the journey into integrated refinery information system
TRANSCRIPT
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
Presented by
The Journey into Integrated Refinery Information System with the PI System
Sergej Horvat
Process Information Engineer
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
History of Rijeka Oil Refinery
• First Europe's industrial oil refinery founded in 1882 with capacity of 60 000 t/y
• Becomes part of INA at 1964
• INA becomes part of MOL group at 2003
2
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About MOL Group
Oil and Gas Company
3
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Business challenge
Adequate material and utility balancing is essential for a refinery. It is the basis for:
• Accounting
• Controlling
• Performance Monitoring & KPI
• Production Planning
• Benchmarking
• Refinery Transparency
• Supporting Supply Chain Management activities
• Emission Control – Legal obligations, Norm obligations
4
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Background
• Inaccurate, EoS, EoL on some primary measurements at tank farms and battery limits of units
• Islands of control systems with own historians
• Rare automated connection of different systems
• Material movements are logged on paper
• Manual data entry into home made applications for reports
• Lately published reports
5
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Solution Establish reliable and accurate primary measurements at tank farms and battery limits of units, implement the PI System for real-time data gathering and Sigmafine for material balance reconciliation in order to:
• Improve data accuracy and quality
• Improve reporting quality and speed
• Enable well-informed intelligent business decisions to users at all levels of the company - from the plant floor to the enterprise level
• Provide better information for Planning and Scheduling
• Reduce production losses
• Identify measurement meter maintenance (setting priority)
• Improve productivity
6
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Execution
1st Subproject: Instrumentation
improvement
• Tanks
• Battery limit measurements
2nd Subproject: Refinery Information System
upgrade
• Server room & Server park implementation
• Connecting distributed control systems
• The PI System integration
7
The project was divided in two parallel subprojects:
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
Server room implementation
• HVAC 2 x 20 kW redundant
• UPS 2 x 20 kVA redundant
• Central supervision and control system
• Fire alarm and fire fighting
• Technical protection and video surveillance
8
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Server park implementation Designed with redundancy on hardware level • 4 copper switches in 2 power zones • 2 power supply from 2 sources • 2 Fiber channel switches • 4 Copper switches Blade Center H Servers with 7 physical machines • 2 PI System servers in high availibility • 3 Vsphere 5 Cluster • Power 7 – Oracle 11 db Server • Management / Tivoli Server
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1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BladeCenter H
LNK
LNK LNK
43
ID/Diag
1 2 LNK LNK
OK
LNK
LNK LNK
43
ID/Diag
1 2 LNK LNK
OK
1 2 1 2
DCOK
ACDCOK
AC
146GBSAS
146GBSAS
146GBSAS
146GBSAS
146GBSAS
146GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
MT
PS700
1
2
3
4
5
6
7
1
2
3
1 VmWare Cluster server 1
3
2
4
1
2
5
3
4
4
6
7
PI server primary, AF, SQL server
PI server secondary, AF, SQL server
Blade Management server
NICE database server
VmWare Cluster server 2
IBM 42U 1200mm Deep Static Rack
IBM BladeCenter(tm) H Chassis
IBM System Storage DS3524 Express Dual Controller
1U 17in Flat Panel Monitor Console
VmWare Cluster server 3
PS
1
4
PS
2
3
7
8
9
10
MM 13
MM 24
1
2
5
6
1
2
OK
TX/RX
Link
IP
OK
TX
/RX
Lin
k 1
TX
/RX
Lin
k 2
TX
/RX
Lin
k 3
TX
/RX
Lin
k 4
TX
/RX
Lin
k 5
TX
/RX
Lin
k 6
RS
23
2
OK
TX/RX
Link
IP
OK
TX
/RX
Lin
k 1
TX
/RX
Lin
k 2
TX
/RX
Lin
k 3
TX
/RX
Lin
k 4
TX
/RX
Lin
k 5
TX
/RX
Lin
k 6
RS
23
2
OK
TX/RX
Link
1
TX/RX
Link
2
TX/RX
Link
3
TX/RX
Link
4
TX/RX
Link
5
TX/RX
Link
6
RS232
OK
TX/RX
Link
1
TX/RX
Link
2
TX/RX
Link
3
TX/RX
Link
4
TX/RX
Link
5
TX/RX
Link
6
RS232
8GbT
TXRX
19LOG
TXRX
18LOG
TXRX
17LOG
TXRX
16LOG
TXRX
15LOG
TXRX
LOG
0
8GbT
TXRX
19LOG
TXRX
18LOG
TXRX
17LOG
TXRX
16LOG
TXRX
15LOG
TXRX
LOG
0
146GBSAS
146GBSAS
300GBSAS
300GBSAS
300GBSAS
300GBSAS
300GBSAS
300GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
600GBSAS
System Storage
DS3524
8
9
16
17
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Connecting distributed control systems
• Based on TCP/IP
• New infrastructure
