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2014 Software Global Client Conference
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2014 Software Global Client Conference
Agenda
● Trends in Petroleum Refining
● Challenges and Influences
● Moving to the Future
● Characteristics of the Refinery of the Future
● Core Technology Requirements for the Refinery of the Future
● The Evolution of Advanced Software Systems to Enable Optimal Performance
of the Refinery of the Future
Industry Trends
Eq
uip
men
t
main
ten
an
ce b
ased
on
bo
th c
on
dit
ion
mo
nit
ori
ng
an
d
eco
no
mic
tra
de
off
s
Use o
f p
roa
cti
ve
safe
ty s
yste
ms
Emphasis on minimizing energy
usage
Increasing investments on
equipment reliability and
process safety management
2014 Software Global Client Conference
Core Challenges
Uncertainty
• Price Volatility
• Geo-Political Unrest
• Financial Crisis
Availability of Skilled
Resources
• Aging Workforce
• Complex Plant Config.
Margin
• Tight Supply & Demand
• Energy & Material Cost
• Capital Availability
Regulation
• HSE
• Asset Availability
• Asset Reliability
Operation Optimization
High Performance Organization
Zero Accident
2014 Software Global Client Conference
Operation Optimization Model Based
Real-Time Optimization
High Performance
Organization
Real-Time Performance
Management
Zero Accident Operator Training Simulator
From Challenge to Solution
2014 Software Global Client Conference
Asset Value Optimization to Maximize the Value of
Every Molecule Processed
● Advances in computer power, optimization technology and mathematical solvers will enable rigorous,
refinery-wide models to run and converge in minutes so that…
● The online models can be used for refinery-wide optimization—including planning and scheduling—without requiring
individual process unit optimizers
● Models will form the core of asset value optimization with model rigor matched to end-user requirements
● Industry-leading refiners will strive to maximize the value of every molecule of feed processed using
various techniques, including:
● Compositional analysis and characterization of feedstocks
● Component-based reactor models
● Equipment and process performance management will be highly-automated, context-sensitive and
predictive in nature
2014 Software Global Client Conference
Integrated Operations Management
● There is a cycle of model-based activities that involves:
● Planning what the facility will do
● Executing to the plan
● Then measuring what took place against the plan
● The cycle is repeated with the intention that the planning processes can be
improved through increased insight into or prediction of:
● What materials will be available (supply chain)
● What product demands will be
● What just happened (model-based analysis of process behavior)
● What the process performance capabilities and limitations will be (maintenance
schedules; predictive analytics to forecast future behavior and constraints)
2014 Software Global Client Conference
Vision Integrated Operations Management
Execution Decisions Reviews, Reports
weeks ago days ago hours ago now hours ahead days ahead months ahead
Performance Management
Performance Management
Plan vs. Actual
Plan vs. Actual
Performance Management
Sched vs. Actual
VA
LU
E Operations
Production
Business
Logistics
Limits & Boundaries
Goals and Targets
Goals
Reconciled
Performance
Results
Reconciled Performance
Synchronization
Business/Yearly
Plan
Quarterly/Monthly
Plan
Schedule Daily Accounting
Hourly Balance
Operations Monitoring
Operations
Management
Process Control &
Optimization
Monthly Production
Accounting
Backcasting
Business Results
Integration
Shift from
feedback to
feedforward
behavior
2014 Software Global Client Conference
Characteristics of the Refinery of the Future
● Rigorous model-based applications form the foundation for managing the refinery’s overall value chain,
from feedstock selection to final product distribution
● More than 10 times the amount of instrumentation and data than traditional refineries
● Visualization and control are designed to address upcoming shifts in targets and constraints, similar to a
vehicle GPS or satellite navigation (SATNAV) system
● Emergency shutdown systems are designed for prevention of almost all unplanned shutdowns
● 50% more instrumentation connections with close feedback sent to the distributed control system
