Sigmafine User Summit

Transcription

1 Achieving Operational Excellence with Automated Hydrocarbon Accounting Sigmafine User Summit September 18 th 2018 Houston, TX. Team : Ramesh Rajaram, Arif Syed, Harshil Vyas By : Vikas Deshmukh

2 Disclaimer Any statement, opinion, prediction, comment, or observation made in this presentation/publication are those of the presenter/author only and in no condition should be construed necessarily representing the policy and intent of Reliance Industries Ltd. (RIL). The information presented herein are of the presenter/author s own and in no way RIL attracts any liability for any inconsistency or irregularity in terms of the accuracy completeness, veracity, or truth of the content of the presentation/publication. In addition, RIL shall not be liable for any copyright infringement and misrepresentation for the presented content as the content is presumed in good faith to be a creation of presenter s/author s own mind. The scope of this presentation/publication is strictly for knowledge sharing purposes and not necessarily to provide any advice or recommendation to the audience/readers. Any endorsement, recommendation, suggestion, or advice made by the presenter/author shall be in his personal capacity and not in professional capacity as an employee of RIL. Any person acting on such endorsement, recommendation, suggestion, or advice will himself/herself be responsible for any injury/damage. 2 of 29

3 RIL Brief Introduction Dhirubhai H. Ambani Founder Chairman Reliance Group Reliance Industries Ltd., Establishes Textile mill in Naroda Public share offering Raised money from public offerings oversubscribed 7X Builds fiber/filament plant in Patalganga Builds Polyolefin plants at Hazira Builds multi-feed cracker at Hazira Builds Jamnagar refinery Acquired IPCL a state run company Builds JERP refinery at Jamnagar Begins KG D6 gas production Builds PBR/SBR plants at Hazira Builds PTA plant at Dahej Builds PET plant at Dahej J3 plants commissioned (C2 complex, PX4), Gasifiers under commissioning. 3 of 29

4 RIL Largest Private Sector Enterprise in India Key Financials FY Revenue Net Profit Investments (2) Exports US$ 51 billion US$ 4.8 billion US$ 17.7 billion US$ 22.8 billion (~8% of India s exports) Net Profit CAGR (1) Market Cap. CAGR (1) 26.7% 31.5% INDIA S FIRST PRIVATE SECTOR COMPANY TO FEATURE IN FORTUNE GLOBAL 500 LIST OF WORLD S LARGEST CORPORATIONS ; CURRENTLY RANKING 203 RD IN TERMS OF REVENUE AND 110 TH IN TERMS OF PROFITS Major Businesses Refining & Marketing Notes: 1. Since IPO(40 years) data Petrochemicals Oil & Gas Retail Digital Services Media & Entertainment Reliance Industries Ltd., of 29

5 Reliance Industries - Businesses Refining & Marketing(R&M) Operates the world s largest and most complex refineries with crude processing capacity of 1.24 million barrels per day Retail Largest retailer in India with over $5 billion turnover Caters to over 3.5 million customers every week Petrochemicals Integrated petrochemical player - in Top 10 rankings globally One of the world s oldest and largest polyester fiber and yarn producer Exploration & Production(E&P) Onshore and offshore exploration and production in India Significant presence in US shale business Corporate Social Responsibility(CSR) Top spenders in CSR (Rs. 674 Cr.) within country with main focus on rural transformation, healthcare, education and sports Digital Services (Jio) Providing world s most affordable data and voice services to 138+ mn users Based on a world-class all-ip data strong future proof network with latest 4G LTE technology Media & Entertainment (M&E) One of India s leading M&E players, with a strong presence across television content production and distribution, theatrical exhibition of films and media services Reliance Industries Ltd., of 29

