6 - Reconcile Data to Make Money (Petrobras)...With access to abundant reserves, Petrobras can more...

Reconcile Data to Make Money

Oscar Rotava, Ph.D.Alcyr Oliveira CremoneziSigmafine Users ConferenceSan Francisco April 23 2012San Francisco, April 23, 2012

Agenda

• Petrobras overview

P t ti bj ti• Presentation objectives

• Reasons to implement mass balancep• Generating reconciled data• Using reconciled data: profits• Using reconciled data: profits

• Perspectives and future work

Sigmafine Users Conference - San Francisco, April 23, 2012© Pimsoft Inc. 2012All rights reserved.

2

Agenda






3

Overview of Petrobras (2011)

• Investments (2012): US$ 51.5 billion• Net earnings: US$ 36.6 billion

Net profit: US$ 19 6 billion• Net profit: US$ 19.6 billion• Shareholders: 463,870• Crude oil production: 2,241,000 Bbl/d + 531,000 Bbl/d natural

gasgas• Production Platforms: 133• Refineries: 15 + 3 refineries + 1 petrochemical/refinery (new

projects)projects)• Ships: 172• Pipelines: 25,966 km • Biofuels: 5 factories (3 in production + 2 in testing)• Biofuels: 5 factories (3 in production + 2 in testing) • Powerplants: 18• Wind powerplants:1 pilot plant

Stations: abo t 8 000


4

• Stations: about 8,000• Fertilizer: 2 factories

New Frontier in Crude Oil Production: Sub-salt


5

Capacity (Mbpd)RPCC

Petrobras’ Refining Infrastructure

Original Upgraded %

Paulínia - Replan (SP) 252 396 57%

Landulpho Alves - Rlam (BA) 218 281 29%

Refineriesp y ( p )

RLAM

LUBNORREMAN RPCC

Henrique Lage - Revap (SP) 189 252 33%

Duque de Caxias -Reduc (RJ) 191 239 25%

Pres. Getúlio Vargas - Repar (PR) 126 195 55%

Alberto Pasqualini - Refap (RS) 142 189 33%

P B d RPBC (SP) 139 172 24%

REGAP

Pres. Bernardes - RPBC (SP) 139 172 24%

Gabriel Passos - Regap (MG) 110 151 37%

Capuava - Recap (SP) 20 49 145%

Manaus - Reman (AM) 37 46 24%

Clara Camarão - RPCC (RN) 25 35 40%

REDUC

REVAP

REPLAN

Clara Camarão RPCC (RN) 25 35 40%

Fortaleza - Lubnor (CE) 3 8 167%

Total Brazil 1,452 2013 38%

United States 100

Argentina 81

RECAPRPBCREPAR REFAP

As Petrobras continues to grow its upstream business, the need for a compatible refining infrastructure becomes more critical With limited investment over the last 20

P t b i d it t t

Argentina 81

Okinawa 100

Total Petrobras 2,289


6

years, Petrobras increased capacity to meet the needs of a growing domestic market.

6

2011-2015 Investments50% of downstream investments are focused in refining expansion

2011‐15 Business Plan

US$224.7 billion

2% 1%1% 2% US$70.6 billion

2011‐15 Business PlanDownstream

14,74,13,24,2

2,314,7

4,1

3,24,22,46%

2%

13.2

3.8

3.14.1

2.4

Fleet Expansion

Logistics for Oil International

65,565,5

57%31%

(*)127.570.6 Refining Capacity

Expansion

Operating Improvement

(*) US$22.8 billion in Exploration

Quality and Conversion

Petrochemical Investments amount to US$3 8 billion

E&P RTC

Gás,Energia & Gás Química Petroquímica

Distribuição Biocombustíveis

Corporativo

E&PGas, Energy & Gas ChemicalsDistributionCorporate

RTMPetrochemicalsBiofuels

E&PGas, Energy & Gas ChemicalsDistributionCorporate

RTMPetrochemicalsBiofuels


7

• 5% of investments will be made overseas, 87% of which in E&P.

amount to US$3.8 billionpCorporateCorporate

RESERVES AND RECOVERABLE VOLUMESRapid growth in reserves from discoveries in deep waters

