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5th AnnualGlobalRefiningSummit2011 May18 20,2011 Rotterdam,Netherlands

IntelligentDataValidationand ReconciliationSolutionsforthe RefiningIndustry f d


MihaelaCristinaPopescu,HeadofPerformance Mihaela Cristina Popescu, Head of Performance Control,ArpechimRefinery,OMVPetrom Dr.RobertoLinares,VicePresident,VisiantPimsoft

Topics
BusinessPerformanceAspectsinRefining Refining Case RefiningCase ProductionAccountingandDataReconciliation (PADR)Requirements (PADR) Requirements PowerfulDataReconciliationConcepts Customer Benefits Using Sigmafine CustomerBenefitsUsingSigmafine YieldAccountingManagementPresentedby OMVPetrom OMV Petrom Conclusion
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BusinessPerformanceAspectsinRefining
Operational
o o o

Yield,Recovery,QualityTargets , y, Q y g ProductionRates ProcessConstraints(e.g.,environmental,physicallimitations) BestOperationalParameters(e.g.,LPs) ComparisonofPlannedvs.Actual MaterialLoss CostAllocation Cost Allocation InventoryPositions Taxes(e.g.,domesticvs.foreign)
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Planning
o o

Financials
o o o o

MarketDrivers
Environmental(GHG) Financial (Sarbanes Oxley Act) Financial(SarbanesOxleyAct) YieldAccountingStandards
o

APIStandard API Standard

RefiningMargins Security Theidealplatformfordatavalidationhastocomplywith emergingregulationsintherefiningindustry.

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RefiningCase
SourceofInformation
o o o o

ProcessHistorian Process Historian OilMovementSystem(OMS) VesselPositioningSystem(VPS) Vessel Positioning System (VPS) LIMS VCFaccordingtoAPI2004 OwnershipTracking ForeignandDomesticTracking MassBalance
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BusinessRules
o o o o

RefiningCase
Integration
o o

AutomaticDataCollection Automatic Data Collection IntegrationofOMSandVPSdataintoProduction AccountingSystem ExcelbasedforProductionAccountants Formaland/orWebbasedforRefineryUsers AutomaticReportingforMeasuredInformation

Reporting
o o o

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SolutionMap
DataFlowforRefiningCase
Historian Sigmafine OMS
Aggregation/ Integration

Excel Reports

Vessel Positioning System

Rules

SQL Access

Report Logic

Webbased Reports

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ProductionAccountingSolutionIntegration
TheBridgeBetweenBusinessandProcessData The Bridge Between Business and Process Data

Process Data

Lab Data

Movements Records

Planning Data

Scheduling Information

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MaximizingthePowerofYourMeasurements Maximizing the Power of Your Measurements


Sigmafineperformsflowssolvabilityanalysis. R Theflowisredundant,soitisbothmeasuredandsolvable. NR The flow is measured but not redundant so the measurement must be trusted Theflowismeasuredbutnotredundant,so themeasurementmustbetrusted. S Theflowisnotmeasured,butitisstillsolvable. NS The flowisnotsolvable.

SolvabilityandRedundancy

R NR

S NR

R
Themoreredundancy The more redundancy thebetter.Thisway, morevaluesmaybe crosscheckedto increaseaccuracy. increase accuracy

S S NR
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R
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MaximizingthePowerofYourMeasurements Maximizing the Power of Your Measurements


Sigmafineperformsflowssolvabilityanalysis. R Theflowisredundant,soitisbothmeasuredandsolvable. NR The flow is measured but not redundant so the measurement must be trusted Theflowismeasuredbutnotredundant,so themeasurementmustbetrusted. S Theflowisnotmeasured,butitisstillsolvable. NS The flowisnotsolvable.

SolvabilityandRedundancy

R R

S NR

R
*Byaddingameter totheflow,theflow becomesredundant. Asaresult,other meteredflowsalso becomeredundant.

*R

S S

R
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R
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FindingtheBestFitforYourModelandData Finding the Best Fit for Your Model and Data
54.2

Reconciliation

98.4 98 4

98.4 98 4

44.2

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OptimalUtilizationofExistingMeters

Non Redundant Network


Accurate Meter

Redundant Network

Accurate Meter

Less Accurate Meter

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ErrorDetection

WhichNetworkCanDetectaMeasurementError? Which Network Can Detect a Measurement Error?