● Safety and operations performance are measured and visualized in real-time
● Full visibility to covert safety indicators
● Value chain information including pricing, logistics, planning and scheduling is tightly integrated with control
● The Refinery of the Future is no more an individual modern plant asset, but an integrated entity in a larger hydrocarbon
value chain
2014 Software Global Client Conference
Characteristics of the Refinery of the Future
● Business processes are highly automated
● These are focused on granular procedural automation
● Start-up and shutdown
● Alerts and notifications are common to Refinery of the Future operations to ensure timely responses to exploit
desired situations and to minimize or prevent undesired situations
● Vessel loading is accomplished using fully automated systems requiring human intervention only in the
event of problems that can not be fixed otherwise
● Training is transformed to include immersive experience that addresses the greater awareness of the
value chain and external factors in addition to the physical and operational factors inside the refinery
● This is implemented using 3-D immersive and augmented reality
2014 Software Global Client Conference
Core Technology Requirements for the Refinery of
the Future
● Common Information Model to ensure interoperability across multiple vendors’ software applications
using industry standards such as B2MML
● Sophisticated information mining tools use pattern recognition to determine where the process is
moving based on past behavior and make recommendations for model changes to correctly manage
the new operating point
● Master data management for “single source of truth”
● Given so many software applications, each with its own data model, it is critical to manage master data to ensure
smooth and reliable communication
● Mobility sub-architecture which treats mobile devices as “first class citizens”
● This is a combination of integrating voice, video, text messaging, cybersecurity and visualization suitable for
tablets, smart phones and laptop computers
● Elimination of the traditional divide between steady-state and dynamic rigorous models
2014 Software Global Client Conference
Core Technology Requirements for the Refinery of
the Future
● Cyber security sub-architecture and business processes which implement a “defense in depth” approach
● Site-wide wireless network with some redundancy (cellular network can be used as well)
● Cloud sub-architecture wherever possible for sharing information, remote expert advice or benchmarking
and comparing plant performances
● Operations center collaboration technology, including display aggregation (such as integrating maps,
videos, applications views, television news feeds, video remote collaboration), recording, remote
annotation and decision support desks
● Immersive 3D visualization and navigation technology for the 3D training
● Human-like robots replace field operators and maintenance personnel for work in hazardous areas
2014 Software Global Client Conference
The Evolution of
Advanced Software Systems
to Enable Optimal Performance of
the Refinery of the Future
Forecasts EPS
Calculator
Actual
Earnings
per Share
Forecasts Actual
Gross Profit Gross Profit
Calculator
SP PV
Throughput
(Fixed Cost Contribution to Mfg. Cost)
SP PV
Energy Cost Contribution
To Mfg. Cost
SP
PV
Raw Mat’l Cost Contribution
To Mfg. Cost
SP PV
Column 301-D
Reboiler Outlet Temp.
Executive
Level
Business
Management
Level
Plant
Management
Level
Process
Management
Level
The Goal…Automate the Business Control Loop
Regulatory &
Advanced Process
Control
Process
Optimization
Asset
Optimization
Enterprise /
Supply Chain
Optimization
KP
Is
Pe
rfo
rma
nc
e M
ea
su
res
Δ = Deviation
Δ = Deviation Δ = Deviation
Δ = Variance
Δ = Variance
2014 Software Global Client Conference
The Problem…Aligning Strategy with Execution in
Refining
We can get the best mix of crudes that
optimizes my profit margins
Business
view
If so, we know in real-time what the refinery is
capable of processing & stay within safety limit
Production
view
I manage the process set-points to improve
margins based on delivered crude quality
Process
view
2014 Software Global Client Conference
Crude Trading
Crude Selection
Crude Property Analysis
Operations Scheduling
Oil Movement Mgmt.
Blending Optimization
Operations Planning
Real-Time Optimization
Advanced Process Control
Inventory Mgmt.
Oil Movement Mgmt.
