© 2008 osisoft, inc. | company confidential rompetrol’s real time information system: a road from...

© 2008 OSIsoft, Inc. | Company Confidential

ROMPETROL’S REAL TIME INFORMATION SYSTEM:

a road from PLANT OPERATIONS FIELD DATA to MANAGERIAL

DECISIONS

ROMPETROL’S REAL TIME INFORMATION SYSTEM:

a road from PLANT OPERATIONS FIELD DATA to MANAGERIAL

DECISIONS

Ana- Maria CiuculanAna- Maria CiuculanAna- Maria CiuculanAna- Maria Ciuculan

3© 2008 OSIsoft, Inc. | Company Confidential

Rompetrol Rompetrol


AgendaAgenda The Rompetrol Group Rompetrol Refinery Information System and the OSIsoft products

OSIsoft products at Rompetrol Refinery 2004: PI implementation PI data sources

Why PI ? PI DataLink – Reports Management Report – Storage Space Management Report – Production HTML visualization Rompetrol Refinery – PI Process Book

• Crude unit• Crude oil – tanks• Operational KPI

Sigmafine – Mass Balance –Model Sigmafine –Data Inputs Sigmafine –Data Outputs Sigmafine –Products Transfers Sigmafine – Mass Balance - Analysis Sigmafine – Mass Balance – Graphic Model

From Past to Future Conclusions


RompetrolRompetrol

• A leader in the regional oil field• A multinational company • Activities in 13 countries • Strong operational base in:

The Black Sea regionThe Mediteranean Sea region


RompetrolRompetrol

Through its 40 subsidiaries, The Rompetrol Group is mainly active in the refining process with implications in complementary projects, exploration and production, distribution, industrial services, maintenance, project management, logistics, industrial ecology and other related services in France, Romania, Spain and South-Eastern Europe.

Other non-core businesses: air transportation, tourism, safety and protection services.


Rompetrol Petromidia Refinery Rompetrol Petromidia Refinery

Designed and built between 1975-1977 Romanian and foreign technology Rompetrol Refinery can process a wide variety of

crude. Refinery capacity = 5.300.000 tones/year.High quality control and information systems:

DCS Information System =OSIsoft Plant Information


PI users: Technical & Non-technical staff

2004: PI implementation2004: PI implementation From DCS – data available only for the operators A lot of Manual Data Collecting Process No real time information about the processes, equipments No on time reports Delay between the figures and facts

Rompetrol Petromidia Refinery 2004 : PI implementation

Managed and eliminated

2004- now

Now-2010Plant Information – future:Vega RefineryPetrochemical Plant

Past- 2004

PI System was a novelty for Petromidia Refinery


OSIsoft products at Rompetrol Refinery OSIsoft products at Rompetrol Refinery

PI Enterprise Server ( 3.4.375.38) : 30000 tagsPI Client Application:

ComboPack Individual (PI ProcessBooK&PI Data Link) - 90 users

Sigmafine Server: AF 1.3. & SF v4.4.0.123Sigmafine Client:

PI AF Explorer: 1.3.0.1434 AF Modeler Add-in: 1.1.1.1323a

SRP


Data sources and interfacesData sources and interfacesField

instrumentation

Production Area DCS

PI NET

OLA OLP

Utilities Area DCS

Field instrumentation

InterfaceInterface

Interface

Crude Tanks

ProductTanks

TankMaster

TankMaster

Interface Interface

Manual Data Entry

Manual Data Entry

InterfaceOnline

Analyser

Sigmafine Server

PI SERVER

Interface

Information Gathered from

Different Sources


CLUSTER

PI SERVERACTIVE

PI NETDCS (PI to PI)

PLC (OPC Interface)Motoare (OPC Interface)

NMRLabInterface

PI SERVER A PI SERVER B

PIRouter

1 2 3 4 5 6

7 8 9101112

AB

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

Eth

erne

t

A

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

C PI Private Switch

1 2 3 4 5 6

7 8 9101112

AB

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

Eth

erne

t

A

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

C PI Switch

1 2 3 4 5 6

7 8 9101112

AB

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

Eth

erne

t

A

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

C AFPE SW

AFPERouter

TankMaster

Products

FoxboroSolaris

1 2 3 4 5 6

7 8 9101112

AB

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

Eth

erne

t

A

12x

6x

8x

2x

9x

3x

10x

4x

11x

5x

7x

1x

C 50000 SW

Tank MasterCrude

PI Router

PetromidiaOLA

PEM LANPIClients

Scanair

OLA

OLP

Overview: System ArchitectureOverview: System Architecture


Why PI ?Why PI ?

