DSM-2005020-ST Basic Data

Downstream Manufacturing Restricted
MBAM Code and Name: Basic Data Document Number:

MAN.20.05 Make Product -
Ensure Plan Delivery DSM-2005020-ST
Shell Downstream Manufacturing
Basic Data
Table of Contents
1. General Information ................. 2 2.3 Reconciliation of Mass Balances
1.1 Scope and Purpose...................... 2 and Key Properties....................... 4
1.2 Abbreviations and Definitions....... 2 2.4 Review and Report Reconciled
Site Basic Data............................. 4
2. Standard.................................... 3
2.1 Mass Balance Closure ................. 3
2.2 Key Stream Properties ................. 4
Version: 1.0 Date: April 2010 Custodian: DME/4 ECCN: EAR99 Page: 1 of 5
Mar 18, 2010

Printed _______________ Printed copies are uncontrolled
Printed copy should not be used more than 1 month after printed date
1. General Information
1.1 Scope and Purpose
1. This Standard (ST) governs the generation, reporting and ownership of Basic Data from
key units at Downstream Manufacturing (DSM) sites.
2. DSM sites, in particular site Manufacturing Technology groups, are accountable to
validate that the Basic Data is accurate and reflects the plant operation. The purpose of
this ST is to assist the DSM sites to maintain and improve (where appropriate) the quality
of information that is placed into planning, scheduling and accounting tools for optimal
operation of sites within safe operating and emission limits. This in turn improves the
quality of site plans, schedules, operating instructions, catalyst selection and ultimately
the profitability of DSM sites.
3. Compliance with applicable country laws and regulations is required. Country laws and
regulatory requirements that conflict with or are more stringent than the requirements
established in this document shall be followed.
1.2 Abbreviations and Definitions
Basic Data This comprises mass balance data, process unit yields and stream
physical properties.
Basic Data Unit(s) Selected process or utility units at a site that have input to monthly
(BDU) fence line balancing, hydrocarbon accounting, Site Measurement
Loss Control, Non-Linear Process Models or Supply planning /
scheduling tools.
Yields Various products generated in a BDU from the conversion or
separation of feed to products, expressed as a % of feedrate to the
unit.
Key Streams Refers to process streams entering or leaving a BDU that define
mass balance of the BDU or have input to Supply planning and
scheduling tools or Non-Linear Process Models, e.g. recycle or
internal streams, or accounting systems.
Key Properties Refers to important measured stream properties such as gravity,
viscosity, sulphur, nitrogen, conradson carbon residue / micro
carbon residue, octane rating, composition, crude source, etc. of a
Key Stream. These properties are used to characterise the Key
Stream in Non-Linear Process Models used to simulate the BDU
or in Supply planning and scheduling tools.
Basic Data Sampling Sampling plan established by site to draw samples of Key Streams
Plan for lab analyses so as to obtain Key Properties.
NLPM Non-Linear Process Model. Technical model supplied by Shell
Projects and Technology or technology vendor and used by
process engineer to simulate performance of a BDU.
Mar 18, 2010

LP Submodel Stand-alone mathematical representation of a single process unit

present in the site Linear Programming model.
Finance Product Role at a site using Basic Data who is responsible for refinery
Analyst fence line balancing and validation that the accounting system
reflects all the hydrocarbon inventories for which the site is
responsible.
Economic Models Supply focal point at site using Basic Data in planning &
Coordinator scheduling tools.
Basic Data Focal point within Manufacturing Technology at site responsible
Coordinator for the calculation, collection, reporting and ownership of the site
Basic Data.
Supply Centre of Organisation within Downstream Supply that is charged with
Excellence attainment of best in class performance in Supply planning and
operations through establishment of standards, processes /
procedures, tools / models, audits and coaching.
2. Standard
2.1 Mass Balance Closure
1. Each site shall compile and maintain a list of Basic Data Units (BDUs) and Key Streams
for each BDU. The list of BDUs shall include all crude distillation units,
hydroprocessing units (including hydrocrackers), catalytic reformers, catalytic crackers,
alkylation units, thermal conversion units, lower olefin plants and fuel systems, as a
minimum where present at site.
2. Each site shall document how the day-to-day compensated mass flow of Key Streams of
each BDU is determined and include in this documentation whether the metering is by
direct flow metering or by indirect methods.
3. Each site shall calculate the day-to-day mass balance closure of each BDU, defined as the
difference between the total intake mass flowrates and output mass flowrates, reported as
% mass on intake and document the methodology employed. It is not required to
calculate the mass balance closure of a BDU every day for the previous day. It is
sufficient to have the day-to-day mass balance closure data established on a weekly or
semi-monthly basis, in time for month-end and year-to-date assessments.
4. Each site shall calculate the monthly mass balance closure and the year-to-date mass
balance closure of each BDU. Both calculations are based on the weighted average of the
absolute value of the day-to-day mass balance closures.
5. The KPI target for the monthly and annual mass balance closures for each BDU shall be
≤3%.
6. BDU mass balance data history shall be archived: the annual mass balance closure, the
day-to-day mass balance closure, the day-to-day compensated mass and volumetric flows
of each Key Stream of each BDU, and the day-to-day uncompensated flows. The
Mar 18, 2010

