ERP at Kochi Refinery Ltd

A STUDY ON THE I.S. OF:

KOCHI REFINERIES LTD.AMAL ROY GEORGE AZRA SULTHANA DARSHANA K NEETHU ANN GEORGIE SARANYA RAJU

SAP-ERPSAP-ERP package was installed in KR in 2003 IS used prior to 2003

INGRES

Current headquarters in Mumbai.

ERPSoftware solution that address the

enterprise needs taking the process view of an organization to meet the organization goals and tightly integrating all functions of an enterprise.

SAP FEATURESDelivering role-based access to crucial data. Application and analytical tools Authorization management Segregation of duties through authorization

governance. Programming language - ABAP

3-TIER ARCHITECTURER/3 client-server three servers: Presentation server for GUI Application server for running business processes Database server for storing business data.

Database used by KRL is Oracle

SAP

SAP BASIS Basis is a business application softwareintegrated solution used for the administration of SAP system. Administration Maintenance Patch management

SAP FINANCIALS

SAP FI - which stands for Financial Accounting - is the SAP Module where regulatory or statutory data is tracked and managed. The SAP FI Module has the capability of meeting all the accounting and financial needs of an organization. It is within this SAP FI Module that Financial Managers as well as other Managers within your business can review the financial position of the company in real time as compared to legacy systems which often times require overnight updates before financial statements can be generated and run for management review. SAP FI module delivers your regulatory books of record , including General ledger Book close Tax Accounts receivable Accounts payable Asset Management (SAP AM) Consolidation Special ledgers

SAP HR MODULE

SAP HR stands for Human Resources and this is the module which helps you optimize your HR processes to attract, develop and attain the right people including Employment history Payroll Training Career management Succession planning

E-HRM IN KRLCONNECTIVITY THROUGH INTRANET

Cochin Refinery is connected with two

intranet services

Intralink (I-link) Local internet

I - LinkI link is known as the corporate link

It is available to all management staff and

clerical staff

Functions Of I- LinkGet latest news Files from different SBOs of the company Other sites include

Yuva march My Portal Win Service disk Employee services Standard information

Support TeamAudit Company secretary Corporate Planning ESE ERP QCC Strategy Eng Project

Site ContentPersonnel General Application Accommodation Asset Report E-leave

IS User HR administrator Line manager & Staff

Claims Medical On line administration Services Travel Transport Job Opportunities Holiday home

Forms online Greeting Web cast

Local Intranet

Local Intranet of Kochin refinery is called as KR and Me

It has the refinery highlights and also includes Public relation IS HR

Learning and Development Movement & Storage Procurement & Contract services

KR And MeIt also have

Application Zone Personal Information General Information Corner Health Zone

SAP SALES & DISTRIBUTION MODULE

SAP SD stands for Sales and Distribution and this is the module which is used to manage customer-focused activities, from selling to delivery, including RFQ Sales orders Pricing Picking ( and other warehouse processes ) Packing Shipping

PM MODULEPlant Maintenance or PM- is where you maintain your equipment. Eg. ,a machine, an oil rig etc Including : labour material down time, and outages

MM MODULEOne of the most important sap modules where mm is materials management underpins the supply chain including Requisitions Purchase orders Good receipts

Accounts payable Inventory management Master raw materials, finished goods etc

QM MODULEQM stands for quality management . It improves the quality of goods including Planning Execution Inspections Certificates

PP MODULEOne of the really big sap modules is production planning. it manages your production process including Capacity planning Master production scheduling Material requirements planning Shop floor

SD MODULE .one of the large sap modules is sales and distribution . it manages all the functions from order to delivery including RFQ(request for quotation) Sales orders Pricing Picking(And other warehouse processes) Packing Shipping