Accurate meter failure

Non Redundant Network. There is no possibility of detection

Redundant Network. An imbalance can be detected

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MeterPerformance
ErrorIdentification Error Identification
Pure Gas E 1750 1600 1400 1200 1000 800 600 400 200 0 02-Sep-01 00:00:00 SLO East 250 C0F1230.AD 1649.4 C0F1230.SF Not Reconciled B2F1003.AD 400.5 400 5 B2F1003.SF Not Reconciled B2F2003.AD 402.47 B2F2003.SF Not Reconciled F0F1013B.AD 19.939 F0F1013B.SF Not Reconciled Pure Gas W 1750 1600 1400 1200 1000 800 600 400 200 0 11-Nov-01 00:00:00 C0F1109M.AD 89.787 ton/h C0F1109M.SF Not Reconciled ton/h C0F1116M.AD 76.712 ton/h C0F1116M.SF Not Reconciled ton/h C9F1004.AD 181.66 m3/h 3/h C9F1004.SF Not Reconciled m3/h SLO West 250 20F0101.AD 1571.4 20F0101.SF Not Reconciled 12F1003.AD 422.08 422 08 12F1003.SF Not Reconciled 12F2003.AD 428.68 12F2003.SF Not Reconciled F0F1013A.AD 0. F0F1013A.SF Not Reconciled

Bias

Drift
30.59 Day(s) 11-Dec-01 14:02:56 20F1109.AD 99.745 m3n/h 20F1109.SF Not Reconciled m3/h 20F1116.AD 89.789 m3/h 20F1116.SF Not Reconciled m3/h 29F1004.AD 192.7 m3/h 3/h 29F1004.SF Not Reconciled m3/h

100.59 Day(s)

11-Dec-01 14:02:54

200

200

150

150

100

100

50

50

0 02-Sep-01 00:00:00

100.59 Day(s)

Meter Error

11-Dec-01 14:03:04

0 02-Sep-01 00:00:00

100.59 Day(s)

11-Dec-01 14:03:05

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OptimumMaintenanceofRefineryMeters
TakingActiontoImproveMeterPerformance Taking Action to Improve Meter Performance

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ImprovingtheOverallPicture
HigherConfidenceinRefineryData Higher Confidence in Refinery Data
30% 25% 20% 15% 10% 5% 0%

Overall DX1 Trend ( Q4 2008 - Q1 2010)

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OilLossMonitoring
BeforeandAfterSigmafine Before and After Sigmafine
Error Elimination Meter Improvements

Better Decisions

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OilLossMonitoring
BeforeandAfterSigmafine Before and After Sigmafine
Loss Accountability Loss Accountability 5 4 3 2 1 0 -1 -2 -3 Sigmafine available

(%)

ja n04 m ar -0 4 m ai -0 4 ju l-0 4 se p04 no v04 ja n05 m ar -0 5 m ai -0 5 ju l-0 5 se p05 no v05 ja n06 m ar -0 6 m ai -0 6 ju l-0 6 se p06 no v06 ja n07 m ar -0 7 m ai -0 7

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OilLossMonitoring
BeforeandAfterSigmafine Before and After Sigmafine
Feb/01 - Jan/02 (Loss % Cumulative = 1.09%)
10.0% 8.0% 6.0% 4.0% 2.0% 2 0% 0.0% -2.0% -4.0% -6.0% Loss % 3 Month Rolling Loss % Cumulative
Benchmark

Mass Balance Before Sigmafine

Oil loss (%) After Sigmafine Implementation


Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan

SF Losses
1.08 1.20 1.00 0.80 0.60 0.40 0.20 0.00 Jun/02 Jul/02 Aug/02 Sep/02 Oct/02 Nov/02 %

0.48 0.23 0.30 0.12

0.53

SF monthly

SF cumulative

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ASignificantBiasCausesFinancialLoss A Significant Bias Causes Financial Loss

