Nexus Transforms Legacy Data for U.S. Refinery’s SAP S4 Migration

Detailed refinery data transformation enables system standardization and operational efficiency during CMMS migration. 

Overview:

A major refinery in the U.S. Midwest faced a critical challenge during the transition from its legacy Computerized Maintenance Management System (CMMS) to a new enterprise-wide SAP S4 CMMS.

This effort required a comprehensive refinery data migration to SAP S4, ensuring alignment with enterprise standards and optimizing operational efficiency. In addition, the transformation tackled unique structural challenges within the refinery’s legacy systems.

Nexus Engineering Group (Nexus) took on the complex scope of work, leveraging its expertise and deep familiarity with the refinery site’s systems and operations. As a result, the successful completion of this data migration project marks a pivotal step in the refinery’s transition to a more modern, efficient, and scalable system.

By creating more structure around equipment management, the SAP S4 CMMS will enable the refinery to track the lifecycle of equipment more accurately, improving maintenance practices and reducing downtime.

Aligned with the refinery’s commitment to fiscal responsibility, the support delivered by Nexus has positioned the refinery to operate more efficiently, reduce costs, and drive informed decision-making.

Challenge:

The refinery’s legacy data structure posed a challenge for the migration effort. Unlike more straightforward data migrations, this refinery data migration to SAP S4 required meticulous transformation of existing data objects, including the creation of new functional location (FLOC) levels that had not previously existed.

Furthermore, compounding this challenge was the need to audit existing Piping and Instrumentation Diagrams (P&IDs) to capture all current data and identify any outliers that were not reflected in the legacy system. The effort was immense, as over 40,000 pieces of equipment and instruments required cleansing, building, and/or development to align with enterprise standards.

Given the complexity of this SAP S4 migration effort, it demanded a partner with an in-depth understanding of the refinery’s operations and expertise in tools like Maximo, Masterkey, and Client Document Management Systems (CDMS). Nexus, with extensive site familiarity and technical expertise, was uniquely positioned to meet the demands of this transformation.

Solution:

Nexus’s Data Solutions Team partnered closely with the refinery’s resources, acting as an extension of the client team to ensure a smooth and accurate refinery data migration to SAP S4.

Using the Masterkey data staging platform, Nexus transformed legacy data into the enterprise-standard format, while ensuring compatibility with SAP S4.

Key aspects of the solution included: 

• Auditing and Hierarchy Development: Nexus conducted a thorough audit of existing P&IDs to capture all current data and identify outliers. From this effort, a comprehensive hierarchy system was developed, creating new FLOC levels and mapping all equipment and instruments appropriately to ensure alignment with both the enterprise-standard structure and site configuration of the refinery.  

• Collaborative Execution: Engaging with the client’s maintenance and operations teams to verify transformed data and ensure alignment with operational goals.  

• Site-Specific Expertise: Drawing on extensive knowledge of the refinery’s historical systems, documentation, and workflows to create new FLOC levels and accurately transform data.  

• Comprehensive Tool Utilization: Leveraging tools such as Maximo, CDMS, and Masterkey to gather and validate the required background information, and Syniti to support data migration efforts.  

With Nexus’s support, the project is progressing toward completing the data transformation, enabling the refinery’s transition to SAP S4. The project improved data integrity and consistency, supporting the broader enterprise initiative for system standardization and operational efficiency.

As a result, the transition simplifies equipment tracking and management, providing the refinery with a more streamlined and efficient platform. This refinery data migration not only resolves immediate challenges but also creates a strong foundation for long-term growth and operational excellence.

Furthermore, Nexus’s collaborative approach and deep understanding of refinery operations have reinforced its reputation as a trusted partner for high-value data solutions. By successfully completing the refinery data migration to SAP S4, Nexus has enhanced system integration and positioned the refinery for sustained success.