engineering support of planning and scheduling revsion 81

8/10/2019 Engineering Support of Planning and Scheduling Revsion 81

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2010 Aspen Technology, Inc. All rights reserved

Engineering Support for RefineryPlanning and Scheduling

Improve performance and marginswith aspenONE Engineering

Aspen Product Management

January 3, 2015


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2010 Aspen Technology, Inc. All rights reserved | 2

Agenda

Why Engineering Support for Planning

Engineering Best Practices

Integrated Petroleum Supply Chain Workflow

Key Activities

Why aspenONE Engineering

Next Steps


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Why Engineering Support for RefineryPlanning and Scheduling

Improve Refining Marginswith accurate planning modelsthrough engineering models

Improve and sustain refinery margins

Faster and better feedstock selection

Accurate planning and scheduling models Agility in response to operational opportunities


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Engineering Best Practices

Feedstockselection

agility

PerformanceMonitoringof units andequipment

Planningmodel

updatesfor accuracy

Capital projectassessments

for optimaldesigns

Plantoperations

decision supportfor timely response


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Asset Engineering Lifecycle and Workflow

Integrating Engineering Business ProcessesEnables Best Practices

Research andDevelopment

ConceptualEngineering

BasicEngineering

DetailedEngineering

PlantOperations

Planning andScheduling

Develop Process

Technology

Select Process

Technology

Produce ConceptualProcess Design

Produce ConceptualEngineering Design

Construct and Pre-commission Plant

Commission andHandover Plant

Daily PlantOperations

MaintainEquipment

Procure and Control Equipment,Materials and Services

Produce DetailedEngineering Design

Identify Plant

Capital Projects

Produce DetailedProcess Design

FEED

Planning andScheduling

PlantOperations

Select Crude Oilsand Feedstocks

Issue OperatingTargets

Monitor and GuidePlant Performance


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Planning and Scheduling Model Updates

Challenge

Challenge Challenge

Impact

Planners andprocess engineerswork in silos

Engineering

models are neededas input to updaterefinery wideplanning models

Reduced predictivecapability andproduct quality

Variation between

plan vs. actual

Lost Margins

Higher margins

with optimal yields and on-time,on-spec performance

Solution

Easier updating of

planning and schedulingmodels to reflect actual

plant performance


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Unique to aspenONE

Workflow toupdate planning

models usingrigorous models

Ease of usewith calibrationtools and links

between models

Supportcollaboration

between engineersand planners

Businessapplication

access by plannersand schedulersthrough Excel

Collaborative workflow to update planning and scheduling models



Refinery activityHeadquarters activity

Market

Demand

Forecasting

Refinery Planning

Refinery

Scheduling

Production Plan

Primary Distribution Scheduling

(depot inventory management)

Distribution PlanningMarket Forecast

Constrained Forecast

Refinery

Production targets

Distribution & Exchange Plan

Market Forecast

Scheduled Movements

to/from Refineries

Secondary

Distribution

Scheduling

Retail Demand(by terminal)

Blend

Scheduling

& optimisation

Trading

Accounting

(SAP)

Deals

Sales History

Production Schedule

Actualised

movements

Advanced Process Control

Process Unit

Set-pointsBlend recipes

Pipeline

simulation &

scheduling

Batch

confirmation

Batchnomination

Integrated Petroleum Supply Chain (IPSC)



Refinery activityHeadquarters activity

Market

Demand

Forecasting

Refinery Planning

Refinery

Scheduling

Production Plan

Primary Distribution Scheduling

(depot inventory management)

Distribution PlanningMarket Forecast

Constrained Forecast

Refinery

Production targets

Distribution & Exchange Plan

Market Forecast

Scheduled Movements

to/from Refineries

Secondary

Distribution

Scheduling

Retail Demand(by terminal)

Blend

Scheduling

& optimisation

Trading

Accounting

(SAP)

Deals

Sales History

Production Schedule

Actualised

movements

Advanced Process Control

Process Unit

Set-pointsBlend recipes

Pipeline

simulation &

scheduling

Batch

confirmation

Batchnomination

Integrated Petroleum Supply Chain (IPSC)

Engineering Models Support

Planning & Scheduling



Example: A Recent IPSC Project

Global Orion

PPIMS

LocalORION/MBO

AtOMS

Advisor

RefSys PSMA

PublishedSchedule (13)