6 Reliance Industries Where We Stand Leadership & Workculture Listed amongst the top 10 for Best Places to work in India by LinkedIn, 2018 Our chairman Mukesh D.Ambani is the only Indian on Forbes Global game changers list Digital Services(Jio) World s largest and fastest growing mobile data network and country s most cost efficient digital services platform Jio has progressed India to No.1 position from 150 th in terms of data usage (1.2 bngb/month) Refining & Marketing Recognized as the world s No.1 Mega project by Discovery Channel in 2012, we are the largest operating refinery in the world 1.5% of world s transportation fuel is produced from Jamnagar refinery Petrochemicals RIL is amongst the world's leading producer with 24.9 MMT of petrochemicals production and global scale capacities across polymers, polyester, fibre intermediates and elastomers. RIL holds 36% and 33% domestic share in polyester and polymer markets respectively Exploration & Production Reliance s Kg-D6 gas discovery has doubled India s natural gas supplies. The block has the potential to produce 40% of India s gas production (3.6mn barrels per day) Reliance Industries Ltd., of 29

7 Successful Backward Integration for Feedstock Security in Pet & Polyester Production Reliance Industries Ltd., of 29

8 Manufacturing Sites JMD HMD VMD DMD PMD NMD I. Jamnagar Manufacturing Division (JMD) Refinery and associated petrochemical plants II. Hazira Manufacturing Division (HMD)- Petrochemical, Polymer and polyester plants III. Dahej Manufacturing Division (DMD)- Petrochemical, Polymer and polyester plants IV. Nagothane Manufacturing Division (NMD)- Petrochemical and Polymer V. Patalganga Manufacturing Division (PMD)- Petrochemical and polyester plants VI. Vadodara Manufacturing Division (VMD) - Petrochemical and Polymer 8 of 29

9 Reliance Hydrocarbon Business Upstream Downstream Oil & Gas Refining Petrochemical Polyester Jamnagar 1. DTA 2. SEZ 3. Gasification 1. Jamnagar 2. Hazira 3. Dahej 4. Vadodara 5. Nagothane 6. Patalganga Fuel retail To manage we have to control. To control we have to measure 9 of 29

10 Agenda 1. Reliance 2. Sigmafine Reliance 3. Business objectives 4. Sigmafine Refining & Petrochemicals business 5. Sigmafine Data consumers & Data flows 6. Hydrocarbon accounting / Loss monitoring before & after Sigmafine 7. Sigmafine up-gradation Jamnagar & other Petrochemicals 8. Benefits of upgrade 9. Reliance wish-list 10. Lesson s learned 10 of 29

11 Reliance Data is new oil for fourth industrial revolution. The foundation of the fourth industrial revolution is connectivity and data. Data is the new natural resource. We are at the beginning of an era where data is the new oil, Mukesh Ambani, Chairman, Reliance Digitalization changes everything 11 of 29

12 Digital Transformation at Reliance Business objectives Integration of whole supply chain Abnormal situation management Operator driven reliability Competency assurance of frontline operating staff Intelligent search Digital solution Platform (IT OT) Big data analytics Operator handhelds AR/VR and Digital twins Cognitive computing (AI) Digital makes excellence operational 12 of 29

13 Digitalization Vision 13 of 29

14 Sigmafine History at Reliance Sr # Description Month / Year 1. First Sigmafine Hydrocarbon model (V3) DTA Refinery, Jamnagar Sep Second Sigmafine Hydrocarbon model (V3) SEZ Refinery, Jamnagar 3. Total 5 Sigmafine Hydrocarbon models (V3) Petchem sites Hazira, Dahej, Nagothane, Patalganga, Vadodara Jan 2009 May of 29

15 Business Objectives 1. Loss monitoring and reduction of unaccounted losses. 2. Production accounting Yield, Mass. 3. Process optimization helps judge yield, flow and inventory data. 4. Production planning (Plan Vs Actual) 5. Instrument management - form the basis of a preventative maintenance of instruments. 6. Facilitate regulatory compliance by creating a single version of data. 7. Enable well-informed accurate business decisions. 15 of 29

16 Sigmafine Data Flow Sigmafine Measured Reconciled DMB DOR GRM SAP PIMS Production Accounting Database Historian TIS LIMS DCS 16 of 29