Million boeProved Reserves – SPE criteria

25,000

30,000

Pre‐15,7 Bi boe

20,000

Roncador

Whales Park, Mexilhão

salt

15,000

Marlim

Roncador

5,000

10,000

GaroupaNamorado

Carmópolis Guaricema

0

53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 01 03 05 07 09 11 11


8* Lula/Cernambi, Sapinhoá, Iara, and Whales Park, ranging from 7.3 to 8.5 Billion boe

*

195319

5519

5719

5919

6119

6319

6519

6719

6919

7119

7319

7519

7719

7919

8119

8319

8519

8719

8919

9119

9319

9519

9719

9920

0120

0320

0520

0720

0920

1120

11

Onshore 0‐300 m 300‐1500 m > 1500 m Pre‐salt's Recoverable Volume Transfer of Rights

ProductionWith access to abundant reserves, Petrobras can more than double production

1.120

246142

6,418

618180

93 96

125

2,386 2,516

3,993

2,772+10 Post‐Salt Projects

+ 35 Systems

2,575

1.855 1.971 2.004

321 317 334 435111 132 144141

2.100

99 9693 96

1 148Pre-Salt’000

boe

/day

845Transfer of Rights

13

+8 Pre‐Salt Projects

+1 Transfer of Rights

Added Capacity

Oil: 2,300,000 bpd

3,070

4,910

2008 2009 2010 2011 2015 2020

Oil Production‐Brazil Natural Gas Production ‐Brazil Oil Production ‐ International Natural GasProduction ‐ International

1,148543

Pre-Salt’

Oil Production‐ Brazil Natural Gas Production ‐ Brazil Oil Production ‐ International Natural Gas Production ‐ International

• Pre‐salt and Transfer of Rights will represent 69% of the additional capacity up to 2020.

• Pre‐Salt participation in the total production will enhance from the current 2% to 18% in 2015 and 40.5% in 2020.


9

Note: Does not include Non‐Consolidated International Production.

2500

Business Challenges – Petrobras Downstream

237 282

777935

128

211

10897

1000

1500

2000

2500

315 368237

201 2240

500

2005 2011

GLP Gasolina Nafta Médios Óleo comb Outros

Compliance to tightening environmental requirements

Increasing demand of gasoline and diesel

q

Increase of heavy domestic oil processing


10

Increasing biofuels demandDemand for product quality improvement

Agenda






11

Presentation Objectives

• To show the usage of SIGMAFINE – in the generation of reconciled data in many different tasks in oil

refineries

– improving data quality

– optimizing refinery operation, resulting in profitsoptimizing refinery operation, resulting in profits

• Hard work and perseverance


12

Agenda






13

Reasons to Implement Mass Balance

• Daily mass balance is fundamental in order to establish the accuracy of flow measurements.

• This will then give good indications of where to make improvements in the management of the HC within the refinerythe refinery.

• Economic justification can then be correctly evaluated.• Evaluate energy index and oil loss KPI: Determination a uate e e gy de a d o oss ete at o

of fuel consumption and oil loss.– Oil is money.– IF IT IS NOT CORRECTLY MEASURED IT CANNOT BEIF IT IS NOT CORRECTLY MEASURED, IT CANNOT BE

CONTROLLED.


14

Reasons to Implement Mass BalanceSIGMAFINE in PETROBRAS

• 11 Refineries in Brazil have SIGMAFINE operational. Not all of them are using it.

• Mass Balance Workshops - 2004/April 2005/March 2007/June 2009/May


15

Agenda






16

Generating Reconciled Data

Process data

PI Tank transactions

ConstraintsConstraints

Sigmafine

Reconciled dataSigmafine Users Conference - San Francisco, April 23, 2012© Pimsoft Inc. 2012

All rights reserved.17

Reconciled data

Agenda






18

Using Reconciled Data

Reconciled data can be used in many daily Reconciled data can be used in many daily activities of the refinery activities of the refinery staff.staff.

• Oil loss accounting• Determination of fuel consumption KPI

P d ti ti t

yy

• Production accounting support • Maintenance support• Test run data reconciliation • Refinery KPIs follow-up • Optimization group support• Inventory monitoring• Inventory monitoring• Production Planning


19

Using Reconciled DataProfits

• Nominal Feed– Above maximum: environmental sanctionAbove maximum: environmental sanction

– Below maximum: financial loss

$$


20


Measurement analysis: actions• A measurement must always be followed by its• A measurement must always be followed by its

reconciled value.– Maintenance report

• Reconciled measurement < Measurement– Lost processing capacity

• Reconciled measurement > Measurement– Check if measurement is inside operational/ environment limits or

licensed value

• In case of doubt, schedule a test with segregated tank.


