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2© 2005 OSIsoft, Inc. – Company Confidential
Nicoletta Aloi - IPLOMMassimo Galli – Pimsoft
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3© 2005 OSIsoft, Inc. – Company Confidential
Increasing refinery yields and profitability using RtPM
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4© 2005 OSIsoft, Inc. – Company Confidential
Agenda1. Iplom refinery presentation2. Performance management3. From PI system to RtPM
1. Planning2. Measuring & reconciling3. Calculating indicators4. Distributing information
4. Return on investment1. Yields profitability2. Organizational
5. Future steps
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5© 2005 OSIsoft, Inc. – Company Confidential
Iplom presentation
Refineries in ItalyRefineries in Italy
IPLOM
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6© 2005 OSIsoft, Inc. – Company Confidential
Iplom presentationIplom RefineryIplom Refinery
Genoa HarborGenoa Harbor
Passo dei GioviPasso dei Giovi
Crude storageCrude storageTanks storageTanks storagein Genoain Genoa
PIPELINESPIPELINES
PROCESS PLANTPROCESS PLANT
Railway LoadingRailway Loading
Finished Product StorageFinished Product Storage
Truck LoadingTruck Loading
Pipeline 8”Pipeline 8”
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7© 2005 OSIsoft, Inc. – Company Confidential
Iplom DNA: a agile refinery Iplom is a independent refinery focused on efficiency to create profit
– Serving a variegated range of customers– Producing both conventional and niche products (e.g. LL Sulphur fuel oil,
CO2)
Production management is based on:– Agility in taking business opportunities– Rapidity in taking business decision– Time to market: very brief period from crude purchase to product sell
To support these objectives, given the constraint of a limited storage capacity, the company needs to manage production dynamically
– 160 crude switches per year– Different plant operating modes
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8© 2005 OSIsoft, Inc. – Company Confidential
Performance ManagementA continuous and iterative approach in
production management supported by a flexible environment:– define production target– assign plan to operations– reconcile measures and calculate KPIs– report and distribute performances– evaluate to act and correct
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9© 2005 OSIsoft, Inc. – Company Confidential
Performance Management
Applied to different timescales to give support to different company functions– Hourly:
• to operating shift people – Daily:
• to production and planning manager– Weekly/monthly:
• to refinery manager
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10© 2005 OSIsoft, Inc. – Company Confidential
From PI System to RtPM
2001 - Reconciling Refinery yields– PI System, Sigmafine3, PI-ProcessBook, PI-DataLink
2003 - Integrating planning tools and calculating KPIs
– PI ModuleDB, PI-ACE
2004 – Distributing information across the company– PI-ICE
2005 – Migration to Sigmafine4, evaluating RtPortal– Sigmafine4, RtWebParts
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11© 2005 OSIsoft, Inc. – Company Confidential
Functional overview
PI-AF Sigmafine
PIACE
PI-ModuleDB
Running plan definition
Assign plan to operations
Modeling &Reconciliation
Automatic proceduresPI-Datalink
PI-PB
ICERtPortal
PI-PB
Reports
Cockpits
PIACE
KPI calculations
Consistency through OSIsoft infrastructure
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12© 2005 OSIsoft, Inc. – Company Confidential
Running plan definition A “running plan” defines all the information needed at execution time to
process a specific crude or crude mix to obtain desired products and qualities
Define for a crude or a crude mix
Calculate expected theoretical yields
and qualitiesusing crude libraries
and algorithms
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13© 2005 OSIsoft, Inc. – Company Confidential
Running plan definition/2 Microsoft Excel as frontend:
simple, powerful, flexible All running plan target data
centralized and stored in the PI-ModuleDB
Support multiple calculation templates
Select which Sigmafine4 layers will be enabled to ensure consistent reconciliation at execution time
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14© 2005 OSIsoft, Inc. – Company Confidential
Assign running plan to operations
Shift chief declares crude switch from the control room using PI-ProcessBook
PI-ACE automatic procedures setup all the systems for execution:– notify Sigmafine4 model enabling layers needed to
reconcile current configuration– notify external systems:
• send target values to advanced control system• notify accounting system
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15© 2005 OSIsoft, Inc. – Company Confidential
