October, 18 2016, Rotterdam

Reliability Driven Asset Management

Plant of the Year 2015

- Gábor Bereznai -

Plant of the Year winners in 2010

2

Small in the world…

Size of the logos are correlating to companies’ revenue.

3

But strong in the region…

4

6 production units

23 mtpa refining capacity

2.1 mtpa petrochemicals capacity

>2000 filling stations

Source: Wood MacKinsey, Global Refinery View, Refining in Europe, Africa and FSU

Business drivers around the Economical crisis

5

6

Diverging world in Donwstream business

Global refining and petrochemical business outside of Europe is growing

New, large scale, high-tech refineries and petrochemical sites in Asia and the Middle East are increasing product export to Europe

The European downstream business is pressurised by worldwide trends and not supported by local politics and regulations

• Becoming a net exporter of oil products

• Huge investments targeting European markets

• Favourable legislation (incl. tax legislation)

• Cheap feedstock,

UNITED STATES

• Strong demand growth

• Favourable legislation for local companies

CENTRAL AND SOUTH AMERICA

• Large new refining sites

• Additional ~2 mbpd refining capacity in 3 years (5x MOL capacity)

• Targeting the European market

MIDDLE – EAST

• Strong governmental support

• New refineries in China, India, Vietnam, etc.

ASIA-OCEANIA

• Not growing with stagnating demand • Record low margins, crude runs at 23-year

low • Still significant overcapacity • Decreased competitiveness, EU regulations

put further pressure on European DS business

EUROPE

2470 kbpd, $95bn

2750 kbpd, $60bn

4070 kbpd, $125bn New and ongoing investments

New and ongoing investments

New and ongoing investments

7

Delivering Business Value: 500M$+500M$ in five years

8

Production loss due to UPDT

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

20092010

20112012

20132014 Q1

Pro

du

ctio

n lo

ss [

USD

]

UPDT: Unplanned Down Time due to

instrumentation causes

FIMS: Field Instrumentation Maintenance System

Source: MOL SAP-PM Maintenance System, 2014

[ 607 kEDC ]

[ 563 kEDC ]

9

Layers of Protection

DCS systems

Definition of

Group of

Assets to

Maintenance

Master Asset

Database

Maintenance

planning and

sheduling

Maintenance

execution

Evalution of

Operative

Maintenance

Field Instrumentations

Risk evaluation

and handling

(Asset Policy)

Asset Strategy

Evaluation

Detailed

Reliability

analysis

Se

ria

l

dig

ita

l

co

mm

.

Strategy

optimisation

Statical equipements

Corrosion

databaseVibration data

collection

Risk Based

InspectionVibration diagnostic,

Oil analysis, Thermo

Control Valve and

Instrumentation

diagn.,

Rotating machines

Computerised

Maintenance

Management

Systems

Maintenance

Strategy

Creation

Data

Collectors

Equipements

Condition

Monitoring

Systems

Reliability

analysis

(MTBF, MTTR)

Failure modes

On

-lin

e,

dia

gn

os

ti

c

Off

-lin

e,

dia

gn

os

tic

On

-lin

e,

dia

gn

os

tic

Off

-lin

e, d

iag

no

sti

c, C

om

mu

nic

ato

r

RF

ID / P

DA

Off

-lin

e,

dia

gn

os

tic

10

AMS DM + AMS

FIMS servers

FIMS (AMS/PRM) user/

expert

SAP-PM server

SAP-PM user

Refinery Information System

DC MUX

On-line FIMS

subsystem

(AMS)

Intelligent

instrumentations

of the DC units

Alarm filtering in the

SAP-FIMS interface

CFV-087

Predictive notifications can save 7k$-700k$

avoiding unit outages.

CMMS integration

11

DCS and Smart Instrumentation in MOL Refining

MOL has 58 units in the

Refining 95% equipped with

DCS and Safety PLC.

(19000)

The number of the non-smart

pneumatic transmitters are

decresing.