Blending Optimization
Supply & Distribution
Crude Sourcing
Crude Blending
Refining Product Blending
Product Distribution
Cru
de P
ricin
g &
Su
pp
ly
Pro
du
ct
Pri
cin
g &
De
ma
nd
Leveraging RTO in the Supply Chain
Today’s Approach to Aligning Strategy with
Execution
Operational Performance
Measures
Energy Optimization
Operations Performance Monitoring
Optimal Regulatory and Advanced Control
Improved Mass Balance
Accuracy & Yield Accounting
Optimal Refinery Planning Support
Process Unit Simulation & Optimization
Corporate Management
Site Management
Management Performance
Measures
Feedstock Selection, Planning & Scheduling
LP Vector Updates
Business Performance Feedback Loop
Financial Impact
of Solution
Investment to Sustain Benefits
9
Operations & Engineering
8
Enterprise Manufacturing Intelligence Financial & Performance Metrics and Decision Support Provided to Solution
Stakeholders
Integrated Information, Workflow and Modeling Platform Asset Performance
Management
Power Management
2014 Software Global Client Conference
SimCentral – The Future of Model-Based Design,
Operate and Optimize
Operate
SimCentral
Optimize
Design
2014 Software Global Client Conference
SimCentral Design Heat and Material Balances and for New Construction
s1 s2 s3 S4 s5 s6 s7
Flow 1.3 2.4 3.3 4.13 4.13 4.13 4.13
Temp 100 120 120 130 130 180 170
Pressure 1000 990 960 940 940 900 900
Phase L V/L V/L V V V V
Composition
Stream Heat and Material balance Table shows that the
proposed process design is efficient
2014 Software Global Client Conference
SimCentral Operate Design Controls and Train Operators
Dynamic Trends show plant operators how to
respond to unexpected events to avoid accidents
2014 Software Global Client Conference
SimCentral Optimize Run Online to Improve Plant Performance
Real-time system reads data
from plant DCS and executes
optimization runs to improve
plant production and profitability
Sequence
INPUT
Data Rec
Macro
Solve
OUTPUT
2014 Software Global Client Conference
Today’s Approach to Aligning Strategy with
Execution
Operational Performance
Measures
Energy Optimization
Operations Performance Monitoring
Optimal Regulatory and Advanced Control
Improved Mass Balance
Accuracy & Yield Accounting
Optimal Refinery Planning Support
Process Unit Simulation & Optimization
Corporate Management
Site Management
Management Performance
Measures
Feedstock Selection, Planning & Scheduling
LP Vector Updates
Business Performance Feedback Loop
Financial Impact
of Solution
Investment to Sustain Benefits
9
Operations & Engineering
8
Enterprise Manufacturing Intelligence Financial & Performance Metrics and Decision Support Provided to Solution
Stakeholders
Integrated Information, Workflow and Modeling Platform Asset Performance
Management
Power Management
2014 Software Global Client Conference
Tomorrow’s Approach to Aligning Strategy with
Execution
Operational Performance
Measures
Optimal Regulatory and Advanced
Control
Corporate Management
Site Management
Management Performance
Measures
Business Performance Feedback Loop
Financial Impact
of Solution
Investment to Sustain Benefits
9
Enterprise Manufacturing Intelligence Financial & Performance Metrics and Decision Support Provided to Solution
Stakeholders
Asset Performance Management
Operations & Engineering
Pattern Recognition & Predictive
Analytics
On-Line Process Safety Risk Assessment
Monitoring of Operator Mental &
Physical Health
Rigorous, Model-Based Refinery-Wide Simulation and Optimization
Improved Mass Balance
Accuracy & Yield Accounting
Operations Performance Monitoring
Process Optimization, Energy Optimization
and Power Management
Feedstock Selection, Planning & Scheduling
Optimal Refinery Planning Support
Workflow & Procedural Automation
2014 Software Global Client Conference
Related Support, Services, Training & Expo Demos
● SimSci Portfolio Tech Support 24/7
● Project-specific Tech Support options
Support
Training
● SimSci Training for Portfolio Products
● Wonderware Portfolio Training Courses
● System Platform Solutions
● APC Implementation
● ROMeo Implementation
● WW partners for integration
● Avantis Implementation
Services
Expo Demos
● SimSci APC Demo
● ROMeo Platform Demo
● Yield Accounting
● ROMeo Simsci Reactors Demo
● Dynsim Demo
● PRO/II Demo