ev intelligent dvr solutions refining

7/29/2019 EV Intelligent DVR Solutions Refining

1/34

5th AnnualGlobalRefiningSummit2011

May18 20,2011 Rotterdam,Netherlands

IntelligentDataValidationand

ReconciliationSolutions

for

the

RefiningIndustry

Mihaela Cristina Po escu Head of Performance

Dr.RobertoLinares,VicePresident,VisiantPimsoft

Control,Arpechim

Refinery,

OMV

Petrom


2/34

Topics

BusinessPerformanceAspectsinRefining

ProductionAccountingandDataReconciliation

PowerfulDataReconciliationConcepts

YieldAccountingManagementPresentedby

Conclusion

Visiant

Pimsoft

Inc.

2011

Allrightsreserved.2Global

Refining

Summit

Rotterdam,May18,2011


3/34

BusinessPerformanceAspectsinRefining

Operational

o Yield Recover Qualit Tar ets

o ProductionRates

o ProcessConstraints(e.g.,environmental,physicallimitations)

o BestOperationalParameters(e.g.,LPs)

o Comparisonof

Planned

vs.

Actual

Financials

o MaterialLoss

o InventoryPositions

o Taxes(e.g.,domesticvs.foreign)

Visiant

Pimsoft

Inc.

2011


Refining

Summit



4/34

MarketDrivers

Environmental(GHG)

YieldAccountingStandards

o

RefiningMargins

Theidealplatformfordatavalidationhastocomplywithemergingregulationsintherefiningindustry.

Visiant

Pimsoft

Inc.

2011


Refining

Summit



5/34

RefiningCase

SourceofInformation

o

o OilMovement

System

(OMS)

o LIMS

BusinessRules

o VCFaccordingtoAPI2004

o OwnershipTracking

o Foreignand

Domestic

Tracking

o MassBalance

Visiant

Pimsoft

Inc.

2011


Refining

Summit



6/34

RefiningCase

Integration

o

o Integrationof

OMS

and

VPS

data

into

Production

AccountingSystem

Reporting

o Excelbased

for

Production

Accountants

o Formaland/orWebbasedforRefineryUsers

o AutomaticReportingforMeasuredInformation

Visiant

Pimsoft

Inc.

2011


Refining

Summit



7/34

SolutionMap

DataFlowforRefiningCase

HistorianExcel

Sigmafine

OMS

Reports

VesselPositioning

Aggregation/Integration

SQLAccess

ReportLogic

Web-basedReportsRules

System

Visiant

Pimsoft

Inc.

2011


Refining

Summit



8/34

ProductionAccountingSolutionIntegration

Process Data Lab DataMovements

RecordsPlanning

DataSchedulingInformation

Visiant

Pimsoft

Inc.

2011

Allrightsreserved.8Global Refining Summit

Rotterdam, May 18, 2011


9/34

SolvabilityandRedundancyMaximizin the Power of Your Measurements

Sigmafineperformsflowssolvabilityanalysis.

R Theflowisredundant,soitisbothmeasuredandsolvable. , .

S The

flow

is

not

measured,

but

it

is

still

solvable. NS The flowisnotsolvable.

S SR R

NR

S SR R

NRNR

S SR R

NRNR

SS SS

thebetter.Thisway,

morevaluesmaybe

crosscheckedto

thebetter.Thisway,

morevaluesmaybe

crosscheckedto

SSS ..

Visiant

Pimsoft

Inc.

2011


Refining

Summit



10/34

SolvabilityandRedundancyMaximizin the Power of Your Measurements

Sigmafineperformsflowssolvabilityanalysis.

R Theflowisredundant,soitisbothmeasuredandsolvable. , .

S The

flow

is

not

measured,

but

it

is

still

solvable. NS The flowisnotsolvable.

S SR R

NRR

S SR R

NR

S SR R

NR *Byaddingameter*Byaddingameter

S*R SS

totheflow,theflow

becomesredundant.

Asaresult,other

meteredflowsalso

totheflow,theflow

becomesredundant.

Asaresult,other

meteredflowsalso

SSS becomeredundant.becomeredundant.

Visiant

Pimsoft

Inc.

2011

Allrightsreserved.10GlobalRefiningSummitRotterdam,May18,2011


11/34

Reconciliation

54.2

..

44.2

Visiant

Pimsoft

Inc.

2011



12/34

OptimalUtilizationofExistingMeters

Non RedundantNetwork

AccurateMeter

Redundant Network

AccurateMeter

AccurateMeter

Visiant

Pimsoft

Inc.

2011



13/34

ErrorDetection

Non RedundantNetwork. There is noossibilit ofdetection

Accurate

failure

Redundant Network.An imbalance can be

Visiant

Pimsoft

Inc.

2011


Refining

SummitRotterdam,May18,2011


14/34

MeterPerformance

Pure Gas E

C0F1230.AD

C0F1230.SF

B2F1003.AD1400

1600

17501649.4

Not Reconciled

C0F1230.AD

C0F1230.SF

B2F1003.AD

Pure Gas W

20F0101.AD

20F0101.SF

12F1003.AD1400

1600

17501571.4

Not Reconciled

20F0101.AD

20F0101.SF

12F1003.AD

B2F1003.SF

B2F2003.AD

B2F2003.SF

F0F1013B.AD

F0F1013B.SF400

600

800

1000

1200.

