Trustable Production Accounting

Transcription

1 Trustable Production Accounting with Sigmafine and PI Mohamed Markoum, IT Project Manager SAMIR Mohammedia Refinery

2 Agenda Introduction to SAMIR and Mohammedia Refinery Business Challenge Production Accounting Architecture and Tools Results/Benefits Future Plans 2

3 Samir Company Samir is a refining company located in Morocco, created in 1959 and privatized in The companyacts acts andoperates onerefinery (a hydroskimming andlube complex refinery located in Mohammedia) and the Sidi Kacem oil terminal connected through a pipeline. SAMIR shareholder structure as ofjune 2007is as follows: Corral Petroleum Holding Group: With 4 refineries, and over 1,000 service stations, Corral Group is one of the largest independent d refining companies in the world. Concentrated on two geographical poles, Scandinavia and the Middle East North Africa, Corral Group controls the petroleum chain from exploration to distribution. 3

4 Mohammedia Refinery The refinery is located in Morocco just 30Km from Casablanca. The Processing capacity is more 47 million barrels per year. The Storage capacity is: m3 Crude Oil: m3 Semi finished & finished products: m3 Main markets are Local 75%, Export 25%. 4

5 Upgrade Refinery Project The Upgrade project is considered as the tuning point of the company. In fact, this project transforms SAMIR from a simple refinery to a complex refinery with much higher margin capable of producing clean fuels in compliance with the strictest international standards. The project involves the installation of a new processing complex (including a fuel hydrocracker unit) which is integrated into the existing refinery at Mohammedia. This allows SAMIR to meet future market requirements for refined products, particularly middle distillates, and to manufacture products suitable for export to Europe and other markets. The process units that comprise the major elements of the upgrade project are as follows: The Upgrade Project includes all necessary expansions of the refinery utility systems to meet the demands of the upgraded refinery as Electric Power, Steam, Demineralised Water, Cooling Water, Refinery Fuel Oil, Fuel Gas, Nitrogen, Instrument & Plant Air and Towns & Utility Water. 5

6 Business Challenges Samir needs a production accounting system in order to have a validation platform which makes available trustable data for performance management system for business decisions. The system has to support a wide range of data sources: Process controls Laboratory systems Manual data Internal refinery oil movements Receipts and shipments Planning data The system has to evaluate some data not measured and to monitor the performance of the plants to identify oil losses, uncover operational problems, calculate and monitor data quality problems, help identify and quantify instrument errors, and prioritize instrument maintenance. The system has to be flexible to support the refinery layout and all the future changes/improvements and to be open to exchange data with existing/future systems for SAMIR Information System consolidation. 6

7 Samir Business Applicative Scenario Business Information System (BIS) CORPORATE PLANNING SAP CORPORATE ACCOUNTING Maintenance Planning Asset Utilization Production Management System Production Planning Scheduling Process Simulation Operations Orders LIMS PIMS (powered by PI) Consistent Economics & Process Models & Data Profitability KPI s Yield Accounting Quality Assurance Production Accounting Process / Equipment Monitoring Data Reconciliation (powered by Sigmafine) SCM Real Time System DCS PROCESS LEVEL Instrumentation data PRODUCT HANDLING /STORAGE CONTROL 7

8 Production Accounting Architecture Corporate Users Corporate web reports Production Accounting Users Refinery graphical model & operative reports Sigmafine SQL Access (RFC) Sigmafine Adv. Diagnostic AF Excel PI- PI- AddIn PI-OLEDB ProcessBook DataLink Mass Balance Utility (SF) Balance Volume Balance Energy Balance PI-AF PI Server PI-SMT Excel Add-In Sigmafine Server AF-SMT Excel Add-In Oil Movement Data Lab Data Process Data Manual Data 8

9 PI System Evolution in SAMIR Existing refinery Units /DCS Control rooms Upgrade Units /DCS Control rooms OPC Server 1 OPCS Server 2 OPCS Server 4 Process Data Process Data Process Data PI System 1 20K PI System 2 50K 9

10 PI System Evolution in SAMIR Existing refinery Units /DCS Control rooms Upgrade Units /DCS Control rooms OPC Server 1 OPCS Server 2 OPCS Server 4 Process Data Process Data Process Data PI System 1 20K PI System 2 50K Movement Files Manual Data OPC Server 3 LIMS Data 10

11 PI System Evolution in SAMIR Existing refinery Units /DCS Control rooms Upgrade Units /DCS Control rooms OPC Server 1 OPCS Server 2 OPCS Server 4 Process Data Process Data Process Data PI HA Collective : SAMIR PI (80 K) PI System 1 PI System 2 20K 50K Movement Files Manual Data OPC Server 3 LIMS Data 11

