Paper 102


Template for Modelling Refinery Logistics and Operation Using ARENA
Authors : Marcelo Moretti -PARAGON (Brasil), Luiz Augusto Franzese , Daniel Pablo Paz PARAGONTECH LOGSIS (Argentina) Coauthor: Carlos Bacigalupo - PETROBRAS ENERGIA


This work describes the development of a template of components for building discrete event simulation models of Petroleum Refinery Processes and Logistics. These components were conceived to be reusable, friendly editable, using industry specific units and terms, intuitive to the final user, and representing real world objects and procedures. The template was created using the software ARENA, combining continuous and discrete simulation components. Using this template we have built a simulation model of the logistics of the San Lorenzo refinery of PETROBRAS ENERGIA (Argentina). By using this tool, it was possible for analysts to evaluate the impact of new investments, testing different plant configurations, operational schemes, and demand scenarios. After testing the Template in this real case, we have obtained a valid, and reusable tool. Further applications of this tools might be in the field of refinery plant design. Also, this tool might be extensible to other process industries, using liquids, like: oil, milk, beverage, etc.

I. TRADITIONAL DISCRETE EVENT SIMULATION A. Simulating Discrete Manufacturing Concepts: Entities: discrete objects moving through the sistem Processes: generally representing machines or stations Resources: adds restrictions to the system, an entitiy has to seize e resource to perform an step to advance in the process Queues: waiting positions Logic: control to the flow of entities among branches of the process

Figure 1: Example of an elemental discrete process

Index Terms—

Discrete event Simulation, Fluid flow, Petroleum, Software reusability.

Traditionally, discrete event simulation has been applied extensively to represent discrete manufacturing processes, like automotive, steel, etc. In such models, “entities” represent parts moving in a system. Most simulation languages define single operations to represent the logic governing the flow of “entities” between “machines” or waiting in “queues”. In order to develop the model required from PETROBRAS ENERGIA was necessary to create new tools which allows a

B. Simulating Continuous Processes Concepts: Tanks: represents continuous level of a fluid(levels) Flow: transference of fluid from one tank to another Valves: regulators of flows among different tanks Logic: opening and closing valves, is the way to control the transference of fluids through the system

Figure2: Example of an elemental continuous process

in a Refinery is impossible to understand a “typical workflow” in such a way. Just defining its parameters for each new instance. and represent the fluid transfer according to common operational practices. calling a Ship to dispatch products. The production line defines a Process very clearly. Understanding process concepts 2 Flow C. there are no “entities” the problem is how to manage the circulation of fluids according to a certain logic. for example. remove fluid. etc. In facts a Refinery has a very big quantity of alternatives to move fluids from a tank to other tank. Templates in ARENA Templates allow to pack an important amount of logic.Paper 102 In the case of a Refinery Process. To represent the “Process Workflow” it is necessary to understand the “typical” operational alternatives. D. Valves. Building Elements To build a useful template it was necessary to represent two kind of elements (like in discrete simulation) 1. blend. C. and interaction with the whole logistics system. • Dialog Window: allows the user to set the parameters defining an instance of the Element • Animation: is the form in which the element will appear in the model animation • Logic Block: is the form in which the element will appear in the model logic Control Logic A variety of elements is represented as “tanks” which are controlled by a logic specific for the behavior of each kind of element. a very big quantity o operational variables. The “Flow Process” template existing in ARENA. Those objects have to be disposed on the process layout. II. Those objects have to be arranged in the logics that represent the typical operations of the plant. add fluid. Conceptualizing Fluid Processing Elements The general approach to represent each Element in a template is: Each template “Element” is a black box that may be accessible to the user in different views: • Icon: represent the element to drag from the template indo and drop into the model layout. tubes. blending formulas. simulation languages are defined in terms of concepts that allows managing such entities. animation and data in a single object which is transparent to the user. For instance: a valve or a tube will be essentially Tanks. Process Units. but having a different control logic. Differences between refinery simulation and traditional manufacturing simulation As traditional discrete process simulation deals with the definition o “entities” flowing through different machines and buffers. B. Additionally it is necessary to represent those processes involving Push or Pull policies for automatic refill. Operational objects: transfer. 2. APPROACH TO THE PROBLEM A. an important amount of model logic may be reusable. Figure 3: Flow Process Template In traditional manufacturing the Workflow is very clear and very easy to understand jus standing for a while in front of the machines. however it requires an important effort to model the logic of a real world operation. Real world physical objects: Tanks. represent small parts of objects and operations related to fluid processing. However. It was necessary to create new elements to represent traditional simulation concepts into a continuous process. etc. .