21


Analysis ofAnalysis of NominalNominal FeedFeed of Coke Unitof Coke Unit -- U052U052Analysis of Analysis of Nominal Nominal FeedFeed of Coke Unit of Coke Unit U052U052

Gabriel Passos Refinery (REGAP)Betim - MG


22

Description of the Problem

• Suspicion of lack of accuracy on the feed flowmeasurement of the Coke Unit U052

• Data reconciliation produced a significant differencebetween measured and reconciled data on the Coke unitfeed Measured value was higher than reconciled valuefeed. Measured value was higher than reconciled value,showing a false processed volume.

• Feed is measured by 052FIC316.y• Reconciled value was consistent with redundant

measurement (sum of flows 052FIC314 e 052FIC315) andl i t t ith h f l l f t k 052TQ02 thalso consistent with change of level of tank 052TQ02, the

feed tank (which is a running tank).


23

Measured and Reconciled Feed Flow Data

Carga U0524200

3800

4000

ada

(m3/

d)

3400

3600

Car

ga P

roce

ssa

3000

3200

06-2

010

06-2

010

06-2

010

07-2

010

07-2

010

07-2

010

07-2

010

08-2

010

08-2

010

08-2

010

09-2

010

09-2

010

09-2

010

1 0-2

010

1 0-2

010

1 0-2

010

1 1-2

010

1 1-2

010

1 1-2

010

1 2-2

010

01-

11-

21-

01-

11-

21-

31-

10-

20-

30-

09-

19-

29-

09-

19-

29-

08-

18-

28-

0 8-

Medido Reconciliado


24

Measured Added Flows & Reconciled Feed Flow Data

Carga U0524200

3800

4000

sada

(m3/

d)

3200

3400

3600

Car

ga P

roce

ss

3000

3200

1-06

-201

0

1 -06

-201

0

1 -06

-201

0

1 -07

-20 1

0

1-0 7

-20 1

0

1 -0 7

-201

0

1 -07

-201

0

0 -08

-20 1

0

0-0 8

-20 1

0

0 -0 8

-201

0

9 -09

-201

0

9 -09

-201

0

9-09

-20 1

0

9-1 0

-201

0

9 -10

-201

0

9 -10

-201

0

8-11

-20 1

0

8-1 1

-201

0

8 -11

-201

0

8 -12

-201

0

0 1 11 21 01 1 1 21 31 10 2 0 30 09 19 2 9 0 9 19 29 0 8 1 8 28 08

Combinado A Montante Reconciliado


25

Coke Unit Feed Flow Test

• A test was made keeping the feed tank segregated (notreceiving from units). The tank level change wascompared with the added flows (two separate pipes, withflow meters (once they had different destinations).

• Test lasted for 07h 07min.

• Results:– Volume change in tank at 20ºC = 3460.32 m3/d– Main flow meter measurement 052FIC316 = 3666.3 m3/d– Added flow of individual flow meters = 3415.00 m3/d.


26

Results

• Flow meter values showed that the Coke unit wasprocessing a volume smaller than the programmed value.

• Daily loss in processed capacity was around 220 m3.

• Considering this difference and taking the averagemarginal value (of that period) of US$ 150 00/m3 anmarginal value (of that period) of US$ 150.00/m , anincrease in monthly profits of US$ 990,000.00 wasachieved.

• The annual gain should be US$ 11,880,000.00.


27

Difficulties

• Main difficulties for identifying the source of the problem:– The inputs of the coke unit U052 feed tank 027TQ02,

come from vacuum residue RV das units U002 and U102, operatingas running tank.

– Flow meters of the vacuum residue flows have low reliability.


28

Analysis ofAnalysis of Nominal FNominal Feedeed of FCC Unitof FCC Unit –– U103U103Analysis of Analysis of Nominal FNominal Feedeed of FCC Unit of FCC Unit U103U103

Gabriel Passos Refinery (REGAP)Betim – MG ( September 2011)


29


• FCC Unit U103, after maintenance, showed a differencebetween reconciled and measured value for gasoil feedflow, measured by flow meter 103FIC157.

Meas ed al e 400 m3/d highe than econciled al e• Measured value 400 m3/d higher than reconciled value.