• Connection with business network
• Securely
– ISO/IEC 27002
– NIST PCSRF
– ISA SP99
10
Management
VLAN
DMZ
VLAN
vmnic0
vmnic2
vmnic1
vmnic3
Process Network
VLAN
Management
VLAN
DMZ
VLAN
Process Network
VLAN 3750-STACK
vSwitch1
VLAN Trunk
vSwitch0
VLAN Trunk
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PI System integration architecture
11
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
Results: Data Integration
12
Connectors • OPC • PI SDK • PI API • PI OLEDB • VB for
applications • Native
applications
NIC
E L
au
nch
Pa
d
R
aw
/ r
ec
on
cile
d d
ata
Honeywell
PHD
Emerson
Delta V
Tank Gaughing
EnrafBentley Nevada
the PI System Real-time Infrastructure
SIGMAFINE 4
NICE Natural Info Center
(Movement Logbook, Reporting, Planning Module,ICA)
Users (Refining, Logistics, Controlling, SCM etc)
Pro
ce
ss d
ata
via
OP
C
Th
in /
We
b c
lie
nts
Emmision monitoring
system
PREN
Lab data base
Laboratory
MD
E De
nsity d
ata
to
DC
S
La
bo
rato
ry a
na
lysis
da
ta v
ia P
I A
PI
Pro
ce
ss d
ata
via
OP
CS
tock
Ra
w m
ea
su
rem
en
ts
Tank Gaughing
SAAB
Ta
nk s
tatu
s v
ia P
I S
DK
Pro
ce
ss d
ata
via
OP
C
Siemens
Simatic
ABB
MicroSCADA
PRO SYS600
Pro
ce
ss d
ata
via
OP
C
Pro
ce
ss d
ata
via
OP
C
Pro
ce
ss d
ata
via
OP
C
Pro
ce
ss d
ata
via
OP
C
PI A
PI in
terf
ace
Aspen Tech ORION
Petroleum Scheduler
LA
B -
PI S
DK
Mo
ve
me
nts
via
PI S
DK
Mo
ve
me
nts
Sto
ck v
ia P
I A
PI
Re
co
ncile
d d
ata
Inve
nto
ry
Excel reports
MDE
Wo
rk o
rde
r p
ara
me
ters
via
VB
.NE
T
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
Results: Refinery material balance improvement
• Based on Sigmafine models by units
• Automatic raw data and movements loading
• Daily reconciliation reports by unit with better insight in unit production – yields – quantities – energy consumption
• Identify primary measurements errors
13
In – Out + Production – Own Consumption – Accumulation = 0
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Results: Productivity
• Easy and fast data acquisition by users for reporting and analysis from one place
• Automated quality monitoring system with notifications in PI Server Asset Framework
• Over 1 000 calculation inside PI Server Asset Framework
• Custom based reports for easy reuse
14
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Results: Visibility
Synthesis –PI WebPart portal
• Layered dashboards for real-time and analyzed data
– Overview and KPI for managers
– Details for engineers
• Over 200 views with integrated data model
15
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Impact on business
• Accurate and faster material balance reports
• Accurate planning
• KPI becomes important
• Earlier and better identification of measurement problems
• Faster reaction on product quality and environmental issues
• Reliable and accurate data for decision making
• One version of the Truth from bottom to top
• External company engagement on control of oil products is not needed anymore
16
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Future Plans and Next Steps
• Continue Synthesis development
• Upgrade to the PI System 2014 and the PI Asset Framework 2014
• Real-time Energy balance
• Sending smart signals to DCS
– Alarm system
• Asset management
– Condition based monitoring
– Connection to SAP
17
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
RESULTS AND BENEFITS BUSINESS CHALLENGES SOLUTION
Summary
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Adequate material and utility balancing is essential for a refinery operations it has direct impact on performance monitoring, planning, benchmarking….and thus directly impacts financial results.
Implementing the PI System as data infrastructure helped us in this challenge.
A. Adequate material and utility balance
B. Performance Monitoring & KPI
C. Production Planning & SCM
D. Refinery Transparency
A. Improve primary measurement accuracy and reliability
B. Implement the PI System for real-time data infrastructure
C. Implement Sigmafine for material balance reconciliation
A. Accurate daily reconciled material balance
B. Accurate planning
C. Increased productivity
D. Visibility on all plant levels with one version of the Truth
© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015
Contact Information
19
Sergej Horvat
Process information engineer
INA d.d.
19
Rijeka oil Rafinery Process information team: • Darko Klarić - Head of process information • Igor Gregurić - Process information engineer • Sergej Horvat - Process information engineer • Ivica Matasić - Process information engineer • Zoran Grgić - Processing IT Independent Technician
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