Reconciling measures Reconciliation is the first
step to consolidate process data before calculating performances
Sigmafine refinery plant model designed for yield reconciliation
The model is composed of several (50) layers which can be combined to represent different plant configurations
Reconciliation is done automatically every hour
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16© 2005 OSIsoft, Inc. – Company Confidential
Migration to Sigmafine4 Some feelings about migration from Sigmafine3 to Sigmafine4
– “Smooth” process helped by automatic conversion utilities– Powerful configuration and maintenance tools (Excel addin, AF Explorer)– Use advanced graphic functions available in PI-ProcessBook (dynamic symbol
behaviour, layering, annotation by drag&drop, …)– Use std tools (PI-ACE) to implement automatic reconciliation procedure
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17© 2005 OSIsoft, Inc. – Company Confidential
Calculating performances
Actual yields calculated via PI-ACE based on reconciled values:– Per hour– Per shift– Per running plan
Overall KPIs calculated via PI-ACE– Performance (positive when producing more valuable
products than expected)– Deviation (gives indication of the distance between
target and actual yields)
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18© 2005 OSIsoft, Inc. – Company Confidential
Reporting performances Using planning tool to evaluate target vs. measured
vs. reconciled
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19© 2005 OSIsoft, Inc. – Company Confidential
Evaluating performances
Selecting running
plan
Comparingyield profiles
for homogeneous running plans
Select search
parameters (time,
running plan code,
crude)
Using std tools (PI-BatchView) to analyze yield profiles
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20© 2005 OSIsoft, Inc. – Company Confidential
Distributing indicators across the company Sharing information through PI-ICE cockpits
Performance indicators
Yields comparison
(teo, hourly, shift, campaign)
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21© 2005 OSIsoft, Inc. – Company Confidential
Evaluating RtPortal
Yields comparison (teo, hourly,
shift, campaign)
Current Running plan general info
KPIsrepresentation
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22© 2005 OSIsoft, Inc. – Company Confidential
Return On Investment
The iterative approach of performance management keeps the company focus on reaching the target objectives– Online performance monitoring in control room allows
to rapidly identify yield degradation due to incorrect operating parameters
– Historical analysis allows the production manager to redefine better targets starting from the improved performance of the refinery
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23© 2005 OSIsoft, Inc. – Company Confidential
ROI: increasing yield profitability e.g. Diesel yield
– Analyzing homogeneous data related to “sweet” crudes:
• 2003 actual average diesel yield37,4%• 2004 actual average diesel yield39,6%
– Average actual diesel yield increased due both to investments on plants and to performance management
– Historical analysis on diesel yield showed that the average increase due to performance management amount to about 0.8% in the period 2003-2004
– This lead to a profit increase estimated in 1 M$ per year
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24© 2005 OSIsoft, Inc. – Company Confidential
ROI: crude switch duration Monitoring reconciled vs. target
helped shift people to better control crude switch operations
This result in reduction of the time needed to complete crude switch and to reach the targeted performance
Just considering the loss of diesel (degradation to fuel oil) during the crude switch, the estimated saving is about 0.3 M$ per year
Crudeswitchperiod
Crudeswitchperiod
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25© 2005 OSIsoft, Inc. – Company Confidential
Organizational benefits
The reduction of the deviation between planned and actual yields (e.g. diesel from 2.2% to 1.3%) demonstrated how sharing information and involving people helped to reach the refinery targets
The smart integration reached using OSI infrastructure allowed to focus engineers on the real business objectives
Performance management approach allowed to keep production and plant management under control with a lean organization
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26© 2005 OSIsoft, Inc. – Company Confidential
Future steps
Performance management– Evaluation of blending efficiency to optimize the
utilization of low-cost components– Composition tracking of complex operations between
the coastal tanks and refinery to improve the quality of crude mix feed
RtPM evolution– Introduction of RtPortal solution to distribute KPIs