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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
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Topics
BusinessPerformanceAspectsinRefining
ProductionAccountingandDataReconciliation
PowerfulDataReconciliationConcepts
YieldAccountingManagementPresentedby
Conclusion
Visiant
Pimsoft
Inc.
2011
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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
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MarketDrivers
Environmental(GHG)
YieldAccountingStandards
o
RefiningMargins
Theidealplatformfordatavalidationhastocomplywithemergingregulationsintherefiningindustry.
Visiant
Pimsoft
Inc.
2011
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RefiningCase
SourceofInformation
o
o OilMovement
System
(OMS)
o LIMS
BusinessRules
o VCFaccordingtoAPI2004
o OwnershipTracking
o Foreignand
Domestic
Tracking
o MassBalance
Visiant
Pimsoft
Inc.
2011
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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
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SolutionMap
DataFlowforRefiningCase
HistorianExcel
Sigmafine
OMS
Reports
VesselPositioning
Aggregation/Integration
SQLAccess
ReportLogic
Web-basedReportsRules
System
Visiant
Pimsoft
Inc.
2011
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ProductionAccountingSolutionIntegration
Process Data Lab DataMovements
RecordsPlanning
DataSchedulingInformation
Visiant
Pimsoft
Inc.
2011
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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
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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
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Reconciliation
54.2
..
44.2
Visiant
Pimsoft
Inc.
2011
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OptimalUtilizationofExistingMeters
Non RedundantNetwork
AccurateMeter
Redundant Network
AccurateMeter
AccurateMeter
Visiant
Pimsoft
Inc.
2011
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ErrorDetection
Non RedundantNetwork. There is noossibilit ofdetection
Accurate
failure
Redundant Network.An imbalance can be
Visiant
Pimsoft
Inc.
2011
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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
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OptimumMaintenanceofRefineryMeters
Visiant
Pimsoft
Inc.
2011
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ImprovingtheOverallPicture
30%
Overall DX1 Trend ( Q4 2008 - Q1 2010)
25%
15%
5%
0%
Visiant
Pimsoft
Inc.
2011
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OilLossMonitoring
Meter ImprovementsMeter Improvements
BetterBetter
VisiantPimsoftInc.2011
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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
VisiantPimsoftInc.2011
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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
VisiantPimsoftInc.2011
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CustodyTransferErrorDetection
VisiantPimsoftInc.2011
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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
VisiantPimsoftInc.2011
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MonitoringRefineryPerformanceValidation of KPIs
RunningPlan KPIs
Current/Shift/Running PlanReconciled vs. Theoretical Yields
VisiantPimsoftInc.2011
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PerformanceMonitoring
ReconciledYields
TheoreticalYields
VisiantPimsoftInc.2011
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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$1 millionperyear.
VisiantPimsoftInc.2011
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LowYieldDetectionAfterCatalystImprovement
Data Quality Improvement: Profits
Mass balance yield - FCC (Fluidized Catalitic Cracking Unit)
110 *Data reconciliation group identifiedLCO flow meter fault
*Durin this eriod it was believed
100
105
yie
ld(%)
that LCO yield had increased.
Flowmeters maintenance
90
95
assbalance
Unit shut downDifferent catalyst loaded
required by reconciliation group
**LCO flow meter repaired**Actual LCO ield e ual to the value
80
85
- - - - - - - - - - - - - - - - - - - -
previously to the catalyst change**Lower light HC and more decantedLower light HC and more decanted
oiloil produced =produced = Less profitsLess profits
VisiantPimsoftInc.2011
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LowYieldDetectionAfterCatalystImprovement
Data Quality Improvement: Profits
Eliminated loss corresponding toUS 23.5 million er ea
M a s s b a l a n c e y i e ld - F C C ( F lu i d iz e d C a t a li t ic C r a c k in g U n i t)
1 1 0 *Data reconciliation group identified LCO
flow meter fault*
9 5
1 0 0
1 0 5
balanceyield(%)
LCO yield had increased.
Flow meters maintenance requiredby reconciliation group
8 0
8 5
9 0
28 -0 1-2 0 05 1 7 -02 -2 00 5 09 -0 3-2 00 5 29 -0 3-2 0 05 1 8-0 4 -20 0 5 0 8 -0 5 -20 0 5 2 8 -05 -2 00 5 17 -06 -2 00 5 07 -0 7-2 00 5 2 7 -07 -2 00 5
Ma
ss
Unit shut downDifferent catalyst loaded
LCO flow meter repaired
**Actual LCO yield equal to the valuepreviously to the catalyst change
**Lower light HC and more decantedoil produced =Less profits
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ReconciliationCoupledwithOptimization
Data Quality Improvement: Profits
os n egra on
with Reconciled Data
Optimizer Result
62,77 US$/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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DetectingOperationalErrors
Data Quality Improvement: Profits
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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Global Refining SummitRotterdam, May 18, 2011
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DetectingOperationalErrors
Data Quality Improvement: Profits
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
$
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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Global Refining SummitRotterdam, May 18, 2011
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DetectingOperationalErrors
Data Quality Improvement: Profits
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
$
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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Global Refining SummitRotterdam, May 18, 2011
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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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Global Refining SummitRotterdam, May 18, 2011
arga me a arga econc a a
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CustomerPresentation
YieldAccountingManagement
b MihaelaCristinaPo escu
OMVPETROM
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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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MihaelaChristinaPopescu,[email protected]
. , . .
34
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