SS OPTMZ-01 Part 1 SimSci Optimization Opening Session. Optimization Update and Integrated Yield Accounting. John Hernandez Tom Kinney

Transcription

1 Slide 1

2 SS OPTMZ-01 Part 1 SimSci Optimization Opening Session Optimization Update and Integrated Yield Accounting / #SoftwareRevolution /InvensysVideos /InvensysOpsMgmt /Group/SimSci John Hernandez Tom Kinney 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

3 ROMeo 6.1 Guiding Objectives Strengthen customer partnerships by developing features that meet their needs with online optimization software by: Meeting Customer Commitments Expanding into Utilities Optimization Market Enhancing Usability, Improve Configuration Efficiency and Maintainability Solution Extensions Slide 3

4 What s New in ROMeo 6.1 First wave of KBC Reactors, NHTR Information Stream Utilities Optimization (ERTO) LP Update Manager Off-sites Integration MBM Enhancements Component balance Slide 4

5 Utilities Enhancements with 6.1 Single platform: Process RTO and Utilities Optimization =>flexibility of training on a single tool Enhance usability => utility models fit for Utilities/Energy optimization New Energy Real-Time Optimization (ERTO) Models: Boiler Model Steam Turbine Model Heat Recovery Steam Generator Model (HRSG) Gas Turbine Generator Model (GTG) Slide 5

6 ERTO Boiler Simple (Steam Side) Model Option to Free Boiler Feed Water Within Model Detailed (Exhaust Side) model Internal or External Fuel & Air Streams Fixed or Calculated Efficiency Slide 6

7 ERTO Boiler Boiler2 icon lay down Slide 7

8 ERTO Boiler Simple Model Simple Flowsheet Feed Water, Steam and Blowdown Fixed Efficiency Slide 8

9 ERTO Boiler Simple Model Simple Model Calculated Efficiency Feed Water, Steam and Blowdown Fuels and Air Choose 1 free fuel Slide 9

10 ERTO Steam Turbine Same Model as Original Steam Turbine Ability to Free Feed Rate Through Model Slide 10

11 ERTO HRSG Can be Paired with the GTG Fired or Unfired Simple and Detailed models Internal or External Fuel Side Streams Slide 11

12 ERTO GTG Paired with the HRSG Model No Feed or Product Streams Curves for: Max Power IGV Position Heat Rate Unfired Efficiency Slide 12

13 Usability Improvement with 6.1 Enhance Usability, Improve Building Efficiency and Maintainability Customers desire improved sustainability and maintainability of ROMeo applications Update features to provide graphical features that make it easier to determine how the model is configured and related. New Information Stream Model Ergonomic Enhancements 33 New keyboard shortcuts RTS Macro Manager Centralized management of scripts used in the Real-Time-System (RTS)

14 InfoStream Graphically Link or Equate variables Graphically Link Parameters Equations in the form of a + b (Var c) Slide 14

15 InfoStream Slide 15

16 InfoVectors User Defined Sets of Variables and/or Parameters that can be Viewed in InfoStream Slide 16

17 InfoVectors Slide 17

18 RTS Macro Manager Same as the Model Macro Manager Standard Macros XML in Server\System\Config Can be Updated and Shared Sequence Macros Available to the Current Sequence Only Slide 18

19 New Reactor Capabilities with 6.1 Customer Commitments Customers desire the ability to use 3rdparty reactor models in ROMeo, like the Naphtha Hydrotreater Model Build interfaces to SimSuite 4.1 New SimSuite 4.1 N-HTR Model Slide 19

20 NHTR (PetroSim 4.1) Reactor New Naphtha Hydrotreater Reactor KBC s PetroSim 4.1 Runs as part of PetroSim, not as a dll Options to Open the PetroSim GUI when Running the Model in ROMeo Requires KBC PetroSim Installation and *.ksc Data File Tip: Keep the PetroSim Model as Small as Possible Slide 20

21 Solution Extensions with 6.1 Integration of ROMeo with other applications Component and heat balance capability to MBM Connect to Invensys Off-sites Suite Updates to planning applications Slide 21

22 MBM Component and Heat Balance Options to Either Report or Balance Components Not Linked to Thermo Split Fractions Option to Report Heat Balance Simplified User input of Duty per Node Slide 22