30

Measured and Reconciled Feed Flow Data

Carga de GOPDD da U103g

3000350040004500

m3)

103FIC157

0500

1000150020002500

Car

ga (m 103FIC157 rec

103FIC157

1/8/

2011

8/8/

2011

15/8

/201

1

22/8

/201

1

29/8

/201

1

5/9/

2011

12/9

/201

1

19/9

/201

1

Data


31

FCC Unit Feed Flow Test

• FCC unit feed tank 81C was isolated for 4 hours and keptsending heavy gasoil to Unit 103, but did not receivegasoil from distillation units.

Measured level diference was compared to processed• Measured level diference was compared to processedamount.

• Level difference was compatible with reconciled feed flowvalues.


32

Increase in Profits

• Average marginal value per m3 of unit feed is US$ 12.60(September 2011).

• Daily loss because of reduced feed equal to US$ 5,040.00.Accrued annual value of US$ 1 839 600Accrued annual value of US$ 1,839,600.


33

Analysis ofAnalysis of Nominal FNominal Feedeed of FCC Unitof FCC Unit –– U4100U4100Analysis of Analysis of Nominal FNominal Feedeed of FCC Unit of FCC Unit U4100U4100

Duque de Caxias Refinery (REDUC)Duque de Caixias – RJ


34


• SIGMAFINE detected a difference between measured andreconcilied feed flow on the feed flow meter of the cokereconcilied feed flow on the feed flow meter of the cokeunit. The measured value was higher than the reconciled.

• The same behaviour was seen when comparing measuredlevel changes of the feed tanks.


35

Identifying the Reason of the Problem

• On the third week of February 2011 it was seen that theflow value measured by feed flow meter FI-006 wasdifferent than the tank level measurements whendifferent than the tank level measurements whenconversion of tank volume difference to mass wascalculated at 20°C, but similar when calculated at roomtemperature.

• The flow meter was erroneously calibrated to produce flow• The flow meter was erroneously calibrated to produce flowvalues at room temperature, but the result was consideredto be calculated at 20°C.

• Afterward it was discovered that all flow meters of theproducts of the coke unit showed the same mistake


36

products of the coke unit showed the same mistake.

Feed to U-4100


37

Difference (Input-Output) x Time

• Effect of the intervention on feed flow meters of unit U4100 - made on 18/02/2011.

Dif b l d ( t d íd )Diferença no balanço de massa (entrada - saída)

1000

1200 18/02/2011

600

800

1000

nça

(m3)

0

200

400

Dife

ren

-200

1-11-2

010

1-11-2

010

1-11-2

010

1-12-2

010

1-12-2

010

1-12-2

010

1-12-2

010

0-01-2

011

0-01-2

011

0-01-2

011

9-02-2

011

9-02-2

011

1-03-2

011

1-03-2

011

1-03-2

011


38

01-1

11-1

21-1

01-1

11-1

21-1

31-1

10-0

20-0

30-0

09-0

19-0

01-0

11-0

21-0

Feed Flow Increase and Difference Reduction

• On 18/02/2011 feed flow was increased and difference between flow measurement and feed tanks level change became smaller.

Dif 4100 d í l t 127 128 361Diferença carga 4100 x desnível tanques 127, 128 e 361

6000.00 18/02/2011

4800 00

5200.00

5600.00

zão

(m3)

4000 00

4400.00

4800.00

Vaz

4000.00

27-08

-2010

16-09

-2010

06-10

-2010

26-10

-2010

15-11

-2010

05-12

-2010

25-12

-2010

14-01

-2011

03-02

-2011

23-02

-2011

15-03

-2011


39

Total Tanques FI-006

Results

• Results have shown that the unit was processing a smalleramount than programmed.

• Daily loss in process volume was around 215 m3.

• Considering this difference and the average marginal profitof US$ 43 73 for m3 the daily gain due to the elevation ofof US$ 43.73 for m , the daily gain due to the elevation offeed rate was of US$ 9,400.00.

• The annual gain is US$ 3,431,000.00.


40

Analysis ofAnalysis of Nominal FNominal Feedeed of Coke Unitof Coke Unit –– U980U980Analysis of Analysis of Nominal FNominal Feedeed of Coke Unit of Coke Unit U980U980

Paulínia Refinery (REPLAN)Paulínia - SP


41

Process Flowsheet

U-210

Unreliable Measurements

TQ 4412

U 210

U-980

FIC98209FI21033

TQ-4412

TQ-4413

U-210A

U-980A

Running tanks make error identification more diffiuclt.