retention period follows the Global Records Retention Schedule and Site Work Group
File Plan.
2.2 Key Stream Properties
1. Each site shall document the list of Key Properties of each Key Stream for every BDU
that is used in NLPMs (Non-Linear Process Models) or Supply planning and scheduling
tools.
2. Each site shall maintain the Basic Data Sampling Plan to obtain the Key Property data of
each Key Stream with the unit sampling being done during the same period of steady-
state operation.
3. Key Property data of each Key stream shall be archived. The retention period follows
the Global Records Retention Schedule and Site Work Group File Plan.
2.3 Reconciliation of Mass Balances and Key Properties
1. Each site shall provide the necessary data required by Finance for the fence line material
balance at the time stipulated in the site's month-end close schedule. Examples of data
include refinery own-produced fuel gas or hydrocarbon by-products that can be used to
generate energy, and oil/chemical interface stream data.
2. Each site shall reconcile day-to-day compensated mass flows of every BDU such that the
day-to-day unit and cross-unit mass balance closes to a tolerance of 0.1%. It is not
necessary to reconcile the mass flows every day. It is sufficient to reconcile the day-to-
day unit and cross-unit mass balance closures on a weekly or semi-monthly basis, in time
for the site's month-end close schedule.
3. Each site shall also reconcile cross-unit Key Properties involving Key Streams common
to two or more BDUs. An example of this would be specific gravity or sulphur of a
product stream from a crude unit routed to downstream hydrotreating or conversion
units.
2.4 Review and Report Reconciled Site Basic Data
1. Each site shall establish a role titled Basic Data Coordinator within the Manufacturing
Technology group to be the focal point at the site for the calculation, collection, reporting
and ownership of Basic Data. The duties of the Basic Data Coordinator are described in
this section.
2. The Basic Data Coordinator sees that the results of the day-to-day reconciled mass flow
rates and day-to-day Key Properties of all Key Streams are compared against the monthly
operating plan and identify/ investigate discrepancies as explained below:
a. Where NLPMs are available, utilize reconciled flow rate and Key Property data in
NLPMs to derive a delta NLPM prediction to actual BDU product Yields and Key
Properties.
b. Where LP Submodels are available and under the guidance of the Economic Models
Coordinator, utilize reconciled flow rate and Key Property data as input into the
critical LP Submodels of the site to calculate a delta LP Submodel prediction to actual
Mar 18, 2010

BDU product Yield and Key Properties. Ensure that updates to plant constraints
assumed in the critical LP Submodels are communicated to the Economic Models
Coordinator.
c. Provide reconciled weighted average data for the whole month, or reconciled
weighted average data for certain days of the month that had more stable operation of
the BDU, to be used as input into the NLPM and LP Submodels.
d. Monthly track the differences between predicted and actual reconciled Yields and
Key Properties, as appropriate.
3. Lead a Monthly Basic Data review meeting where reconciled mass flow rates and
reconciled Key Properties of all Key Streams are reviewed with data obtained from fence
line balancing, site energy utilisation, hydrocarbon loss and BDU performance
expectations. Typical attendees include:
a. Finance Product Analyst
b. Process Technology representative
c. Economic Models Coordinator
4. Issue a Monthly Basic Data Report to Finance, Production Support, Process Technology,
Site Measurement Loss Control and Supply (Economic Models Coordinator and Supply
Centre of Excellence) that contains the following information:
a. Day-to-day reconciled flowrates (mass and volume) and day-to-day reconciled Key
Properties of all Key Streams of each BDU.
b. Differences between actual yields and properties against predicted yields and
properties for critical LP Submodels and NLPMs.
c. List of issues and action items arising from the monthly discussion with the Finance
Product Analyst, Process Technology representative and the Economic Models
Coordinator.
5. Archive the monthly reports according to the Global Records Retention Schedule and
Site Work Group File Plan.
6. Participate in a quarterly LP Basic Data meeting where discrepancies and issues are
reviewed with Process Technology, the Economic Models Coordinator and Supply
Centre of Excellence. Examples of potential improvement actions are:
a. Process Technology to conduct test runs for various BDUs to update NLPMs through
Shell Projects and Technology or technology licensors.
b. Supply to update the site planning and scheduling models.
c. Other site studies to improve performance of the site, e.g. catalyst evaluation,
advanced control strategies, energy efficiency, plant changes, etc.
Mar 18, 2010


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Downstream Manufacturing Restricted

MBAM Code and Name: Basic Data Document Number:

Shell Downstream Manufacturing

Mar 18, 2010

1.1 Scope and Purpose

1.2 Abbreviations and Definitions

Mar 18, 2010

LP Submodel Stand-alone mathematical representation of a single process unit

2.1 Mass Balance Closure

Mar 18, 2010

2.2 Key Stream Properties

2.3 Reconciliation of Mass Balances and Key Properties

2.4 Review and Report Reconciled Site Basic Data

Mar 18, 2010

Mar 18, 2010

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