Not Reconciled

402.47

Not Reconciled

19.939

Not Reconciled

B2F1003.SF

B2F2003.AD

B2F2003.SF

F0F1013B.AD

F0F1013B.SF

12F1003.SF

12F2003.AD

12F2003.SF

F0F1013A.AD

F0F1013A.SF400

600

800

1000

1200.

Not Reconciled

428.68

Not Reconciled

0.

Not Reconciled

12F1003.SF

12F2003.AD

12F2003.SF

F0F1013A.AD

F0F1013A.SF

Bias

02-Sep-01 00:00:00 11-Dec-01 14:02:54100.59 Day(s)

200

0

11-Nov-01 00:00:00 11-Dec-01 14:02:5630.59 Day(s)

200

0

SLO East

C0F1109M.AD

ton/h

C0F1109M.SF

250

89.787

C0F1109M.AD

ton/h

C0F1109M.SF

SLO West

20F1109.AD

m3n/h

20F1109.SF

250

99.745

20F1109.AD

m3n/h

20F1109.SF

Drift

ton/h

C0F1116M.AD

ton/h

C0F1116M.SF

ton/h

C9F1004.AD100

150

Not Reconciled

76.712

Not Reconciled

181.66

ton/h

C0F1116M.AD

ton/h

C0F1116M.SF

ton/h

C9F1004.AD

m3/h

20F1116.AD

m3/h

20F1116.SF

m3/h

29F1004.AD100

150

Not Reconciled

89.789

Not Reconciled

192.7

m3/h

20F1116.AD

m3/h

20F1116.SF

m3/h

29F1004.AD

02-Sep-01 00:00:00 11-Dec-01 14:03:04100.59 Day(s)

m

C9F1004.SF

m3/h

50

0

Not Reconciled

m

C9F1004.SF

m3/h

02-Sep-01 00:00:00 11-Dec-01 14:03:05100.59 Day(s)

m

29F1004.SF

m3/h

50

0

Not Reconciled

m

29F1004.SF

m3/h

Meter

Error

Visiant

Pimsoft

Inc.

2011


Refining



15/34

OptimumMaintenanceofRefineryMeters

Visiant

Pimsoft

Inc.

2011


Refining



16/34

ImprovingtheOverallPicture

30%

Overall DX1 Trend ( Q4 2008 - Q1 2010)

25%

15%

5%

0%

Visiant

Pimsoft

Inc.

2011


Refining



17/34

OilLossMonitoring

Meter ImprovementsMeter Improvements

BetterBetter

VisiantPimsoftInc.2011


Refining



18/34

OilLossMonitoring

Loss Accountability

3

45

Loss Accountability

Sigmafine available

0

1

2

(%)

-3

-2

-1

-04

-04

-04

-04

-04 -0

4-05

-05

-05

-05

-05 -0

5-06

-06

-06

-06

-06 -0

6-07

-07

-07

jam

a

m

a ju

se

n

o jam

a

m

a ju

se

n

o jam

a

m

a ju

se

n

o jam

a

m

a



Refining



19/34

OilLossMonitoring

Mass Balance Before SigmafineFeb/01 - J an/02

(Loss % Cumulative = 1.09%)

4.0%

6.0%

8.0%

10.0%

-6.0%

-4.0%

-2.0%

0.0%

.

Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan

Oil loss (%) After Sigmafine Implementation

SF Losses

1.081.001.20

0.230.12

0.48

0.30

0.53

0.00

0.20

0.40

0.60

0.80

%

Benchmark

J un/02 J ul/02 Aug/02 Sep/02 Oct/02 Nov/02

SF monthly SF cumulative



Refining



20/34

CustodyTransferErrorDetection


Allrightsreserved.20Global Refining SummitRotterdam, May 18, 2011


21/34

AccountingFuelConsumption

4,500

5,000

FuelConsumption,Oct2010

3 000

3,500

4,000 Sigmafine

2,000

2,500

500

1,000

1,500

Legacy

1Oct

2Oct

3Oct

4Oct

5Oct

6Oct

7Oct

8Oct

9Oct

10

Oct

11

Oct

12

Oct

13

Oct

14

Oct

15

Oct

16

Oct

17

Oct

18

Oct

19

Oct

20

Oct

21

Oct

22

Oct

23

Oct

24

Oct

25

Oct

26

Oct

27

Oct

28

Oct

29

Oct System




22/34

MonitoringRefineryPerformanceValidation of KPIs

RunningPlan KPIs

Current/Shift/Running PlanReconciled vs. Theoretical Yields




23/34

PerformanceMonitoring

ReconciledYields

TheoreticalYields




24/34

IncreasingYieldProfitability

Exampleofdieselyieldimprovements

2003actual

average

diesel

yield 37,4%

2004actualaveragedieselyield 39,6%

o Averageactualdieselyieldincreasedduebothtoinvestmentson

plantsandtoperformancemanagement.

o Historicalanalysis

on

diesel

yield

showed

that

the

average

increase

uetoper ormancemanagementamountwasa out0.8%int e

period20032004.

o ThisledtoaprofitincreaseestimatedinUS$1 millionperyear.


