amplaiom.invensys.com/en/softwaregcc14presentations/simsci/ss...backcasting business results...

2014 Software Global Client Conference Ampla

The Role of

Advanced

Software

Systems in the

Refinery of the

Future SS OPT-05

2014 Software Global Client Conference

Mobile App: Please take a moment…

Check into Session by:

●Select Detailed Schedule

●Select the specific session

●Click on “Check in”

Take Session Survey by:

●Select Detailed Schedule

●Select the specific session

●Scroll Down to “Survey” and Provide Feedback


Agenda

● Trends in Petroleum Refining

● Challenges and Influences

● Moving to the Future

● Characteristics of the Refinery of the Future

● Core Technology Requirements for the Refinery of the Future

● The Evolution of Advanced Software Systems to Enable Optimal Performance

of the Refinery of the Future


Trends in Petroleum Refining

Divider Slide

Industry Trends

Eq

uip

men

t

main

ten

an

ce b

ased

on

bo

th c

on

dit

ion

mo

nit

ori

ng

an

d

eco

no

mic

tra

de

off

s

Use o

f p

roa

cti

ve

safe

ty s

yste

ms

Emphasis on minimizing energy

usage

Increasing investments on

equipment reliability and

process safety management


Challenges and Influences


Core Challenges

Uncertainty

• Price Volatility

• Geo-Political Unrest

• Financial Crisis

Availability of Skilled

Resources

• Aging Workforce

• Complex Plant Config.

Margin

• Tight Supply & Demand

• Energy & Material Cost

• Capital Availability

Regulation

• HSE

• Asset Availability

• Asset Reliability

Operation Optimization

High Performance Organization

Zero Accident


Operation Optimization Model Based

Real-Time Optimization

High Performance

Organization

Real-Time Performance

Management

Zero Accident Operator Training Simulator

From Challenge to Solution


Moving to the Future


Asset Value Optimization to Maximize the Value of

Every Molecule Processed

● Advances in computer power, optimization technology and mathematical solvers will enable rigorous,

refinery-wide models to run and converge in minutes so that…

● The online models can be used for refinery-wide optimization—including planning and scheduling—without requiring

individual process unit optimizers

● Models will form the core of asset value optimization with model rigor matched to end-user requirements

● Industry-leading refiners will strive to maximize the value of every molecule of feed processed using

various techniques, including:

● Compositional analysis and characterization of feedstocks

● Component-based reactor models

● Equipment and process performance management will be highly-automated, context-sensitive and

predictive in nature


Integrated Operations Management

● There is a cycle of model-based activities that involves:

● Planning what the facility will do

● Executing to the plan

● Then measuring what took place against the plan

● The cycle is repeated with the intention that the planning processes can be

improved through increased insight into or prediction of:

● What materials will be available (supply chain)

● What product demands will be

● What just happened (model-based analysis of process behavior)

● What the process performance capabilities and limitations will be (maintenance

schedules; predictive analytics to forecast future behavior and constraints)


Vision Integrated Operations Management

Execution Decisions Reviews, Reports

weeks ago days ago hours ago now hours ahead days ahead months ahead

Performance Management


Plan vs. Actual

Plan vs. Actual


Sched vs. Actual

VA

LU

E Operations

Production

Business

Logistics

Limits & Boundaries

Goals and Targets

Goals

Reconciled

Performance

Results

Reconciled Performance

Synchronization

Business/Yearly

Plan

Quarterly/Monthly

Plan

Schedule Daily Accounting

Hourly Balance

Operations Monitoring

Operations

Management

Process Control &

Optimization

Monthly Production

Accounting

Backcasting

Business Results

Integration

Shift from

feedback to

feedforward

behavior


Characteristics of the Refinery

of the Future

Divider Slide


Characteristics of the Refinery of the Future

● Rigorous model-based applications form the foundation for managing the refinery’s overall value chain,

from feedstock selection to final product distribution

● More than 10 times the amount of instrumentation and data than traditional refineries

● Visualization and control are designed to address upcoming shifts in targets and constraints, similar to a

vehicle GPS or satellite navigation (SATNAV) system

● Emergency shutdown systems are designed for prevention of almost all unplanned shutdowns

● 50% more instrumentation connections with close feedback sent to the distributed control system

● Safety and operations performance are measured and visualized in real-time

● Full visibility to covert safety indicators

● Value chain information including pricing, logistics, planning and scheduling is tightly integrated with control

● The Refinery of the Future is no more an individual modern plant asset, but an integrated entity in a larger hydrocarbon

value chain


Characteristics of the Refinery of the Future

● Business processes are highly automated

● These are focused on granular procedural automation

● Start-up and shutdown

● Alerts and notifications are common to Refinery of the Future operations to ensure timely responses to exploit

desired situations and to minimize or prevent undesired situations

● Vessel loading is accomplished using fully automated systems requiring human intervention only in the

event of problems that can not be fixed otherwise

● Training is transformed to include immersive experience that addresses the greater awareness of the

value chain and external factors in addition to the physical and operational factors inside the refinery

● This is implemented using 3-D immersive and augmented reality


Core Technology Requirements


Core Technology Requirements for the Refinery of

the Future

● Common Information Model to ensure interoperability across multiple vendors’ software applications

using industry standards such as B2MML

● Sophisticated information mining tools use pattern recognition to determine where the process is

moving based on past behavior and make recommendations for model changes to correctly manage

the new operating point

● Master data management for “single source of truth”

● Given so many software applications, each with its own data model, it is critical to manage master data to ensure

smooth and reliable communication

● Mobility sub-architecture which treats mobile devices as “first class citizens”