CustodyTransferErrorDetection

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AccountingFuelConsumption
5,000 4,500 4,000 3,500 3,000 , 2,500 2,000 1,500 1,000 500 14Oct 15Oct 16Oct 17Oct 18Oct 19Oct 20Oct 21Oct 22Oct 23Oct

OptimizationofEnergyUseRequiresInformation Optimization of Energy Use Requires Information


FuelConsumption,Oct2010 Sigmafine

Legacy System
24Oct 25Oct 26Oct 27Oct 28Oct 10Oct 11Oct 29Oct 1Oct 2Oct 3Oct 4Oct 5Oct 6Oct 7Oct 8Oct 9Oct 12Oct 13Oct

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MonitoringRefineryPerformance
ValidationofKPIs Validation of KPIs
Current/Shift/Running Plan Reconciled vs. Theoretical Yields Running Plan KPIs

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PerformanceMonitoring
ValidatingYieldData Validating Yield Data

Reconciled Yields

Theoretical Yields

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IncreasingYieldProfitability
PerformanceManagementImprovement Performance Management Improvement

Exampleofdieselyieldimprovements
o

Analyzinghomogeneousdatarelatedto sweet crudes: Analyzing homogeneous data related to sweetcrudes: 2003actualaveragedieselyield 37,4% 2004actualaveragedieselyield 39,6% Averageactualdieselyieldincreasedduebothtoinvestmentson ld l ld dd b h plantsandtoperformancemanagement. Historicalanalysisondieselyieldshowedthattheaverageincrease duetoperformancemanagementamountwasabout0.8%inthe d f b h period20032004. ThisledtoaprofitincreaseestimatedinUS$1 millionperyear.

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LowYieldDetectionAfterCatalystImprovement
UnmaskingHiddenProblems Unmasking Hidden Problems

Data Quality Improvement: Profits


Mass balance yield - FCC (Fluidized Catalitic Cracking Unit)
110

105

*Data reconciliation group identified LCO flow meter fault *During this p g period it was believed that LCO yield had increased.

M Mass balance yield (%)

100

95

Flow meters maintenance required by reconciliation group Unit shut down Different catalyst loaded

90

85

**LCO flow meter repaired Actual **Actual LCO yield equal to the value previously to the catalyst change

**Lower light HC and more decanted Lower oil produced = Less profits
17-02-2005 09-03-2005 29-03-2005 18-04-2005 08-05-2005 28-05-2005 17-06-2005 07-07-2005 27-07-2005

80
28-01-2005

Date
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LowYieldDetectionAfterCatalystImprovement
UnmaskingHiddenProblems Unmasking Hidden Problems

Data Quality Improvement: Profits

Eliminated loss corresponding to US$ 23.5 million per y $ p year


M a s s b a la n c e y ie ld - F C C (F lu id iz e d C a ta litic C r a c k in g U n it)
110 105

Mass balance yield (%)

*Data reconciliation group identified LCO flow meter fault *During this period it was believed that During LCO yield had increased.

100

95

Flow meters maintenance required by reconciliation group Unit shut down Different catalyst loaded

90

85

80
2 8 -0 1 -2 0 0 5 1 7 -0 2 -2 0 0 5 0 9 -0 3 -2 0 0 5 2 9 -0 3 -2 0 0 5 1 8 -0 4 -2 0 0 5 0 8 -0 5 -2 0 0 5

**LCO flow meter repaired **Actual LCO yield equal to the value previously to the catalyst change **Lower light HC and more decanted oil produced = Less profits
2 8 -0 5 -2 0 0 5 1 7 -0 6 -2 0 0 5 0 7 -0 7 -2 0 0 5 2 7 -0 7 -2 0 0 5

D a te

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ReconciliationCoupledwithOptimization
ValidatingBlendingOptimization Validating Blending Optimization

Data Quality Improvement: Profits


Cost Integration C tI t ti with Reconciled Data Optimizer Result

62,77 US$/m3

63,84 US$/m3

1,00 US$/m3

difference

Measurement Problem Hydrotreated Diesel Flow

x 15 000 m3 15.000 15.000,00 US$/batch x 40 batches/month 600.000,00 US$/month x 12 month/year 7.200.000,00 US$/year