23 MBM Component and Heat Balance Report Component Balances Reconcile Component Balances Report Heat Balances Slide 23

24 Offsites Integration with ROMeo 6.1 Objectives Leverage Offsites Crude composition data for ROMeo Optimization Leverage ROMeo product properties with Offsites Product Blending Value Improved Crude Feed composition improves ROMeo Optimization results Optimized Product property data improves Offsites product blending output Engineering or RTO Model Offsites Operations Crude/Feed Data Product Properties Slide 24

25 Off-sites Integration with 6.1 via EDI SQLOLEDB Connection Designed to Work Specifically with Offsites Option to Import All Tags when First Creating Port Group (This option goes away once the group has been created) Slide 25

26 Updating LP Models with ROMeo 6.1 Capabilities Update any LP model with rigorous model results (vectors) Accommodate the variety in the LP model structures Reliable and easy Process Import LP model coefficients from ROMeo rigorous model run(s) Planner retains control of the Mapping process Ability to make custom unit conversions if required Export results in spread sheet form, ready for use in LP Retains record of all model updates and ability to trend coefficient values over time Slide 26

27 LP Update Manager RTO Model Plant Data Crude/Feed Data DCS Plant RTDB LP Update Manager Refinery LP Slide 27 LP Vectors

28 LP Update Manager Overview Slide 28

29 LP Update Manager Environment Slide 29

30 Updated LP Sub-model or Module All updated coefficients are blocked Slide 30

31 What s Coming Up in 6.1. ROMeo Spiral Integration Information Stream Improvements REFSim 4.1 Integration Slide 31

32 ROMeo Spiral Integration MINLP On track for ROMeo release Mixed Integer non-linear optimization Planned for ROMeo 7 release 64-Bit Operation ROMeo servers to be native 64-bit KBC v3.3 models currently 32-bit, v4.1 will be 64-bit compatible (not a barrier, separate processor) Spyro 64-bit release uncertain pending commitment from Technip Release will be a ROMeo v7 issue Slide 32

33 ROMeo Intelligence ROMeo imonitor ROMeo 6.0 release with Intelligence: Integration component to push data from ROMeo to WWIntelligence environment Uni-directional data flow: ROMeo Addressed need to: Monitor ROMeo RTO applications and Key Performance Indicators Provide user-accessibility via the browser Invensys is moving to incorporate imonitor into the ROMeo Suite WWIntelligence Extends the features that are offered by the WWIntelligence integration Users can interact with ROMeo via the web browser (data entry capability) Invensys will maintain and support imonitor moving forward Slide 33

34 ROMeo imonitor Orientation between Shell and Invensys initiated Code and documentation supplied to Invensys Next steps: Analyze code and documentation Compile and test code on Invensys system Conduct additional orientation and instruction webinars Design architecture for system in Invensys offices Define features, if any to add Lodge code and platform development into Invensys development workflow structure Planned release with ROMeo 6.2 Slide 34

35 Leveraging ROMeo within the Invensys Portfolio Operations Planning ROMeo Inventory Management Product Quality Tracking Blend Execution Slide 35

36 High-level Roadmap Efficiency Enhancements ERTO 1st release LP Bridge-Rxtrs Off-sites Integration 64-Bit Support Line Up Manager MINLP ISOMAR Rxtr Integration with Spiral imonitor Improved FCC Model Enhanced APC Integration MBM Component Balance Focused Development Patches Released as required Customer driven Slide 36 Customer Satisfaction Leverage via Integration Ease of Use Partnering with our customers Improved Integration with Spiral NH3 Rxtr Models

37 Integrated Yield Accounting 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

38 ErrorSolver User Environment Models Details and Drilldown Analysis Slide 38

39 Integration to Off-sites Slide 39

40 Integrated Mass Balance & Reconciliation Yield Accounting Reporting System 2 Purchase and sales ERP Automatic DR DR Models 4 DR results 3 RTDB Process Data Lab. Data Material Balance 1 Composition Tracking LIMS Slide 40 Tank and movement data Tank Inventory & Movement System

41 Modeling Capability for Mass, Volume and Energy H2 - Energy Fuel Gas/LNG - Energy Fuel Oil - Energy Heater & Boiler etc. H2 Supply H2 Consumption Process Yield DR Models Slide 41 Fuel Gas Supply Rundown Charge Fuel Oil Supply OFF-SITES