Kochi Refinery is implementing world - class technologies in its operations for improving its margins as well as to face the competition from other players . The Refinery has implemented the SPM facilities capable of receiving Very Large Crude Carriers (VLCC), along with allied facilities including shore tank farm. The facilities were commissioned in Dec 2007. The technology was provided by, M/s Blue Water Energy Services, Netherlands. The project helped BPCL-KR to obtain the benefits of the latest technological developments and advances in the filed of Crude oil procurement. The benefit derived out of this effort is cost reduction in crude oil transportation cost. Other major technology absorptions done at Kochi refinery in the last few years are as follows : FCC Feed Injection Technology, Riser termination Device, Packed Stripper (Stone & Webster) for yield improvement. Process technology for blocked out mode operation of VGO and Diesel in DHDS from M/s. Axens, France Process technology for sweetening (MEROX) of catalytically cracked gasoline from M/s UOP, USA Colloidal Mill technology for production of Bitumen Emulsion from M/s. ENH Engineering, Denmark. DHDS Reactor catalyst change to new generation HDS catalyst supplied by M/s Axens, France in Dec 2006 to produce Low Sulfur Diesel for meeting the Euro III Diesel demand. A new Bitumen Blowing unit using Biturox technology from M/s Poerner Ingenieurgesellschaft MBH, Austria.

ADVANCED DOCUMENT MANAGEMENT SYSTEMThis super script expertly programmed in PHP is a web based document managed system featuring fine grained control of access to files, and automated install and upgrades. KRL uses ADMS for : Storing and accessing; Plant Flow Diagrams Equipment Diagrams Edition possible by authorized personnel Useful during Repair, Maintenance and Renovation. Uses the application software- Humming Bird Enterprise Webtop

Kochi Refinery divided its IT initiatives into a three-pronged strategy it planned to create a communication network within the organization to create a basic information network for the entire corporation to process transactions with customers all over the country.

VPN FROM CISCOBy installing a VPN connection from Cisco,

Kochi refinery has benefited considerably, from faster deployment, to providing its partners with a cost-effective and secure gateway for business transactions

Cisco's VPN solutions have made it possible for

Kochi Refinerys partner locations to access the company's SAP servers for online business functions such as order entry invoice generation etc at almost zero running-cost. "Currently VPN is being used by 130 users from 110 locations across the country for carrying out SAP transactions. Most of these users are its partners. Eg) A few mobile users of refinery are also using it

WHY VPNat KR will offer services to its mobile The SAP platform

teleworkers and its other operating locations as fallback connectivity. Further, these partners will get access to the KR Intranet for online business functions such as order entry and invoice generation as well as back up access to the Intranet.

KR wanted a cost-effective technology and they

evaluated various options like VSAT and leased line connections. They had remote locations to be connected that didn't have the need to be connected throughout the day. Therefore a VPN solution appeared useful.

The VPN will enable any of KRs partners to use the

Internet as a cost-effective transport mechanism to become a part of KR's extended secure infrastructure. The process of setting up such a connection was accomplished by installing a software VPN client on the PC or notebook. At the central site in Mumbai, a VPN concentrator has been installed on a 2 Mbps Internet link, which is connected through a firewall. PCs at remote locations have Cisco's VPN client software installed. This software came with the central office's VPN concentrator

VPN PREFERRED OVER OTHER DEDICATED MEDIA Availability of dedicated media at remote places-in most

remote places telephone exchanges do not have equipment to support leased/ISDN lines. Longer commissioning time of any dedicated media Higher cost of operations of dedicated media Low bandwidth requirements at these remote locations Limited uptime Faster rollout of SAP was required at these VPN locations.

Meridiums Inspection Management System TCS is helping Kochi refinery to implement

Meridiums Inspection Management System (IMS)

This will be inteMeridiums Inspection Management System integrated with the existing SAP system.

The IMS system will enable risk-based inspection

prioritizing the failure potential of assets based on criticality and impact on the business

With the integration, a regular

recommendation management from IMS to SAP will be generated which will in turn generate notification to users for creating work orders.

Once closed, the work orders can be

updated in both the SAP and the Meridium system

BENEFITS With the implementation of Meridium, Kochi

refinery will get a complete IT-based inspection management and Risk Based Inspection systems. The solution is expected to Optimize maintenance cost and enhance the maintenance performance

Enhance inspection performance and data

recording practices

Move from manual to IT enabled inspection

management and decision processes for asset maintenance/replacement

Improve decision making during inspections

and Maintenance

Improve safety and environmental performance