FIC98709

FI21533


42

Difficulties in Detecting the Errors

• Production of Vacuum residue of units U210 and U210A donot have reliable measurements.

• Tanks involved on the feed operations are running tanks.

• Feed flow meters have a historian of small corrections andhence good reliabilityhence good reliability.


43

Historian

• 18/04/2010 : Coke unit U-980 starts operating again afterturn around.

• Coke unit is submitted to a feed test making use ofsegregated feed tankssegregated feed tanks.

• Process unit data is collected from databaseProcess unit data is collected from database.

• Differences are found considering the unit mass balancegas well as the measured and reconciled data.

l C98209 dSigmafine Users Conference - San Francisco, April 23, 2012© Pimsoft Inc. 2012

All rights reserved.44

• Flow meter FIC98209 was repaired.

Results

• Reconciliation procedure allowed the discovery that theunit feed was 600m³/d smaller than what was shown bythe flow meters.

The faulty flow meter had its controller set point altered in• The faulty flow meter had its controller set point altered inorder to achieve the programmed load.

• Flow meter FIC98209 was submitted to recalibration andwas back in operation in 21/05/2010.


45

Losses and Avoided Losses

Marginal value (U980) = US$ 10.29/ m³

18/04/2010 01/05/2010 11/05/2010 21/05/2010

f13 days between the starting of the unit and the first evaluation with

segregated feed

Period of 10 days until new feed test

More 10 days until effective action on the

flow meter

US$80 262 00 US$61 740 00 US$61 740 00

Recalibrated meter in place and back to the programmed

unit load

US$80,262.00 US$61,740.00 US$61,740.00

Loss for the period: US$203,742.00

Avoided losses: US$2,253,510.00/year


46

Leakage through a filter of HTU Leakage through a filter of HTU –– U283U283g gg g

Paulínia refinery(REPLAN)Paulínia - SP


47

Sigmafine Model of U283

Heavy diesel from distillation units

Light gasoil from coke unit

Light gasoil f FCCfrom FCC units


48

Feed to U283

• Feed to U283 shows redundancy because total and individual measurements of each one of the three feeds exist:

FIC28005 = FIC28001+ FIC28002+ FIC28003

• Historically the accrued flow of each individual product shows a small difference in comparison to the total flow p(smaller than 5%).

• From June 9, 2010, a larger discrepancy was identified.


49

Observed differences between total feed flow meter and summation of individual feed flow meters on unit U283 in the period June 9th to June 14th:


50

The following reconciliation procedures showed even larger differences.

Data FIC-28005(m3)

Soma FIs Individuais (m3) Diferença (m3) Desnível tanque que recebe

(m3)

g

09-jun 5751 5841 -90 5966 * A partir das 17:20. TQ-4213

10-jun 5750 6306 -556 6578 TQ-4213 e TQ-4721

11-jun 5750 6354 -604 6439 TQ-4721 e TQ-4212

12-jun 5750 6316 -566 6547 TQ-4212, TQ4-213, TQ-4721

13-jun 5750 6335 -585 6548 TQ-4721 e TQ-4722

14-jun 5622 5937 -315 5711 * Até as 15:30. TQ4722, TQ4213


51

Event Detection Using Sigmafine

• Once the event was detected by the reconciliation team, operational people discovered the leakage in a filter.

• Light gasoil from FCC units and light gasoil from coke unit were sent to final product tank without being p ghydrotreated.

• Difficulties in specifying sulphur contained in product• Difficulties in specifying sulphur contained in product (diesel) tank was a confirmation of the leakage.


52

Loss

• A loss in diesel S-500 production occurred because high sulphur flows arrived into two diesel final product tanks and did not satisfy sulphur specificationsand did not satisfy sulphur specifications.

• Diesel was specified and sold as diesel S-1800 (smaller p (values).

• The degradation of diesel (S 500 to S 1800) produced a• The degradation of diesel (S-500 to S-1800) produced a loss of US$ 800,000.00 in 6 days.

• More losses were avoided thanks to the quick findings of the reconciliation group.


53

Agenda






54

Perspectives and Future Work

• Include loss models into SIGMAFINE model

• Migration to SIGMAFINE 4


55

Thank you.

Oscar Rotava Ph DOscar Rotava, Ph.D. [email protected]

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