42 Questions & Answers Slide 42

43 Slide 43

44 Additional Slides Slide 44

45 Opportunities Refineries that have blend operations and optimization practices are potentially not leveraging two sources of information to improve efficiency and profitability. Refiners are faced with the challenge of updating their planning models which affect the yield patterns. ROMeo models of the conversion units can be used to generate accurate predicted yield patterns and yield sensitivity values (delta vectors) for the LP. Actual crude blend data should be used as input to the ROMeo conversion models, resulting in more accurate yield vectors for the LP Models Slide 45

46 Optimizing the Planning Process Do we have a close connection between our Planning and Scheduling functions and our day-to-day Plant Optimization strategies and applications? Do we have consistency between the models used in the planning process and the conversion units? How can we better coordinate between what the planner needs for his LP updating and what the plant engineer can provide? Slide 46

47 Connecting disparate data sources Some key questions: Crude Oil Testing Compositions, properties, etc. How can existing data be leveraged? How can we be certain of the quality of the data? How can the associated tasks be completed with ease and confidence? Which aspects of the operation or business will be improved? What are the financial benefits? Ultimately how can data be exchanged and work processes be sustained? Crude oil values Crude Oil Manager Updated ASSAYS Crude Oil Blending Actual compositions, properties, etc. Real time Optimization Real time Optimization Refinery LP Operating goals & targets Base and delta vector coefficients Optimal setpoint targets Stream properties Inventories & blend stocks Tank Inventories Lifting Schedule Product Blending Starting point - the use of information sources based on best available data Slide 47

48 Summary of concepts: Addressing some of the most important operational and business decisions such as feed What are the results: stock purchases, plant shutdowns, product qualities, etc. System developments; Crude Blending to ROMeo Extend existing applications to benefit each other Sustainable solutions; completing task with Improve crude oil management Reduced upsets to operations Crude Unit Optimization Reduced Plan vs. Actual gap More profitable unit operations Feed Stock Acquisitions necessary ease and confidence Additional value from existing investments The specific aspects of the operation or business will be improved Actions more profitable & reliable operations Slide 48 More profitable crude unit operations Operations through sharing of data and ROMeo LP Update Manager Crude Oil Blending More profitable crude oil and feed stock purchases Product Blending Inventory Forecast Reduced product cost $0.10 to $1.00 per barrel processed

49 Potential Benefits from Improved LP Models Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Refinery Capacity bbl/day Refinery Refinery Refinery Refinery Slide 49 Coker FCC Reformer DSL HT FCC Pre HT Alky Unit Capacity (bbl/day) Estimated Benefits ($/bbl) Estimated Annual Benefits per Unit ($ MM/yr) Estimated Savings Range $ MM/yr $ MM/yr $/bbl Isom Total from Unit contributions

50 LP Model Challenges How do we update any LP model with rigorous flow sheeting models? There is a great variety in the LP model structures Any approach or method should be reliable and easy Goals Import LP model coefficients from ROMeo rigorous model run(s) Planner retains control of the Mapping process Ability to make custom unit conversions if required Export results in spread sheet form, ready for use in LP Retains record of all model updates and ability to trend coefficient values over time Slide 50

51 Case Comparison Interface Coker Example Slide 51

52 Case Comparison Interface Reforming Example Slide 52

53 LP Update Manager Overview Slide 53

54 LP Sub-model or Module Template Slide 54

55 Imported Rigorous Model Values Mapping Controls Slide 55

56 Generated Worksheet updated coefficients Slide 56

57 Tracking Coefficient Values Slide 57

58 Updated LP Sub-model or Module All updated coefficients are blocked Slide 58

59 LP Updating with Rigorous Models RTO Model Plant Data Crude/Feed Data DCS Plant RTDB LP Update Manager Refinery LP Slide 59 LP Vectors

60 Integrated Off-sites, Optimization & Planning Leverage real-time information usage between Off-sites and Optimization: Provide most accurate real-time information to enable optimization of Crude Units Provide bulk stream properties to product inventory and blending operations Streamline workflow and planning, scheduling, oil movements and optimization to minimize value loss Reduction in off-spec streams leaving the Crude unit Achieve tighter quality and blend control on products Slide 60

