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Introduction of S-OIL
KPIC
KNOC
ISU Poongsan M etal
LS Nikko
Storage Tanks (Shinwon Area) SPM
S-OIL Refinery in Ulsan, Korea
1. Location S-OIL is located at On-San national Industrial area in Ulsan, Korea.
Ulsan
Seoul
Yeosu
Daesan
Inchon
(Yeosu)
(Daesan)
(Ulsan)
(Inchon)
(Ulsan 669 MB/D)
Ⅱ.온산공장 소개
2
#4 Facility #3 Facility
#2 Aro. Complex
HYC
#1 RHDS
#3 CDU
#2 Facility
#2 CDU
#1 Aromizer
#1 PX
RFCC
#2 RHDS
#1 Facility
#1 CDU Lube
#1/2 Jetty
#3 Jetty
SPM 1 & 2
KPIC LS Nikko
2. View of S-OIL
Area : 2.74 mil.㎡
- SPM : 350.000 DWT x 2ea
- 9 Shipping Berths : 5,000 ~ 120,000 DWT
Ⅱ.온산공장 소개
3
#5 Facility
SSangyong Oil Refin ing Co., Ltd .,
‘ 80
Korea Iran Petro leum Co., Ltd . ‘ 76
#1 CDU(90MBD) ‘ 80
Lube base o il p lant ‘ 81
4
6MB/D
60MB/D
178 (Unit : b il. KRW) 822
#2 CDU(240MBD) ‘ 91
330MB/D
90MB/D
#1 Arom izer(BTX) ‘ 91
J/V(Saudi Aram co) ‘ 91
#3 CDU(250MBD) ‘ 95
580MB/D
3 ,474
BCC(Hydrocracker / #1 RHDS) ‘ 96
885
BCC(RFCC / VGO HDS) ‘ 97
181MB/D
#1 PX plant ‘ 97
1,550KTA 97MB/D
900KTA
S-OIL. Ltd . ‘ 00
8,083
BCC(#2 RHDS) ‘ 02
252MB/D
12 ,232
1 ,600KTA
#2 Arom atics Com plex
‘ 11
20,530
669MB/D
2 ,430KTA
34 ,723
790KTA
14MB/D
28MB/D 40MB/D 43MB/D
History of S-OIL
170 (Unit : m il. USD) 783 3 ,309 843 7 ,698 11 ,650 19 ,552 33 ,070
(As of 2012 , $1 = 1 ,050 KRW)
Atmospheric Residue
LPG
Naphtha Kero
DSL
#1 /2 /3
CDU
Crude
3. Production Process The main production process step
CFU
Benzene Toluene M-Xylene Para Xylene
Benzene #1
ARO
#2 ARO
Aromizate Para Xylene Benzene
#1 PX Heavy Aro.
#1/2 Aromatics Complex
#2 PX
DAO
MDO
HDO
Asphalt
Lube Base Oil / Wax
Lube Base Oil Complex
Lube Plant
#1 VDU
SDA
Vacuum Gas Oil
Hydrotreated Heavy Oil
Lube Base Oil
LPG Naphtha
Kerosene ULSD
Propylene
Gasoline
MTBE / Alkylate
LPG
Diesel
Naphtha ULSD
Naphtha DSL
LS B-C
MTBE Alkylation
VGO HDS
VGO
#2 VDU
Bunker-C Cracking Center
Hydro- cracker
#2RHDS #1RHDS RFCC Vac. Residue
Ⅱ.온산공장 소개
5
“Laying the foundation for growth w ith strategic investment in upgrading facilit ies”
“Stable growth w ith contribution to the local community, advanced management of safety and the environment and operational
excellence”
“Sustainable profitable growth through new investment”
6
“The most competit ive refining and marketing company in Asia Pacif ic region”
S-OIL Customized OTS Introduction
Background Progress
Background
Increase of new employees
• Retirement of experienced operators
• Expansion of the Refinery
Less opportunities for S/U & S/D
• Extended turnaround interval
• Decrease of process troubles due to enhanced
reliability of facilities
Increase of process complexity
Training simulator is the most effective method
to secure skillful workforce
• Increase of integration between processes for
more efficient operation
Challenges and Solutions
Advantages of training simulator
Training Simulator
( National Training Laboratories, The Learning Pyramid ) Most effective training method
• Fastest and most effective way for system familiarization
• Training simulator provides realistic, hands-on training
of operation without any operation risk
• Operators can obtain various experience in a short time
Standardized knowledge transfer
• Standardized knowledge transfer with systematic training programs
• Standardized and effective responds to various operation cases
(Normal, S/U, S/D, Emergency Case)
Background Progress Challenges and Solutions
Global company trend
• Global leading companies such as ExxonMobil, Shell, Total increase application of training simulator
• Other domestic refineries(GSC,HDO) also introduced training simulator and increase its application
Expected benefit
• Unplanned S/D, C/D would be reduced
• Efficient and Safe turn-around
• Profit improvement through operational excellence - According to World Oil report (2012), decrease the number of unplanned S/D is 3 times a year which result in saving loss from unplanned S/D : 2.6 mil.$ - Typical loss from operational error in the Refinery about 1.2 mil.$
<1M$
1~3M$
3~10M$
10~20M$
20~30M$
> 30M$
Decrease number of unplanned S/D per year & Saving Loss
Training simulator is key solution to achieve
“Best-in-class operational excellency”
Background Progress Challenges and Solutions
Training center named as “S-OIL Operation Training Center” located in Welfare and Education BLDG
Training center have 8 rooms and 15 trainees can be trained at a time.
Operation training center
Eight(8) Major Processes : #2 CDU, #2 VDU, #2 RHDS, HYC, RFCC, #3 HMP, #1 ARO, #1 PX
Completion of training simulator introduction
Kick off
13.07.02
MAT (Model Acceptance Test)
13.12 ~ 14.03
FAT (Factory Acceptance Test)
14.04 ~ 14.06
SAT (Site Acceptance Test)
14.05 ~ 14.06
Completion of Introduction
(14.6.27) Simulation Training
14.07 ~
(복지교육관)
Background Progress Challenges and Solutions
It was very tight to deliver 8 process units within a year.
Most of the 8 process units were complex ones, including Aromatics, PX, RFCC, RHDS, HYC
Designed heat and material balance was not applicable due to plant expansion/modifications, so reconciled heat and material balance needed to be created
Most Challenging and Aggressive Delivery
Resource Arrangement Challenges
For some process units, T/A schedule was overlapped with OTS project schedule, so it was very difficult to fix resource arrangement and testing schedule for S-Oil.
The S-Oil project team members had to be away from plant operation for MAT/FAT activities, which were 2 weeks for each MAT and FAT of each process unit, so there was challenge for operation team in the normal operation.
Background Progress Challenges and Solutions
Challenges
Steering Committee from both S-Oil and Schneider Software delivery was formed in the very beginning of project execution and guided the project execution at management level
Dedicated Project Manager and Project Coordinator at Project execution level
Management Commitment
Best and Consistent Resource Arrangement from S-Oil
S-Oil arranged the same best resource (operators & managers) throughout the project execution, so the tests were highly effective and efficient, and both technical and project management issues were addressed timely
Background Progress Challenges and Solutions
Solutions
Closely Work with Schneider Project Team
Reconciled heat and material balance was firstly created in Pro/II based on actual operation data by Schneider Project Team and then validated by S-Oil before they were implemented in OTS
Highly professional OTS delivery team together with excellent Korean local project management and technical support
14
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