Trustable Production Accounting with Sigmafine and...

Sigmafine Users GroupBarcelona, May 23, 2011

Trustable Production Accountingwith Sigmafine and PI

Mohamed Markoum, IT Project Manager

SAMIR – Mohammedia Refinery

Agenda

• Introduction to SAMIR and Mohammedia Refinery

• Business Challenge

• Production Accounting Architecture and Tools

• Results/Benefits

• Future Plans• Future Plans

© Visiant Pimsoft Inc. 2011 All rights reserved.

2Sigmafine Users GroupBarcelona, May 23, 2011

Samir Company

• Samir is a refining company located in Morocco, created in 1959 and privatized in 1997.

• The company acts and operates one refinery (a hydroskimming and LubeThe company acts and operates one refinery (a hydroskimming and Lube complex refinery located in Mohammedia) and the Sidi‐Kacem oil terminal connected through a pipeline.

• SAMIR shareholder structure as of June 2007 is as follows:SAMIR shareholder structure as of June 2007 is as follows:

• Corral Petroleum Holding Group: With 4 refineries, and over 1,000 service l f h l d d fstations, Corral Group is one of the largest independent refining

companies in the world. Concentrated on two geographical poles, Scandinavia and the Middle East ‐ North Africa, Corral Group controls the petroleum chain from exploration to distribution.



Mohammedia Refinery

• The refinery is located in Morocco just 30Km from Casablanca.• The Processing capacity is more 47 million barrels per year.• The Storage capacity is: 2.000.000 m3

• Crude Oil: 1.000.000 m3• Semi‐finished & finished products: 1.000.000 m3

• Main markets are Local 75%, Export 25%.



“Upgrade Refinery” Project

• The Upgrade project is considered as the tuning point of the company. In fact, this project transforms SAMIR from a simple refinery to a complex refinery with much higher margin capable of producing clean fuels in compliance with the strictest international standards. The project involves the installation of a new processing complex (including a fuel hydrocracker unit) which is integrated into the existing refinery at Mohammedia. This allows SAMIR to meet future market requirements for refined products, particularly middle distillates, and to manufacture products suitable for export to Europe and other markets.

• The process units that comprise the major elements of the upgrade project are as follows:

• The Upgrade Project includes all necessary expansions of the refinery utility systems to meet the demands of the upgraded refinery as Electric Power, Steam, Demineralised Water, Cooling Water, Refinery Fuel Oil, Fuel Gas, Nitrogen, Instrument & Plant Air and Towns & Utility Water.



Business Challenges

• Samir needs a production accounting system in order to have a validation platform which makes available trustable data for performance management system for business decisions.

• The system has to support a wide range of data sources:– Process controls– Laboratory systemsManual data– Manual data

– Internal refinery oil movements– Receipts and shipments– Planning data

• The system has to evaluate some data not measured and to monitor the performance of the plants to identify oil losses, uncover operational problems, calculate and monitor data quality problems, help identify and quantify instrument errors, and prioritize instrument maintenance.prioritize instrument maintenance.

• The system has to be flexible to support the refinery layout and all the future changes/improvements and to be open to exchange data with existing/future systems for SAMIR Information System consolidation.



for SAMIR Information System consolidation.

Samir Business Applicative Scenario

CORPORATE ACCOUNTINGCORPORATE ACCOUNTINGCORPORATE CORPORATE PLANNINGPLANNING

Business Business InformationInformationSystem (BIS)System (BIS)

SAPSAP

Consistent Consistent

Maintenance Maintenance PlanningPlanning

Production PlanningProduction Planning

Asset UtilizationAsset Utilization

ProfitabilityProfitability

KPI’KPI’

y ( )y ( )

EconomicsEconomics&&

Process Process ModelsModels

SchedulingScheduling

Process Process SimulationSimulation

KPI’sKPI’s

Yield AccountingYield Accounting

Quality AssuranceQuality Assurance

ProductionProductionManagement Management SystemSystem

SCM

ModelsModels&&

DataData

Operations OrdersOperations Orders

LIMSLIMS

Production AccountingProduction Accounting

Process / Equipment Process / Equipment MonitoringMonitoring

Data Reconciliation Data Reconciliation

M

PIMS (powered by PI)PIMS (powered by PI)(powered by Sigmafine)(powered by Sigmafine)

DCSDCS PRODUCT HANDLINGPRODUCT HANDLING/STORAGE CONTROL/STORAGE CONTROL

Real Real Time Time SystemSystem

PROCESS LEVEL Instrumentation data



yy

Production Accounting Architecture

Corporate UsersCorporate web reports

Production Accounting UsersRefinery graphical model & operative reports

AF Excel PI- PI-OSigmafine SQL Sigmafine Adv.