Excel Reports before PI DataLink Excel Reports – with PI Data Link A huge number of reports delivered by e-mail

Various data sources

Inconsistencies between figures

Large volume of calculations

Performance computing module

One database for data process

The information is updated in real time

Formulas predefined

An overview of the entire refinery process data in real time: Production Parameters:

•Temperature•Pressure•Flows•Level

Equipment Health and Period of On-line Operation

ONE DATA BASE for reportsREAL TIME updates


PI DataLink PI DataLink Without PI DataLink:

Only general view of the process parameters

Limited number of values for the parameters

No real time reporting, only reports by shifts and by day

01-Aug-08 09:29:36 135.8695221

01-Aug-08 09:29:37 152.0245514

01-Aug-08 09:29:46 159.1876373

01-Aug-08 09:29:47 132.4098969

01-Aug-08 09:29:50 121.8366547

01-Aug-08 09:30:08 110.6049042

01-Aug-08 09:30:12 111.4638214

01-Aug-08 09:30:20 117.6300812

01-Aug-08 09:30:24 104.4804459

01-Aug-08 09:30:29 117.6047363

Generate reports at any moment of the day

Many values for each

parameter

Detailed overview of refinery processes

PI DataLink

REAL TIME


Excel DataLink – ReportsExcel DataLink – Reports

Management Reports : Stocks and storage space available :

for the raw materials main products

Production (values from PI) versus scheduled productions versus MOP.

Operational Reports : Stocks reports -detailed information:

Materials and grades Storage Capacity Material Properties: Density etc. Level Water level Temperature

Production reports- by shift

TrendsReports Graphics


Reziduu

Spatiu liberPompabilNepompabil

Stocuri&Capacitati de stocare

Motorine

Date PI nereconcilate

10/14/08 1:00 PM

Materii Prime

7297

26244

162175

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Capacitate stocare Titei = 195715 tone

0178

806

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Capacitate stocare METANOL = 984 tone

75

441

570

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Capacitate stocare Motorina super euro 5 =

1086 tone

1620

12133

11594

0%

20%

40%

60%

80%

100%

Capacitate stocare Motorina super euro 4 =

25348 tone

1695

12574

12164

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Capacitate stocare MotorinaStoc Total = 26433 tone

585

1021

5149

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Capacitate stocare COMPONENTI MOT.EURO4

= 6756 tone

600

2228

2610

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Capacitate stocare REZIDUU DE VID DA =

5438 tone

Management Report – Storage SpaceManagement Report – Storage Space

VISUALIZATIONS Based on PI DATA

7297

26755

161598

0%

20%

40%

60%

80%

100%

CRUDE STORAGE =195659t

Users can select the type of data they want to see


Management Report – ProductionManagement Report – Production

Supus instalatii 8/28/08 4:00 AM 8/29/08 4:00 AM

HB

784 784 784

2,351

802 802 802 2,406774 764 756

2,294

-

500

1,000

1,500

2,000

2,500

3,000

Sch.1 Sch.2 Sch.3 8/28/2008

MOP(PIMS) Program (Orion) Realizat

DAV

4,243 4,243 4,243

12,730

4,333 4,333 4,333 13,0004,429 4,430 4,429

13,288

-

2,000

4,000

6,000

8,000

10,000

12,000

14,000

Sch.1 Sch.2 Sch.3 8/28/2008


RC

468 468 468

1,403

517 517 517 1,550468 468 467

1,403

-

200

400

600

800

1,000

1,200

1,400

1,600

1,800

Sch.1 Sch.2 Sch.3 8/28/2008


HPM

924 924 924

2,773

953 953 953 2,860946 918 919

2,782

-

500

1,000

1,500

2,000

2,500

3,000

3,500

Sch.1 Sch.2 Sch.3 8/28/2008


-

200

400

600

800

1,000

1,200

1,400

1,600

Sch.1 Sch.2 Sch.3 8/28/2008-

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

Sch.1 Sch.2 Sch.3 8/28/2008

HIGH VISIBILITYof

ACTUAL PRODUCTIONvs

PLAN&SCHEDULES


From EXCEL to HTMLFrom EXCEL to HTML

Management Report

EXCELPI DATA LINK

HTML

RESULTS:AGGREGATED OVERVIEWBETTER INFORMEDCORRECT DECISIONS


HTML visualizationHTML visualization

High speed for report uploadGraphic visualization Multiple possibilities for accessing data :

INTRANET (done) INTERNET (in progress) SMART PHONE (in progress)

Increasing the visibility of the information through the company systems

Getting the required INFORMATION for the analysis on TIME

SUPPORT for INFORMED DECISIONS

Engineers Report

Management Report

Valuable informationIn Real TimeTo Any Place


Rompetrol Refinery – PI ProcessBookRompetrol Refinery – PI ProcessBook

EASY NAVIGATION


Crude unitCrude unit

REAL TIME VIEW

BEST MONITORING


Crude oil – tanksCrude oil – tanks

REAL TIME DATA CRUDE UNIT FEEDSTOCK


OPERATIONAL KPIOPERATIONAL KPI

PROCESS DATA vs TARGET

REPRESENTATIVE INFORMATION FOR

MANAGEMENT


Sigmafine – Mass Balance -ModelSigmafine – Mass Balance -Model

756 elements 320 Flows 88 Nodes 53 Gas Meters 95 Liquid Meters 19 Processes 6 Receipt Points 21 Shipment Points 154 Tanks