Tank andVessel

MovementsData

Tank Info,Products, Units

Stream flows &Qualities from

IP21

From IP.21:

process and lab

data such as

flows, temp,

pressure, level,

inventory data

To Oracle

Financials

From IP.21:

process and lab

data

Plan Data

From IP.21: lab

data

ReconciledData

PPIMS

LocalORION/MBO

AtOMS

Advisor

RefSys PSMA

PIMS to Orion(11)

Orion Imports (12)

Tank andVessel

MovementsData


From IP.21:

process and lab

data such as

flows, temp,

pressure, level,

inventory data

From IP.21:

process and lab

data

Plan Data

From IP.21: lab

data

ReconciledData

PPIMS

LocalORION/MBO

AtOMS

Advisor

RefSys PSMA

Tank andVessel

MovementsData


From IP.21:

process and lab

data such as

flows, temp,

pressure, level,

inventory data

From IP.21:

process and lab

data

Plan Data

From IP.21: lab

data

ReconciledData

XPIMS1. Mid-Term

Planning

2. Short-Term

PlanningIRT

InventoryProjections (9)

3. RefineryScheduling

DSS

To Oracle

Financials

To Oracle

Financials

4. Operations

Execution

5. Production Accounting

6. Operational PerformanceManagement

PS EM

RBV ODM

Data Loading

Line of Pallots

MAA MAB SHUMOG

XPIMS

KPC Int Mktg

$

Ref MAA, MAB, SHU

Demand,Prices (1)

Demand (2)

ShutdownDays (3)

Sales, Target Inventory (4)

IRT (5)

Shares Same DataBase

KPC Supply Ops

Nominations

Shipment Events (Vol, Prd, Dem, etc)

Finalised Feasible Shipments to Local Orion (7)

AggregatedDemand (8) Aggregated

Demand (8)AggregatedDemand (8)



Global Targets: Sales, IRT, Capacity Inventory to Local Plan (10)

PIMS to Orion(11)

PIMS to Orion(11)

Orion Imports (12)Orion Imports (12)Published

Schedule (13)Published

Schedule (13)

Reuters, Platts, etc

Component & Product Prices (14)

Nominations


IP21


IP21

KPC Supply Ops

Supply Program

HQ Refinery 1 Refinery 2 Refinery 3



Example: A Recent IPSC Project

Global Orion

PPIMS

LocalORION/MBO

AtOMS

Advisor

RefSys PSMA

PublishedSchedule (13)

Tank andVessel

MovementsData



IP21

From IP.21:

process and lab

data such as

flows, temp,

pressure, level,

inventory data

To Oracle

Financials

From IP.21:

process and lab

data

Plan Data

From IP.21: lab

data

ReconciledData

PPIMS

LocalORION/MBO

AtOMS

Advisor

RefSys PSMA

PIMS to Orion(11)

Orion Imports (12)

Tank andVessel

MovementsData


From IP.21:

process and lab

data such as

flows, temp,

pressure, level,

inventory data

From IP.21:

process and lab

data

Plan Data

From IP.21: lab

data

ReconciledData

PPIMS

LocalORION/MBO

AtOMS

Advisor

RefSys PSMA

Tank andVessel

MovementsData


From IP.21:

process and lab

data such as

flows, temp,

pressure, level,

inventory data

From IP.21:

process and lab

data

Plan Data

From IP.21: lab

data

ReconciledData

XPIMS1. Mid-Term

Planning

2. Short-Term

PlanningIRT


3. RefineryScheduling

DSS

To Oracle

Financials

To Oracle

Financials

4. Operations

Execution

5. Production Accounting

6. Operational PerformanceManagement

PS EM

RBV ODM

Data Loading

Line of Pallots

MAA MAB SHUMOG

XPIMS

KPC Int Mktg

$

Ref MAA, MAB, SHU

Demand,Prices (1)

Demand (2)

ShutdownDays (3)

Sales, Target Inventory (4)

IRT (5)

Shares Same DataBase

KPC Supply Ops

Nominations

Shipment Events (Vol, Prd, Dem, etc)

Finalised Feasible Shipments to Local Orion (7)

AggregatedDemand (8) Aggregated

Demand (8)AggregatedDemand (8)



Global Targets: Sales, IRT, Capacity Inventory to Local Plan (10)

PIMS to Orion(11)

PIMS to Orion(11)

Orion Imports (12)Orion Imports (12)Published

Schedule (13)Published

Schedule (13)

Reuters, Platts, etc

Component & Product Prices (14)