17 Sigmafine Refining business Integrated refining, petrochemical & gasification complex Sigmafine model details: Refinery Hydrocarbon Utilities network Sigmafine Mass Balance Models Jamnagar DTA SEZ Elements counts 15,255 World s largest Sigmafine model 17 of 29

18 Sigmafine Petrochemicals business Reliance has 5 petrochemical sites with cracker (Gas/ Naphtha / Ethane) and downstream polymer complex. Description Hydrocarbon Utilities network Sigmafine Mass Balance Models Elements counts Hazira Manufacturing Division Dahej Manufacturing Division Vadodara Manufacturing Division Nagothane Manufacturing Division Patalganga Manufacturing Division of 29

19 Sigmafine Data Consumers 1. Operations, 2. Finance, Compliance and Accounting, 3. Planning and scheduling 4. Instrument reliability 5. Technical Services 6. Benchmarking studies Conditioned data from Sigmafine ensures data quality, credibility and usability across the enterprise 19 of 29

20 Hydrocarbon Accounting Before Sigmafine 1. Difficult to perform daily mass balance (too much effort involved & manhours) 2. Manual entry of daily production records 3. Plant-wide KPIs missing 4. Arbitrary manual adjustments required for monthly balance. 5. Difficult to trace losses. Before Sigmafine, the data lacked Accuracy 20 of 29

21 Hydrocarbon Accounting After Sigmafine 1. Material balance based on standard data reconciliation platform 2. Automated accurate daily Mass balance 3. Established KPI s. 4. Daily and monthly balances are mutually consistent. Controlling Unaccounted Loss and Ensuring Robust Mass Balance 21 of 29

22 Sigmafine Migration 1. SigmafineV.3 support discontinued. 2. Ever growing models with limited space in canvas for future expansion. 3. Stand-alone system 4. Application runs on windows XP platform. 5. Access control & data security issues. 22 of 29

23 Sigmafine Migration- Project Success story 1. Utilized PIMSOFT expertise in SF3 to 4 conversion 2. Major challenge was J3 (C2-Complex) plants were in commissioning stage and integration with existing model was difficult. 3. Parallel run in SF3 & SF4 to validate the reconciled results 4. Knowledge sharing 5. Team work 23 of 29

24 Sigmafine Migration: Highlights 1. Speedy migration of DTA & SEZ Refineries using migration utility provided by Pimsoft. 2. Gone live without any downtime with available resources and within stipulated time frame. 3. Able to integrate with existing systems without any hassles. 4. Faster and smoother migration for the remaining models of petrochemical sites. 24 of 29

25 Sigmafine History at Reliance: Sr # Description Month / Year 1. First Sigmafine Hydrocarbon model (V3) DTA Refinery, Jamnagar 2 Second Sigmafine Hydrocarbon model (V3) SEZ Refinery, Jamnagar 3. Total 5 Sigmafine Hydrocarbon models (V3) Petchem sites Hazira, Dahej, Nagothane, Patalganga, Vadodara Sep 2002 Jan 2009 May Sigmafine version upgrade (V3 to DTA, SEZ Refinery and newly commissioned C2 and Gasifier Jamnagar Dec Sigmafine version upgrade (V3 to Petchem sites Hazira, Dahej, Nagothane, Patalganga, Vadodara (Underway) Dec of 29

26 Benefits of Sigmafine Upgrade 1. Reduction of time required for model execution and troubleshooting. 2. Improved reconciliation analysis 3. Better multi-user environment 4. Enhancement in user access control and security 5. Elimination of manual steps 6. Restrictions on Manual intervention 7. Sigmafine Excel add-in : Useful in making ad-hoc reports. 8. Ease of integration with third party systems using IF (Integration Framework). 26 of 29

27 Lesson Learned 1. Automate everything 2. Put efforts in documentation, templates, etc 3. Begin communication between IT, modeling, and process units early 4. Effective and timely project management is critical 5. Build strong operating model for sustenance 27 of 29

28 Reliance Wish-List 1. Capability to host model on cloud based. 2. Web-based user interface 3. Mobility 4. Dash board and reporting solution 28 of 29

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