61 Why Perform Data Reconciliation? Physical loss Accounting loss Receipt Feedstock inventory (Purchase) Material Balance using Data Reconciliation Accounting loss Process Product inventory Shipment (Sales) Increasing accuracy of measurements using Data Reconciliation Data Reconciliation will produce more accurate and reliable data. Slide 61

62 Measurement Reliability - Bad Actors Measurement error of flow meter in normal refinery/petrochemical plant (Measurement Error) Slide 62 Slide 62

63 Where can Losses Occur? Feedstock inventory Receipt Process Physical Losses Fugitive Emissions Leakage and Misdirection Major plant disturbance Slide 63 Product inventory Shipment Accounting Losses Measurement

64 Required Data for Closing the Balance Feedstock inventory Receipt Process Product inventory 1) Daily purchase & sales data of materials 2) Daily Tank inventory & movement data Slide 64 Slide 64 3) RTDB process data of each plant Shipment

65 Receipts and Shipments Receipts Cargo tickets Pipeline transfer tickets Transport Certificates Slide 65 Shipments Potential Losses Fugitive during transport Data management

66 Off-sites Raw Materials Products Gauging Temperature Composition Slide 66 Dippings Filling/Emptying Blending Potential Losses Stuck gauges Leaks/misdirection Emissions Calibration Breathing

67 Inventory Management Measure, validate and track tank inventories in real-time Ullage Maximum Working Volume Tank Capacity LAHHH, Interlock, no TIS alarm LAHH, Movement shutdown Maximum Working Level LAH Measured level Pumpable Volume Minimum Working Volume Total Observed Volume Operator setpoint LAL Minimum Working Level LALL, movement shutdown Calculations to adjust data for material types, blending, conditions, and other tank activities Slide 67

68 Order & Movement Management Must unify the work & data flows between marketing, planning & scheduling, operations, & accounting. Must manage all tank, unit, pipeline/dock/rack terminal movement categories, including blending operations, and other complex orders Slide 68

69 Emissions Monitoring Breathing Losses Expellation Losses Evaporation Losses HOLD FILL LEVEL EMPTY TIME Slide 69

70 Composition and Tank Quality Product Composition Tracking Tank Quality Integration Equipment configurations Flow-by E Mx1 Mxn Fill/Draw Mx1 Mxn E Slide 70 My1 Mym My1 Mym

71 Movement Automation Line-up Checks and Validations Integration with Field Devices Reduced product contamination, slops, stock loss, off-spec product release, demurrage Slide 71

72 Process Units Flow meters Temperature gauges Pressure gauges Lab and field quality data Potential Booked Losses from Calibration Properties changed, multiple phases Different service Instrument faults Plugged meter connections Eroded orifice or nozzle Signal losses Misalignment of quality data Slide 72

73 Potential for Human Errors Feeds Slide 73 Products Inventory change? No Loss

74 Automated Data Gathering Electronic data gathering everywhere possible eliminates the possibility of human error in the data Slide 74

75 Steps in Closing the Balances Data Reconciliation Gross Error Detection Representative Model Model Validation Missing Flow Detection & Variable Faulty Classification Measurement Detection Data Reconciliation Optimization Increase Accuracy Inaccurate Measurement Value Material Balance (Constraint) Slide 75 Accurate Reconciled Value with Material Balance Accurate Optimized Value with all kinds of Constraints (such as min/max of stream)

76 ErrorSolver User Environment Models Details and Drilldown Analysis Slide 76

77 Integration to Off-sites Slide 77

78 Easy Access to Details Slide 78

79 Reconciliation Reporting Slide 79

80 Summary Reports Slide 80

81 Loss Analysis Views Slide 81

82 Modeling Capability for Mass, Volume and Energy H2 - Energy Fuel Gas/LNG - Energy Fuel Oil - Energy Heater & Boiler etc. H2 Supply H2 Consumption Process Yield DR Models Slide 82 Fuel Gas Supply Rundown Charge Fuel Oil Supply OFF-SITES

83 Integrated Mass Balance & Reconciliation Yield Accounting Reporting System 2 Purchase and sales ERP Automatic DR DR Models 4 DR results 3 RTDB Process Data Lab. Data Material Balance 1 Composition Tracking LIMS Slide 83 Tank and movement data Tank Inventory & Movement System