Nominations


IP21


IP21

KPC Supply Ops

Supply Program

HQ Refinery 1 Refinery 2 Refinery 3

Engineering Support for Planning

and Scheduling is built into this project



Refinery Plant Data enters IPSC via theEngineering Models (see terms next slide)

RTOReal Time 24/7 Automatic

Data Collection

APCDMCplus

Real Time Data Base (IP.21, PI, PHD)

Simplified Modelsto Aspen PIMS &

Scheduler

Plant Targets(APC setpoints)

ASW Link

Plant DCS

ASWOn DemandManual DataCollection

AODReal Time 24/7Automatic Data

Collection

To IPSC From IPSC

Aspen RefSYS FlowsheetsEngineering Models forPlanning and Scheduling Support with

Data Reconciliation and Calibration



Planning and Scheduling Support WorkflowsStart with Aspen RefSYS*

Aspen RefSYS Flowsheets

Aspen PIMS andAspen Petroleum Scheduler

* The new name for Aspen RefSYS is Aspen HYSYS Petroleum Refining

Excel

Assay Tables forCrude Distillation

Case Study/Excel orSwing Cut Utility

Workflow 1 Excel

LP Submodelsfor Reactors

Case Study/Excel orPIMS Support Utility

Workflow 2


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Planning and Scheduling Support Workflowswith PIMS to Petroleum Scheduler Integration

Workflow 2

Aspen RefSYSFlowsheets

Aspen PIMS

Excel

Assay Tables forCrude Distillation

Case Study/Excel orSwing Cut Utility

Workflow 1 Excel

LP Submodelsfor Reactors

Case Study/Excel orPIMS Support Utility

Aspen PIMS

Aspen Petroleum

Scheduler

Aspen Petroleum

SchedulerWorkflow 3V7.3 Utilities

Workflow 4SMC file transfer


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Crude Assay Management

ChallengeChallenge ChallengeImpact

Characterizingeach crudesproperties andcomposition is

time consuming Blending crudes

into a singlefeedstockcomplicates settingoperational targets

Errors can havesignificant impacton simulationresults

Lost opportunitycrude oils

Lost Margins

Higher marginsExploit opportunity feedstocksand improve operating plans

Solution

Improved crude oil

blending to increaseaccuracy and reduce

simulation times


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Why is Crude Oil Characterization Important?

Petroleum refinery profit margins are under great pressure

Crude oil prices and product prices move independentlydestabilizing profit margins

Feed and product costs must be well understood to protect

profit margins

Crude oil compositions must be well defined to correctlyprice feed stocks and products


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How does Crude Oil CharacterizationImprove Profits?

Crude oil characterization data is used in three main ways: Engineering models (Aspen HYSYS Petroleum Refining)

Planning models (Aspen PIMS)

Scheduling models (Aspen Petroleum Scheduler)

Engineering models confirm crude distillation units cansuccessfully process purchased crude oils

Planning models select optimal crudes oils for refinery

Scheduling models assure smooth and predictable delivery ofproducts


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Where is Crude Oil Characterization Done?

Planning and Scheduling Support tools Third party products

Flowsheet simulators

Aspen HYSYS Oil Manager Aspen RefSYS MacroCut

Aspen Plus (ADA)

In house crude cutting programs

Large oil companies


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Crude Oil Characterization Methods Used inAspen HYSYS and Aspen RefSYS

Feed

StreamModel

Lab Data:

Gravity,Distillation,

etc.

RefSYS

Macro CutInput

Table

RefSYSAssay

Manager

HYSYS

Oil

Manager

3rdparty

assay managers

Other crude

cutting programs

RefSYS Macro Cut

Input Table


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2010 Aspen Technology Inc All rights reserved | 23

Crude Oil Characterization Usage

Feed

Stream

Model

Lab Data:

Gravity,

Distillation,

etc.

RefSYS

Macro Cut

Input

Table

RefSYS

Assay

Manager

HYSYS

Oil

Manager

3rdparty

assay managers

Other crude

cutting programs

RefSYS Macro Cut

Input Table

HYSYS/RefSYS

Fractionation

Models

RefSYS cases

confirm crude

unit can

process crude

Yields

& Properties

for PIMS

Yields

& Properties

for Petroleum

Scheduler

Fractionation models re-assemble narrow range hyposinto wider range product cuts for PIMS assay tables

engineering support of planning and scheduling revsion 81

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