine its language independent descriptions of individuals, quality; organizations, locations, goods, and services. the processes to ensure data quality Arising out of the logistics world, the standard Components of ISO 8000 defines the requirements, data model and XML exchange formats Part 100: Master data: Overview Master Data Part 110: Master data: Specifies general, syntax, Dictionary (Catalogue) ISO 22745-10 semantic encoding and data specification is coded using concepts in ISO 22745-40 requirements for master data messages between organizations and systems constrains conforms Part 120: Master data: Provenance the use of to the Part 130: Master data: Accuracy constraints in Identification Part 140: Master data: Completeness Guide Master data describes individuals, organizations, ISO 22745-30 locations, goods, services, rules and regulations Customers  The standard also includes a web services interface Suppliers for searching an open technical dictionary Materials Services Assets Locations MSDS ISO TC184/SC4 is developing standards which provide ……… capabilities to describe and manage industrial product data throughout the life of the product

Defining International Data requirements (As-Is) ISO 8000 Data Quality ISO 8000-110

Specifies general, syntax, semantic encoding and data specification requirements for exchanging master data between organizations and systems

ISO 22745

ISO 10303 (STEP)

AP 203: Configuration controlled design AP 210: Electronic assembly, interconnection, and packaging design AP 212 Electrotechnical design and installation AP 227: Plant spatial configuration AP 239: Product life cycle support

SmartPlant

Industrial terminology

Standard for software neutral exchange of product model data. Typically CAx type data exchange:

Collaborate / Visualise (XML) ISO 22745 Characteristic data Requirements, query and exchange

ISO 15926

ISO 13584 (PLIB)

Standard for Oil and Gas process plant life-cycle data integration, sharing, exchange, and hand-over between computer systems

Standard for representation and exchange of libraries of parts.

eOTD

Sasol Ramis

Characteristics of individual items used in the plant

Defining International Data requirements The question for Sasol is not to ask how all these standards impact on Sasol, but rather to define which standard to use in collaborating with the EC / EPC / IPC / CPC on data acquisition during capital projects Projects Operations ISO 8000 Data Quality ISO 8000-110

Specifies general, syntax, semantic encoding and data specification requirements for exchanging master data between organizations and systems

ISO 22745 ISO 10303 (STEP)

ISO 13584 (PLIB)

ISO 22745

Standards

Standards

Data & Exchange

Data & Exchange

Industrial terminology

Standard for software neutral exchange of product model data. Typically CAx type data exchange: AP 203: Configuration controlled design AP 210: Electronic assembly, interconnection, and packaging design AP 212 Electrotechnical design and installation AP 227: Plant spatial configuration AP 239: Product life cycle support

ISO 29002

Collaborate / Visualise (XML)

ISO 29002

ISO 22745

Standards

Characteristic data Requirements, query and exchange

ISO 15926

ISO 13584 (PLIB)

Standard for Oil and Gas process plant life-cycle data integration, sharing, exchange, and hand-over between computer systems

Standard for representation and exchange of libraries of parts.

eOTD

Sasol Ramis

Characteristics of individual items used in the plant

ISO 13584 (PLIB)

ISO 22745

Data & Exchange

Data & Exchange

STEP

Sasol Smart Plant

eOTD

Sasol Ramis

EC contractual obligations ISO 8000 / 22745 – Data Quality : Buyer contract clause

 The contractor, sub-contractor or supplier shall supply technical data in electronic format on any of the items covered in this contract as follows:  The data shall be certified as ISO 8000-110 compliant.  The data shall comply with applicable ISO 22745-30 compliant Identification Guides.  The data shall be encoded using concept identifiers from the ECCMA* Open Technical Dictionary (eOTD), an ISO 22745 compliant open technical dictionary.  The data shall be provided in eOTD-r-xml, an ISO 22745-40 compliant Extensible Markup Language (xml) format published by ECCMA*. * ECCMA (www.eccma.org) is the Dictionary Maintenance Organization for the eOTD, a compliant open technical dictionary as defined by ISO 22745 and can provide technical assistance in meeting this requirement.

ISO 8000 -110: Master Data Quality – Motivation

 Suppliers and Manufacturers recognise that:  data integration is one of the keys to a long term relationship  the ability to provide their customers with quality data is a significant differentiating factor.  Suppliers and Manufacturers are:  publishing the specifications of their products, capabilities and services on their web sites.  looking to increase their visibility and understand that the best way to do this is to improve the quality of their data. Suppliers and manufacturers are looking for a Standard that they can use to identify the quality of their data

Data Acquisition Needs The Value of Planned Data Acquisition

Sourcing

PM Equipment Functional Locations BoM’s Maint Tasks Task BoM’s

Operational Procurement

Proc strategy Price Lead time Vendor Master

DOC Eng Drawings Data Sheets O&M Manuals

ROP Criticality ABC analysis Strategic spares Contracts Mat type

Warehouse Management

Inventory

Capital Project Procurement

MRP

MM PO Text Mat Group, Standardization Bin location Preservation QA strategy

FIN Valuation class Costing

Data Acquisition Needs Utilising a structured Process to gain the required Deliverables

Master Data Material Master

Spares Acquisition

Asset Data Acquisition

Engineering Design

Equipment Master BoM’s

Master Data Strategies Identification of MD Requirements Identification of MD Sources Creation of Baseline

Vendor Master Inventory Classification

Expediting of Master Data Creation and Upload of Master Data

Manage and Control Master Data Review and Approval of Master Data Feedback !!!

Procurement Functional Locations Maintenance Tasks

Upload of Master Data to ERP The Processes The Deliverables

Master Data hand over - project to operations Enterprise Resource Planning Plan Plan

Design Design

Build Build

Acquisition

Commission Commission

Maintenance Management System

Production Planning & Scheduling System

EQUIPMENT LISTS

P&ID

SPIR LISTS

BOM’S

Logistics Information System

Maintenance

MASTER DATA MANAGEMENT

Capital Projects

Plant Information Management System

Existing Plant Operations FUNCTIONAL LOCATIONS

Manage the following: • Supplier Master • Material Master • Equipment Master • Equipment BoM • Procurement Data • Inventory Data

START-UP SPARES

VENDOR MANAGEMENT

STRATEGIC SOURCING

WAREHOUSE MANAGEMENT

P&SM PLANT OPERATIONS

PLANT MAINTENANCE

OPERATIONS OUTBOUND LOGISTICS

SUPPLY CHAIN

SALES & MARKETING

The Benefits of a structured Spares Management Process  Single point of entry and exit for all Project Spares Data within multi Plant       

Project. Centralisation of all SPM functions in a single system maintains control over Master Data and Spares. Workflow ensures visibility and approval of data by responsible personnel. Integration with PM module saves time, effort and costs relating to ERP Master Data Acquisition. Procurement and receiving of Spares carried out in same system. Optimise inventory qty’s ordered before procurement process commences, optimisation can be relative to existing MM inventory. Control Project Spares spend interactively. Cut Project Spares spend by at least X%.

Way Forward    

Structured master data collection methodology Gain alignment with project/engineering managers Ensure required clauses are contained in EC / EPC / IEC / CEC contracts Get systems in place