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
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– – –
– – – – – – – – – – –
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