12

Integrated Maintenance Systems

219

2114

1347

0

413

0 0 42 0 0

500

1000

1500

2000

2500

Honeywell AM Emerson AMS Yokogawa PRM D

evi

ces

[PC

S]

AM - AMS - PRM protocols (4135 pcs devices)

HART FFB Wireless HART

0

2110

850

0

413

0 0 9 0 0

500

1000

1500

2000

2500

Honeywell AM Emerson AMS Yokogawa PRM

Dev

ice

s [P

CS]

AM - AMS - PRM protocols (3382 pcs devices)

HART FFB Wireless HART

2010 2015

15

Improved organisational model is needed to

achieve the Refinery objective

Business rational of organisational model change:

Align the organisation with refinery objectives

Improve cooperation and eliminate silo operation

Put more focus on key areas in order to improve our efficiency and performance based on Solomon benchmark (maintenance, operational availability, energy efficiency)

16

Peolpe behind the systems

October, 16 2016, Rotterdam

- Csaba Molnár-Valkó -

17

Man behind system

Asset management system (AMS, PRM, FDM)

Online equipment types

Adding equipment / configuration

ALERT setting / handling

Valve diagnosis

Pressure transmitter calibration

Analytical instrument calibration

Tranings / courses

18

Asset Management System

AMS Asset Manager System

8 online unit:

- MSA

- REF4

- GOK1

- HGY1

- HGY2

- REF100

- KGÜ

- BK4

Tags:

~1450 online

6 online unit:

- CL4

- CL6

- BEK5

- FCC

- AV2

- PEM1

Tags:

~ 1600 Online

PRM Plant Resource Manager

FDM Field Device Manager

5 online plant:

- DCU

- GOK3

- CL5

- HDS

- KBI

Tags:

~ 2600 online

~ 5000 offline

2010 2015

19

On-line equipment types

- Transmitters

- Pressure

- Differential pressure

- Level

- Temperature - Flow transmitter

- Valves

- Control valave

- ON-OFF valve (with positioner)

20

Adding device / Configuring

Add new online device

- Connecting new device to the system

- Scanning and Denomination

- Placing it in Plant structure

- Setting all the 3-level alerts:

- configaurated in the device

- adjustable in the maintenance system

- setting interface filter

21

Setting Alerts / Handling

Device Alert handling DVC5000 (66 pcs parameters / 33 alerts)

DVC 6200 (150 pcs parameters / 50 alerts)

22

Setting Alerts in maintenance system

Setting Alerts / Handling

23

Setting Alerts / Handling

Setting interface

24

Valve diagnostic

― ValveLink Online/Offline

― DTM based (Metso, Flowserve)

― Flowscan

― ValVue

― OVD

25

Pressure Transmitter Calibration

Process

- Adding device, scanning, denomination

- Test-scheme assigning, placing in the Plant structure

- Check Out

- Calibration

- Check IN

- Report template assign

- Report preparation

26

Analyser equipment calibration

Process

- Offline TAGS download from AMS to PDA

- Device identification with RFID

- Calibration (manual)

- Check IN from PDA

- Report generation

- Notice posting to ERP

27

Skills / Competance

A high level knowledge of systems (AMS, PRM, FDM)

Knowledge of specific devices

Database handling at user level

Calibration knowledge

Valve diagnostic on a really high level

Delivering Business Value from Digital Transformation

October, 18 2016, Rotterdam

- Tibor Komróczki

Operational Availability

Maintenance Efficiency

Energy Efficiency

Yield improvement

Digital Transformation of New & Next Downstream program

• Interlock statuses • Integrity Operating

Windows • Corrosion control

(HTHA) • Alarm management • Preventing coke steam

eruption

• Product quality • Analyser reliability

(Argus) • Yield Accounting via

Sigmafine (PI AF based)

• Operating envelopes • NG (natural gas) and

fuel gas demand forecasting

• Normal mode of control loops

• APC control monitoring • Diesel sulphur

optimization • Coker yield optimization

Safety & Asset

integrity (PSM)

Yields Operational

optimization

• Energy monitoring and management • Energy KPI breakdown • Column energy efficiency dashboard • Hydrogen, utilities - energy balances • Flaring