PI-SMT Excel Add-In

AddInPI

ProcessBookPI

DataLinkPI-OLEDBg Q

Access (RFC) gDiagnostic

MassBalance

Volume Balance

PI Server

Sigmafine Server

PI-AFUtility (SF)Balance

EnergyBalance

AF-SMT Excel Add-In



Process DataLab DataOil Movement Data

Manual Data

PI System Evolution in SAMIR

Existing refinery Units /DCS Control rooms

OPC Server 1 OPCS Server 2

Upgrade Units /DCS Control rooms

OPCS Server 4

Process Data Process Data Process Data

OPC Server 1 OPCS Server 2 OPCS Server 4

PI System 120K

PI System 250K







OPCS Server 4



PI System 120K

PI System 250K

Movement Manual Data OPC Server 3



Files Manual DataLIMS Data





OPCS Server 4



PI – HA Collective : SAMIR PI (80 K)PI System 1

20KPI System 2

50K

PI – HA Collective : SAMIR PI (80 K)

Movement Manual Data OPC Server 3



Files Manual DataLIMS Data

PI and Sigmafine Dataflow

PI Server Sigmafine ServerImport

Process, Tanks and Transaction Raw Data

Export

LAN

Reconciled Data



Sigmafine & PI Clients

PI and Sigmafine Dataflow

Publish: Make available

PI Server Sigmafine ServerImport

Process, Tanks and Transaction Raw

Publish: Make available data for corporate users

Data

Export

LAN

Reconciled Data



Sigmafine & PI Clients

Production Accounting Solution Key Points

P d b d l i• Product‐based solution:– based on industry standards– no custom programming, but products configuration only

• Entire architecture based on OSIsoft technology:Entire architecture based on OSIsoft technology:– Sigmafine graphical models are built with PI‐ProcessBook– Accounting ad‐hoc Excel reports built with PI‐Datalink and AF Excel Add‐In– Sigmafine relies on PI‐AF with native link with PI System

• Easy to use and configure:– A unique graphical integrated environment for user’s and administrators– Handle configuration changes seamlessly either for process/timestamped and

transactional data– Quick deployment over clients (web reports use only Internet Explorer)

• High Scalability:– It is capable to handle thousands of tags and elements in the same model

It i b f d l / l i fitti ti d / t i t– It can grow in number of models/analysis fitting accounting needs/constraints– It can be used on single or multiple time‐ranges (even automatically)

• Reconciled results can be historicized into the PI Server for long‐term analysis and comparisons.



p

Refinery‐wide Model Evolution

O i i l d l d 1300 PI t d 500 Si fi l t

F t h t (TOPPING 4 it)

Original model: around 1300 PI tags and 500 Sigmafine elementsNow more than 4000 PI tags and 1450 Sigmafine elements

Future enhancements (TOPPING 4 unit)…

Adding other utilities: steam networks, fuel-oil consumptions, electrical network… etc

Added Sidi-Kacem tanks and pipeline

Added Mohammedia pipelines and hold-ups

Added utilities: Sulphur, WaterTreat… etcp ,

Added “upgrade project” units

Original Samir efine modelrefinery model



Tools: Graphical Refinery Model

The Sigmafine refinery graphical model is built with PI‐ProcessBook and allows integrated graphical environment for all the data, easy maintenance, quick

d ti ti d t i ti d d d di ti f tproduction accounting data navigation and advanced diagnostic features.

Graphical model in “Run-mode”

Smart diagnostic Processbook Add-InDiagnostics rank data issues and guide to correction actions.

Graphical model in “Build-mode”Allows to easily maintain the model in the same user GUI.What administraor see s is what user gets!



Tools: Manual Inputs to PI

TIME‐STAMPED DATA: A set of predefined Excel spreadsheet powered by PI‐SDK and PI‐Datalink allows massive manual input to insert data that are not directly collected from DCS or tank gauging system (levels, temperatures, materials…).

MOVEMENT DATA: Dedicated Excel spreadsheets allows to manage all operations regarding oil and products movements through AF‐SMT Excel Add‐In.

Easy manual data insertwith a unique button!



Tools: Operational Reports

Operational, quick, and smart reports for daily production accounting are built in Excel using PI‐Datalink and PI‐AF Add‐In.

Units and utility networks production & consumptions are extracted from reconciled PI tags by using PI-DataLink

Refinery stock data are extracted with PI-AF Excel Add-In



Tools: Company Reports

Company‐wide reports with consolidated stock and reconciled process‐unit yields are available through Samir intranet. Reports are daily and cumulated (e.g. monthly) and built using Microsoft SQL Reporting Services extracting data through Sigmafine SQL Access layer (RFC) and PI‐OLEDB. Some reports also show data coming from LIMS system.

Reports in build mode: quick and smart report with SQL Server tools



Tools: Company Reports

Company‐wide reports with consolidated stock and reconciled process‐unit yields are available through Samir intranet. Reports are daily and cumulated (e.g. monthly) and built using Microsoft SQL Reporting Services extracting data through Sigmafine SQL Access layer (RFC) and PI‐OLEDB. Some reports also show data coming from LIMS system.

Sample of a deployed report in the intranet



Tangible Benefits

• Contributes to a broader vision of the refinery data:– Supports the “One Version of the Truth” pp– Better and consolidated quality of information – Valid Data for Stock Management and evaluation

• Easy distribution of the data to refinery users:– Operational reports only for accountantsCompany reports for other dpts accessible over the– Company reports for other dpts accessible over the intranet

• Availability and visibility of the valid informationAvailability and visibility of the valid information contribute effectively to timely decision making and to take advantage of opportunities.



Future Plans

• PI infrastructural upgrade: merge the 2 PI Systems in a unique new PI‐HA collective

• Include the upcoming TOPPING4 unit (Crude Distillation: 88 000 BPSD under construction and commissioning by April 2012)

• Run Sigmafine energy balances for FuelGas and Steam networks

• Integrate the production accounting system with SAP

• Enhance the movement management part with Sigmafine IMM



Thank you!Thank you!Questions ?

Mohamed Markoum m markoum@samirmaMohamed Markoum, [email protected]



Date post:	25-Jul-2018
Category:	Documents
Upload:	danglien
View:	221 times
Download:	0 times

Trustable Production Accounting with Sigmafine and...

Documents