Reliability Driven Asset Management Plant of the Year 2015 - Gbor - - PowerPoint PPT Presentation

October, 18 2016, Rotterdam

Reliability Driven Asset Management Plant of the Year 2015

• Gábor Bereznai -

Plant of the Year winners in 2010

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Small in the world…

Size of the logos are correlating to companies’ revenue.

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But strong in the region…

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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

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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

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

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Production loss due to UPDT

500,000 1,000,000 1,500,000 2,000,000 2,500,000

2009 2010 2011 2012 2013 2014 Q1

Production loss [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 ]

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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

Serial digital comm.

Strategy

• ptimisation

Statical equipements

Corrosion database

Vibration data collection

Risk Based Inspection

Vibration 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-line, diagnosti c Off-line, diagnostic On-line, diagnostic

Off-line, diagnostic, Communicator RFID / PDA

Off-line, diagnostic

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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

• f the DC units

Alarm filtering in the SAP-FIMS interface

CFV-087

Predictive notifications can save 7k$-700k$ avoiding unit

• utages.

CMMS integration

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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.

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Integrated Maintenance Systems

219 2114 1347 413

42 500 1000 1500 2000 2500 Honeywell AM Emerson AMS Yokogawa PRM Devices [PCS]

AM - AMS - PRM protocols (4135 pcs devices)

HART FFB Wireless HART

2110 850

413 9

500 1000 1500 2000 2500 Honeywell AM Emerson AMS Yokogawa PRM

Devices [PCS]

AM - AMS - PRM protocols (3382 pcs devices)

HART FFB Wireless HART

2010 2015

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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)

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Peolpe behind the systems

October, 16 2016, Rotterdam

• Csaba Molnár-Valkó -

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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

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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

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On-line equipment types

• Transmitters
• Pressure
• Differential pressure
• Level
• Temperature
• Flow transmitter
• Valves
• Control valave
• ON-OFF valve (with positioner)

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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

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Setting Alerts / Handling

Device Alert handling

DVC5000 (66 pcs parameters / 33 alerts) DVC 6200 (150 pcs parameters / 50 alerts)

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Setting Alerts in maintenance system

Setting Alerts / Handling

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Setting Alerts / Handling

Setting interface

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Valve diagnostic

― ValveLink Online/Offline ― DTM based (Metso, Flowserve) ― Flowscan ― ValVue ― OVD

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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

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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

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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
• ptimization
• Coker yield optimization

Safety & Asset integrity (PSM)

Yields Operational

• ptimization
• 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

• ptimization

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

• ptimization

Condition based & predictive maintenance

Ad Advan anced ced An Anal alytics cs an and IoT Oil & Ga Gas Downs nstr tream eam

Analytic Ascendancy Model

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 ud Intel elli ligence

Ad Advan anced ced An Anal alytics cs

• 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

Digit ital al tran ansfor

• rmati

ation

• n

Peo eople Proce cess ss Tec echno nology logy

Success ess

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

Mac achine ne lea earni ning ng

• 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 I e Import rtance ance of Ha Having ing an an OT OT D Dat ata a Inf nfras astruc ructure re

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PI System Opralog NICE LIMS

Laboratory data Natural Info Center E-Logbook Real-time data & Meta data PI Integrator for BA

DCS SCADA

Mac achine ne Lea earni ning ng Ar Archit itectu ecture e – Current ent & Future

Field

Bu Busines ness s issues es in n Del elay ayed ed Coker er Uni nit

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

• f 2016 it was 15.5

(4X increase) 1 % Coke yield decreasing ~ $6M/year benefit in Danube Refinery!

Coke e Yiel eld d & Ex Explosio sion

• 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

Traini aining ng series ies Co Competence petence improvement provement

• 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