180 Layers Strapping tablesDensity tables Material tables

ONE CONSISTENTMODEL

for REFINERY

Automatic data reconciliation


Sigmafine –Data InputsSigmafine –Data Inputs

Measured Mass Measured Volume Density Temperature Tank Level

Strapping tables Density tables Material tables Volume correction factor (VCF) Products Transfers

MANUAL DATA INPUTSPI SYSTEM

ONLINE DATA MANUAL DATA INPUTS

Sigmafine Model


Sigmafine –Product TransfersSigmafine –Product Transfers

StartTime EndTime Source Destination MeasuredMass3/1/2008 4:00 3/3/2008 2:00 Refinery Model\ReceiptPoint_Conpet_Titei Refinery Model\Node_Titei 140970003/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_DILB Refinery Model\ShipmentPoint_AFPE 62110003/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_GPL_REZ_OUT Refinery Model\ShipmentPoint_GPL 9270003/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_Cocs_CX_OUT Refinery Model\ShipmentPoint_Cocs 14350003/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_GILB Refinery Model\ShipmentPoint_AFPE 20850003/1/2008 4:00 3/3/2008 2:00 Refinery Model\ReceiptPoint_Gaze naturale Refinery Model\Node_Gaze_naturale_IN 480003/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_Sulf_RS_OUT Refinery Model\ShipmentPoint_Sulf 1850003/3/2008 4:00 3/4/2008 2:00 Refinery Model\ReceiptPoint_Conpet_Titei Refinery Model\Node_Titei 20690003/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_DILB Refinery Model\ShipmentPoint_AFPE 43940003/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_Calor_Extra Refinery Model\ShipmentPoint_Calor_Extra 250003/3/2008 4:00 3/4/2008 2:00 Refinery Model\C-99 Refinery Model\ShipmentPoint_Calor_Economic 690003/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_GPL_REZ_OUT Refinery Model\ShipmentPoint_GPL 13820003/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_Cocs_CX_OUT Refinery Model\ShipmentPoint_Cocs 5620003/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_GILB Refinery Model\ShipmentPoint_AFPE 12140003/3/2008 4:00 3/4/2008 2:00 Refinery Model\ReceiptPoint_Gaze naturale Refinery Model\Node_Gaze_naturale_IN 330003/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_Sulf_RS_OUT Refinery Model\ShipmentPoint_Sulf 75000

*xls FILEDAILY INPUTS

MANUAL DATA


Sigmafine –Data OutputsSigmafine –Data Outputs

PI Tags : Reconciled Mass Any reconciled

Value

Inventory Report Yields Report Measurements Report Loss Report

*xls Reports

Sigmafine Model

PI SYSTEM

ANALYSISFEEDBACKDECISION


Sigmafine – Mass Balance - AnalysisSigmafine – Mass Balance - Analysis

DAILY BASIS ANALYSIS24H, WEEKENDS


Sigmafine – Mass Balance- Graphic ModelSigmafine – Mass Balance- Graphic Model


What we had and what we have nowWhat we had and what we have now

2004

BEFORE PI IMPLEMENTATIONBEFORE PI IMPLEMENTATION AFTER PI IMPLEMENTATIONAFTER PI IMPLEMENTATION

COLLECTING DATA = TIME CONSUMING ACTIVITIES

MORE TIME FOR ANALYSES

LIMITED HISTORY LONG TIME DATA HISTORY

DELAY BETWEEN THE FACTS AND FEEDBACK

REAL TIME INFORMATION , REAL TIME ACTIONS

A HUGE MANUAL DATA INPUTS FOR REPORTS

HIGH QUALITY DATA INPUTS FOR REPORTS

ERRORS on NUMBERS ACCURATE DATA ALL THE INFORMATION IN ONE PLACE

LIMITED DATA ACCESS HIGH DATA AVAILABILITY

DATA from PI SYSTEM =

QUALITY, AVAILABILITY, INTEGRITYREAL TIME


Future DirectionsFuture Directions

PI System Upgrading the PI system to ensure a PI solution for other

sites Develop new applications for other areas:

Tanks Farm Product Loading Terminal Utilities Area

Sigmafine Improving the production Mass Balance Model Develop and implement a model for the Utilities

PI SYSTEM for ANOTHER SITESIGMAFINE MASS BALANCE SIGMAFINE for UTILITIESRT WEBPARTSACE MANUAL DATA INPUTS


ConclusionsConclusions

PRODUCTION AREA

MANAGEMENT

TECHNICAL STAFF

CONTROLSYSTEM

DECISIONS

VARIOUSDATA SOURCES

PI SYSTEM

Reports

INFORMATION

PI S

YS

TEM

DIRECTIO

N

CORRELATE THE PRODUCTION

WITH THE BUSINESS NEEDS

MONEY

REAL TIME

RAW DATA RAW DATA

IN

FO

RM

AT

IO

N

ON TIME

DECISIONS


WE ARE LOOKING FORWARD TO ANSWERING ALL YOUR

QUESTIONS

© 2008 osisoft, inc. | company confidential rompetrol’s real time information system: a road from...

Documents

pi system

company confidential

petromidia refinery

company confidential

pi af explorer

srp slide

sigmafine client

refinery capacity