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24Global Refining SummitRotterdam, May 18, 2011


25/34

LowYieldDetectionAfterCatalystImprovement

Data Quality Improvement: Profits

Mass balance yield - FCC (Fluidized Catalitic Cracking Unit)

110 *Data reconciliation group identifiedLCO flow meter fault

*Durin this eriod it was believed

100

105

yie

ld(%)

that LCO yield had increased.

Flowmeters maintenance

90

95

assbalance

Unit shut downDifferent catalyst loaded

required by reconciliation group

**LCO flow meter repaired**Actual LCO ield e ual to the value

80

85

- - - - - - - - - - - - - - - - - - - -

previously to the catalyst change**Lower light HC and more decantedLower light HC and more decanted

oiloil produced =produced = Less profitsLess profits


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25Global Refining SummitRotterdam, May 18, 2011

Date


26/34

LowYieldDetectionAfterCatalystImprovement


Eliminated loss corresponding toUS 23.5 million er ea

M a s s b a l a n c e y i e ld - F C C ( F lu i d iz e d C a t a li t ic C r a c k in g U n i t)

1 1 0 *Data reconciliation group identified LCO

flow meter fault*

9 5

1 0 0

1 0 5

balanceyield(%)

LCO yield had increased.

Flow meters maintenance requiredby reconciliation group

8 0

8 5

9 0

28 -0 1-2 0 05 1 7 -02 -2 00 5 09 -0 3-2 00 5 29 -0 3-2 0 05 1 8-0 4 -20 0 5 0 8 -0 5 -20 0 5 2 8 -05 -2 00 5 17 -06 -2 00 5 07 -0 7-2 00 5 2 7 -07 -2 00 5

Ma

ss

Unit shut downDifferent catalyst loaded

LCO flow meter repaired

**Actual LCO yield equal to the valuepreviously to the catalyst change

**Lower light HC and more decantedoil produced =Less profits


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26

Global Refining SummitRotterdam, May 18, 2011


27/34

ReconciliationCoupledwithOptimization


os n egra on

with Reconciled Data

Optimizer Result

62,77 US$/m3 63,84 US$/m3

1,00 US$/m3 differenceMeasurement Problem

Hydrotreated Diesel Flow

15.000,00US$/batch

.

600.000,00US$/month

7.200.000,00US$/year

x 40batches/month

x 12month/year


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27



28/34

DetectingOperationalErrors


o ume r c en ra nmen osses rom e aroma c remova un , o a

amounts by month from Jun-2006 to may-2007.

1000

Financial losses of the aromatic removal unit, total amount by monthfrom J un-2006 to may-2007.

160000

600

700

800

ment,m3

100000

120000

140000

$

rubber solvent entrainment fromsolvent unit to gasoline unit.

300

400

500

olvententrai

40000

60000

80000

Loss,

U

0

100

200

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 08-04-2007 07-06-2007

S

0

20000

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 08-04-2007 07-06-2007


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28


DateDate


29/34





1000


160000

600

700

800

ment,m3

100000

120000

140000

$

difference between rubber solventand gasoline prices

300

400

500

olvententrai

40000

60000

80000

Loss,

U

0

100

200

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 08-04-2007 07-06-2007

S

0

20000

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 08-04-2007 07-06-2007


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29


DateDate


30/34





1000


160000

600

700

800

ment,m3

100000

120000

140000

$

Total annual losses: US$ 0.7 million

300

400

500

olvententrai

40000

60000

80000

Loss,

U

0

100

200

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 08-04-2007 07-06-2007

S

0

20000

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 08-04-2007 07-06-2007


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reserved.

30


DateDate


31/34

LossofCapacityVersusNominalCapacity

Loss of processing capacity

Carga U283A5800

.

5200

5400

ssada(m3)

4800

5000

CargaProc

4400

01-09-07

15-09-07

29-09-07

13-10-07

27-10-07

10-11-07

24-11-07

08-12-07

22-12-07

05-01-08

19-01-08

02-02-08

16-02-08

01-03-08

15-03-08

29-03-08

12-04-08

26-04-08

10-05-08

24-05-08

07-06-08

21-06-08

05-07-08

19-07-08

02-08-08

16-08-08

30-08-08

13-09-08

27-09-08


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31


arga me a arga econc a a


32/34

CustomerPresentation

YieldAccountingManagement

b MihaelaCristinaPo escu

OMVPETROM


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32



33/34

Conclusions

Territories

NorthAmerica

deliversignificant

benefits

to

refiningcustomersworldwide.

Europe&Russia

Asia&

Pacific

LatinAmerica

Solutionshavetobeadaptive,keepingthecustomer

6%

MiddleEast&Africa

.

Sigmafinetechnologiesare28%17%

futurebusiness

requirements.

28%

21%


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33



34/34

MihaelaChristinaPopescu,[email protected]

. , . .

34


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