● This is a combination of integrating voice, video, text messaging, cybersecurity and visualization suitable for

tablets, smart phones and laptop computers

● Elimination of the traditional divide between steady-state and dynamic rigorous models


Core Technology Requirements for the Refinery of

the Future

● Cyber security sub-architecture and business processes which implement a “defense in depth” approach

● Site-wide wireless network with some redundancy (cellular network can be used as well)

● Cloud sub-architecture wherever possible for sharing information, remote expert advice or benchmarking

and comparing plant performances

● Operations center collaboration technology, including display aggregation (such as integrating maps,

videos, applications views, television news feeds, video remote collaboration), recording, remote

annotation and decision support desks

● Immersive 3D visualization and navigation technology for the 3D training

● Human-like robots replace field operators and maintenance personnel for work in hazardous areas


The Evolution of

Advanced Software Systems

to Enable Optimal Performance of

the Refinery of the Future

Forecasts EPS

Calculator

Actual

Earnings

per Share

Forecasts Actual

Gross Profit Gross Profit

Calculator

SP PV

Throughput

(Fixed Cost Contribution to Mfg. Cost)

SP PV

Energy Cost Contribution

To Mfg. Cost

SP

PV

Raw Mat’l Cost Contribution

To Mfg. Cost

SP PV

Column 301-D

Reboiler Outlet Temp.

Executive

Level

Business

Management

Level

Plant

Management

Level

Process

Management

Level

The Goal…Automate the Business Control Loop

Regulatory &

Advanced Process

Control

Process

Optimization

Asset

Optimization

Enterprise /

Supply Chain

Optimization

KP

Is

Pe

rfo

rma

nc

e M

ea

su

res

Δ = Deviation

Δ = Deviation Δ = Deviation

Δ = Variance

Δ = Variance


The Problem…Aligning Strategy with Execution in

Refining

We can get the best mix of crudes that

optimizes my profit margins

Business

view

If so, we know in real-time what the refinery is

capable of processing & stay within safety limit

Production

view

I manage the process set-points to improve

margins based on delivered crude quality

Process

view


Crude Trading

Crude Selection

Crude Property Analysis

Operations Scheduling

Oil Movement Mgmt.

Blending Optimization

Operations Planning

Real-Time Optimization

Advanced Process Control

Inventory Mgmt.

Oil Movement Mgmt.

Blending Optimization

Supply & Distribution

Crude Sourcing

Crude Blending

Refining Product Blending

Product Distribution

Cru

de P

ricin

g &

Su

pp

ly

Pro

du

ct

Pri

cin

g &

De

ma

nd

Leveraging RTO in the Supply Chain

Today’s Approach to Aligning Strategy with

Execution

Operational Performance

Measures

Energy Optimization

Operations Performance Monitoring

Optimal Regulatory and Advanced Control

Improved Mass Balance

Accuracy & Yield Accounting

Optimal Refinery Planning Support

Process Unit Simulation & Optimization

Corporate Management

Site Management

Management Performance

Measures

Feedstock Selection, Planning & Scheduling

LP Vector Updates

Business Performance Feedback Loop

Financial Impact

of Solution

Investment to Sustain Benefits

9

Operations & Engineering

8

Enterprise Manufacturing Intelligence Financial & Performance Metrics and Decision Support Provided to Solution

Stakeholders

Integrated Information, Workflow and Modeling Platform Asset Performance

Management

Power Management


SimCentral – The Future of Model-Based Design,

Operate and Optimize

Operate

SimCentral

Optimize

Design


SimCentral Design Heat and Material Balances and for New Construction

s1 s2 s3 S4 s5 s6 s7

Flow 1.3 2.4 3.3 4.13 4.13 4.13 4.13

Temp 100 120 120 130 130 180 170

Pressure 1000 990 960 940 940 900 900

Phase L V/L V/L V V V V

Composition

Stream Heat and Material balance Table shows that the

proposed process design is efficient


SimCentral Operate Design Controls and Train Operators

Dynamic Trends show plant operators how to

respond to unexpected events to avoid accidents


SimCentral Optimize Run Online to Improve Plant Performance

Real-time system reads data

from plant DCS and executes

optimization runs to improve

plant production and profitability

Sequence

INPUT

Data Rec

Macro

Solve

OUTPUT


Today’s Approach to Aligning Strategy with

Execution


Measures

Energy Optimization


Optimal Regulatory and Advanced Control




Process Unit Simulation & Optimization


Site Management


Measures


LP Vector Updates


Financial Impact

of Solution


9


8


Stakeholders

Integrated Information, Workflow and Modeling Platform Asset Performance

Management

Power Management


Tomorrow’s Approach to Aligning Strategy with

Execution


Measures

Optimal Regulatory and Advanced

Control


Site Management


Measures


Financial Impact

of Solution


9


Stakeholders

Asset Performance Management


Pattern Recognition & Predictive

Analytics

On-Line Process Safety Risk Assessment

Monitoring of Operator Mental &

Physical Health

Rigorous, Model-Based Refinery-Wide Simulation and Optimization




Process Optimization, Energy Optimization

and Power Management



Workflow & Procedural Automation


Related Support, Services, Training & Expo Demos

● SimSci Portfolio Tech Support 24/7

● Project-specific Tech Support options

Support

Training

● SimSci Training for Portfolio Products

● Wonderware Portfolio Training Courses

● System Platform Solutions

● APC Implementation

● ROMeo Implementation

● WW partners for integration

● Avantis Implementation

Services

Expo Demos

● SimSci APC Demo

● ROMeo Platform Demo

● Yield Accounting

● ROMeo Simsci Reactors Demo

● Dynsim Demo

● PRO/II Demo

amplaiom.invensys.com/en/softwaregcc14presentations/simsci/ss...backcasting business results...

Documents