12 PI and Sigmafine Dataflow PI Server Import Process, Tanks and Transaction Raw Data Sigmafine Server Export Reconciled Data LAN 12 Sigmafine & PI Clients

13 PI and Sigmafine Dataflow Publish: Make available data for corporate users PI Server Import Process, Tanks and Transaction Raw Data Sigmafine Server Export Reconciled Data LAN 13 Sigmafine & PI Clients

14 Production Accounting Solution Key Points Product based dsolution: based on industry standards no custom programming, but products configuration only Entire architecture based on OSIsoft technology: Sigmafine graphical models are built with PI ProcessBook Accounting ad hoc Excel reports built with PI Datalink and AF Excel Add In Sigmafine relies on PI AF with native link with PI System Easy to use and configure: A unique graphical integrated environment for user s and administrators Handle configuration changes seamlessly either for process/timestamped and transactional data Quick deployment over clients (web reports use only Internet Explorer) High Scalability: It is capable to handle thousands of tags and elements in the same model It can grow in number of models/analysis dl/ l ifitting accounting needs/constraints d/ t It can be used on single or multiple time ranges (even automatically) Reconciled results can be historicized into the PI Server for long term analysis and comparisons. 14

15 Refinery wide Model Evolution Original i model: around 1300 PI tags and 500 Sigmafine elements Now more than 4000 PI tags and 1450 Sigmafine elements Future enhancements (TOPPING 4 unit) Adding other utilities: steam networks, fuel-oil consumptions, electrical network etc Added Sidi-Kacem tanks and pipeline Added Mohammedia pipelines and hold-ups Added utilities: Sulphur, WaterTreat etc Added upgrade project units Original Samir refinery model 15

16 Tools: Graphical Refinery Model The Sigmafine refinery graphical model is built with PI ProcessBook and allows integrated graphical environment for all the data, easy maintenance, quick production accounting data dt navigation and advanced ddiagnostic features. Graphical model in Run-mode Smart diagnostic Processbook Add-In Diagnostics rank data issues and guide to correction actions. Graphical model in Build-mode Allows to easily maintain the model in the same user GUI. What administraor see s is what user gets! 16

17 Tools: Manual Inputs to PI TIME STAMPED DATA: A set of predefined Excel spreadsheet powered by PI SDK and PI Datalink allows massive manual input to insert data that are not directly collected from DCS or tank gauging system (levels, temperatures, materials ). MOVEMENT DATA: Dedicated Excel spreadsheets allows to manage all operations regarding oil and products movements through AF SMT Excel Add In. Easy manual data insert with a unique button! 17

18 Tools: Operational Reports Operational, quick, and smart reports for daily production accounting are built in Excel using PI Datalink and PI AF Add In. Units and utility networks production & consumptions are extracted from reconciled PI tags by using PI-DataLink Refinery stock data are extracted with PI-AF Excel Add-In 18

19 Tools: Company Reports Company wide reports with consolidated stock and reconciled process unit yields are available through Samir intranet. Reports are daily and cumulated (e.g. monthly) and built using Microsoft SQL Reporting Services extracting data through Sigmafine SQL Access layer (RFC) and PI OLEDB. Some reports also show data coming from LIMS system. Reports in build mode: quick and smart report with SQL Server tools 19

20 Tools: Company Reports Company wide reports with consolidated stock and reconciled process unit yields are available through Samir intranet. Reports are daily and cumulated (e.g. monthly) and built using Microsoft SQL Reporting Services extracting data through Sigmafine SQL Access layer (RFC) and PI OLEDB. Some reports also show data coming from LIMS system. Sample of a deployed report in the intranet 20

21 Tangible Benefits Contributes to a broader vision of the refinery data: Supports the One Version of the Truth Better and consolidated quality of information Valid Data for Stock Management and evaluation Easy distribution of the data to refinery users: Operational reports only for accountants Companyreports for other dpts accessible over the intranet Availability and visibility of the valid information contribute effectively to timely decision making and to take advantage of opportunities. 21

22 Future Plans PI infrastructural upgrade: merge the 2 PI Systems in a unique new PI HA collective Include the upcoming TOPPING4 unit (Crude Distillation: BPSD under construction and commissioning by April 2012) Run Sigmafine energy balances for FuelGas and Steam networks Integrate the production accounting system with SAP Enhance the movement management part with Sigmafine IMM 22

23 Thank you! Questions? Mohamed Markoum, ma 23