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DetectingOperationalErrors
FindingUndetectedProblems Finding Undetected Problems

Data Quality Improvement: Profits


Volum etric entrainmof the aromatic removalaromtotal amount byunit, total V l Financial t i t i tl f th ti l it t losses ent losses from the unit, atic rem oval month t l am ounts by m Jun-2006 to Jun-2006 to m ay-2007. from onth from may-2007. 1000 160000 900 140000 800 120000 700 100000 600 500 80000 400 60000 300 40000 200 20000 100 0 0
13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 07-02-2007 08-04-2007 08-04-2007 07-06-2007 07-06-2007

Solvent entrain nment, m3 Loss, US S$

Data reconciliation group detected rubber solvent entrainment from solvent unit to gasoline unit.

Date Date
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DetectingOperationalErrors
FindingUndetectedProblems Finding Undetected Problems

Data Quality Improvement: Profits


Volum etric entrainmof the aromatic removalaromtotal amount byunit, total V l Financial t i t i tl f th ti l it t losses ent losses from the unit, atic rem oval month t l am ounts by m Jun-2006 to Jun-2006 to m ay-2007. from onth from may-2007. 1000 160000 900 140000 800 120000 700 100000 600 500 80000 400 60000 300 40000 200 20000 100 0 0
13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 07-02-2007 08-04-2007 08-04-2007 07-06-2007 07-06-2007

Solvent entrain nment, m3 Loss, US S$

Potential profit depends on the difference between rubber solvent and gasoline prices

Date Date
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DetectingOperationalErrors
FindingUndetectedProblems Finding Undetected Problems

Data Quality Improvement: Profits


Volum etric entrainmof the aromatic removalaromtotal amount byunit, total V l Financial t i t i tl f th ti l it t losses ent losses from the unit, atic rem oval month t l am ounts by m Jun-2006 to Jun-2006 to m ay-2007. from onth from may-2007. 1000 160000 900 140000 800 120000 700 100000 600 500 80000 400 60000 300 40000 200 20000 100 0 0
13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 07-02-2007 08-04-2007 08-04-2007 07-06-2007 07-06-2007

Solvent entrain nment, m3 Loss, US S$

Total solvent entrainment: 14 % of feed Total annual losses: US$ 0.7 million

Date Date
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LossofCapacityVersusNominalCapacity
BiasDetectionofaMeter Bias Detection of a Meter

Loss of processing capacity US$ 25.7M/year 25 7M/year


Carga U283A
5800 5600

Carga Proce essada (m3)

5400 5200 5000 4800 4600 4400

01-09-07

15-09-07

29-09-07

13-10-07

27-10-07

10-11-07

24-11-07

08-12-07

22-12-07

05-01-08

19-01-08

02-02-08

16-02-08

01-03-08

15-03-08

29-03-08

12-04-08

26-04-08

10-05-08

24-05-08

07-06-08

21-06-08

05-07-08

19-07-08

02-08-08

16-08-08

30-08-08

13-09-08

Carga medida C did

Carga R C Reconciliada ili d

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27-09-08

CustomerPresentation
YieldAccountingManagement by byMihaelaCristinaPopescu ae a s a opescu OMVPETROM

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Conclusions

SatisfyingGlobalRefineryNeedsintheFieldofPADR Satisfying Global Refinery Needs in the Field of PADR


Territories

Sigmafinebased solutions Sigmafine basedsolutions deliversignificantbenefitsto refiningcustomersworldwide. Solutionshavetobeadaptive, keepingthecustomer requirementsinmind. requirements in mind Sigmafinetechnologiesare designedtosatisfycurrentand designed to satisfy current and futurebusinessrequirements.

NorthAmerica Europe&Russia Asia&Pacific LatinAmerica MiddleEast&Africa


6% 17% 28%

21% 28%

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Thankyou! Thank you!


MihaelaChristinaPopescu,Mihaela_Cristina.Popescu@petrom.com Dr.RobertoLinares,roberto.linares@visiant.com Dr Roberto Linares roberto linares@visiant com

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