Energy

Operational Availability

Maintenance Efficiency

Energy Efficiency

Yield improvement

Asset Reliability from

Proactive & Predictive

Advanced Analytics

• SAP PM Integration • Health Score in PI AF • CBM on all rotating

equipment • PSA – Pressure Swing

Adsorbers • Chillers • Heat Exchangers • Electrical Infrastructure

Deeper understanding of technological processes - Alternative crude oil usage as feed; yield optimization

Increase productivity and efficiency across all major business units through the best practices for data harmonization

Alarm Management System (alarm rationalization) – Mode Base alarm , new alarm logics

Analyze control loops behavior

Inferential and descriptive statistics

Energy modelling optimization

Condition based & predictive maintenance

Advanced Analytics and IoT Oil & Gas Downstream

An

alyt

ic A

sce

nd

ancy

Mo

de

l

VALUE

DIFFICULTY

What happened?

Why did it happen?

What will happen?

How can we make it happen?

Gartner, March 2012

Descriptive

Analytics

Diagnostic

Analytics

Predictive

Analytics

Prescriptive

Analytics Data

Cloud

Intelligence

Advanced Analytics

Enablement of Contextual Data Based Decision Making & Management

Improving skill knowledge capture changing paradigms about data - leading by example

Reengineering the workflow around enhanced & consistent data

Digital transformation

People

Process Technology

Success

Azure ML predictive

model building and scoring

Evaluation of results and data visualization

Data analysis and feature selection for

modelling

Find the optimal mixture of different feeds into the Delayed Coker process

Achieve minimal level of coke yield

Diesel Hydrotreater unit product sulfur content estimation based on available data

Azure ML technology adaptation

compare laboratory, online analyzer, APC soft sensor and ML data

Machine learning

Rapid development and scalability of applications

Reinforce the use of data and analytics based decision making

Support cultural change and normalization

Leverage advanced technologies including advanced analytics and IOT to accelerate business value

Enable sustainable business value in the 21st century

The Importance of Having an OT Data Infrastructure

35

35

PI System Opralog NICE

LIMS Laboratory data

Natural Info Center

E-Logbook

Real-time

data

&

Meta data

PI Integrator for BA

DCS SCADA

Machine Learning Architecture – Current & Future

Field

Business issues in Delayed Coker Unit

Steam Eruptions

Increasing coke yields from 25.39% to 27.43% (+2.04 %) from 2012.01.01 and 2016.03.01.

Average monthly steam eruptions in 2012-2015 period was 3.85, in the first month of 2016 it was 15.5

(4X increase)

1 % Coke yield decreasing

~ $6M/year benefit in Danube Refinery!

Coke Yield & Explosion

Blue: coke yield (output value)

Red: steam eruption ~In case of > 3100 t

Furnace feed input the coke explosion likelihood is increasing

Blue histogram: Row count coke cycle Between the 2550 -2800 t

intervallic the coke yield could be decreased without coke explosion

Improve Azure ML and Data Analyst competences

Participants: Process technologist, Developer technologist, Automation, operation and energy management; IT specialist

(with superlative PI and statistics knowledge)

Overview of tools (Azure ML environment , R, Python)

Regression methods, interpretation of models, regression tree, linear regression, evaluation methods

Steps of real data mining projects

Deeper analyses of Delayed Coker unit

Support Delayed Coker Feed Blender project

Training series Competence improvement

• OSISoft PI – SAP PM Connection

• Support Condition Base maintenance

• Ongoing Project

Challenge – Critical Availability Problems

• Hydrogen Production Plants (HPP) are critical units in the refinery

• Pressure Swing Adsorbers (PSA) are critical equipments in unit operation

• Cyclic operation – Heavy load on valves (9-10 open-close hourly)

• 1.2 MUSD loss in three years due to PSA valve failures

• UPTIME program: 97 % Operational availability

Architecture – Roles of components

PI Server

• Process database

• Online analysis of process information

• Calculation of asset health – Asset condition – Running hours – Performance

• User Interface – PI Coresight – PI DataLink

SAP PM

• Maintenance database

• Management of

maintenance processes

• Creation of work orders or

notifications

• Trigger maintenance

strategies based on asset

health

Connection

(WebLogic)

Calculated asset

health

Maintenance

related information

Future Project

PI Connector for HART-IP

PI Connector for HART-IP