Additionally. tanks capacity. several ports. process units. Using Elements This would be virtually impossible or extraordinary extensive to model one by one. Previous experiences have allowed to model the shipping process. At the beginning and the end o this model we can connect traditional ARENA logic to represent the operation of transport units. Additionally. At the second step. Therefore the template approach has allowed to do this effort in less than six months. continuously. The model to develop have to represent the flow. which defines how the fluid will move though the process: by batch. as well as a single plan operation in detail. storage stations and refineries. the solution was to build the genera model and construct separated submodels when was necessary to analyze a single process in detail. Because it is quite impossible to represent a very wide model with a high level of detail. At the other side. ducts. ducts. push or pull. the model to create will have to be easy to modify by the user. docks. plant capacity. we define the parameters of those elements Finally we have to represent the operational practices. and were to invest in order to provide such capacity. arranging in it the different ports. the user needs to evaluate in detail a single Truck Loading process into a single plant. 2) Complexity. and process units. transferences by ship and tucks dispatches. The Problem to Solve Petrobras Energia have to decide how to invest in new logistic assets in order to align its logistics system to a significant increase in Refining Capacity. we begin to drag drop any real world object we find in the Process Workflow. and operational policies. supply schemes. valves. like Tanks. Extension an Detail The total extension of this model involves the hole map of Argentina. this tool will have to be useful to represent the whole supply chain in Argentina. It was no clear if an increase in production would be limited or not by the logistic system. Tank Process Units Tubes Ducts Auxiliar elements (manifolds. integrating the two refineries.Paper 102 Template Elements: Real World 3 III. truck bays. in order to test different demand scenarios. but no previous work or product have dealt with the logistic inside the refinery. Model’s Complexity 1) San Lorenzo Refinery Process (Petrobras) To model this refinery was necessary to represent: To build a model of a refinery. and the restrictions of each operation. . We connect those objects using “tubes”. B. REAL APPLICATION A. content and utilization of tanks.etc) Control Logics 80 17 140 16 35 180 Template Elements: Operational Objects E.

Has leaded the application of simulation in Argentina and other countries. leading and pioneer company in simulation in Latin America. PARAGONTECH LOGSIS S.and Master in Business Administration (U. 1999). Barcelona. to represent several operational alternatives.A. and trained more than 1. K. Contact: carlos. Simulation for Recurring Decisions. AUTHORS 4 LUIZ AUGUSTO COAUTHOR CARLOS MARIA BACIGALUPO is Chief of Schedulling and Planning of New Businesses at PETROBRAS ENERGIA. Is consultant in simulation. Additionally it was necessary to generate variations and sensibilities. demand Repsol YPF y Petrobras Energía S. in several areas as New Businesses..N. by now has successfully completed 150 projects in simulation. Proceedings of the 2004 Winter Simulation Conference.bacigalupo@petrobras. Less effort Additionally. (2004). 3) Scenarios and Alternatives Combining the different demand scenarios. (2000)... He has founded the first exportation group of TIC’s of Argentina and conducted the Cluster of High Tech Companies “Polo Tecnologico Rosario” Contact: dpaz@paragontech. McGraw Hill 2006 [2] Arons H. Sturrock. FRANZESE is Production Engineer . USA. R. the model may be used b people with just a basic training in simulation. Stoutjesdijk W. MARCELO MORETTI FIORONI is consultant in simulation Electrical Engineer.. Has recently founded with Luiz Franzese.200 professionals in simulation.. ACKNOWLEDGMENT Carlos Gratti – Logistics Director.Paper 102 The template created was useful to represent the global level. Buenos Aires).R. is Industrial Engnineer (U. DANIEL P. Master in Production. as well to represent the detailed level. Contact: paragon@paragon. Flexibility It results relatively easy to modify the process definition. and trained more than 1. Founded PARAGON Technologic in 1992. 1993).200 profesionals in simulation.. Cofounder of PARAGON Tecnología in 1992. USA. Contact: marcelo@paragon. Asperen E. Is consultant in . [3] Ruiter.. by now has sucessfully completed 150 projects in simulation. Dekker R. Torcuato Di Tella.Rosario. Sluijs J. even to modify the process.. Bachelor in Marketing and MBA (U. It provides an intuitive way of documenting a dynamic representation of the refinery process. and investment alternatives. PAZ Is consultant in logistics. in order to evaluate precisely the effects of any mayor investment or significant change in the operational logic. working at TECHINT group until year 2000. B. operation logic and test different plant configurations and scenarios Designing New Plants It may be a valuable tool to design new plants testing its whole operation before building them. and coursing Doctorate in Logistics. CONCLUSION Success Dealing with Complexity Using a refinery template allows an organization to model very complex refinery process and logistics. Coordination in a Supply Chain for Bulk Chemicals. Management Control. PETROBRAS ENERGIA (ARGENTINA) Alberto Martinez –Downstream Planning Manager . IV. Teaches Operations Research and Simulation in Facultades Integradas de San Pablo (FISP). C. and drastically reduces the time needed to build a model. we would wave to create more than six different models. first logistics simulation company in Argentina.and Master in Logistics. Proceedings of the 2000 Winter Simulation Conference. PETROBRAS ENERGIA (ARGENTINA) REFERENCES [1] Simulation With Arena . Has worked in Oil companes like Astra CAPSA. Polman M.