The Pursuit of Reliable Data - OSIsoft · M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd 1...

1 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd

The Pursuit of Reliable Data

OSIsoft Asia Technology Conference 2007

The Pursuit of Reliable Data

OSIsoft Asia Technology Conference 2007

M Faisal ZainalAdvanced Process Control (APC) EngineerPETRONAS Penapisan (Melaka) Sdn Bhd.

Prakash KumarPrincipal Engineer, Advanced Process Control (APC)

PETRONAS Penapisan (Melaka) Sdn. Bhd.


AGENDAAGENDA

• Introduction• Our Aspiration• Data Utilization• Issues and Challenges• PP(M)SB Way of Data Management• Benefits• Conclusion


INTRODUCTIONINTRODUCTION

• PETRONAS Penapisan (Melaka) Sdn Bhd is a subsidiary of PETRONAS.

• Consist of 2 refineries:– PSR-1 (process 100MBD of sweet crude)– PSR-2 (process 135MBD of sour crude)

• Use Solomon Benchmarking to identify current ranking with peers:– PSR-1; 1st in the world (74 refineries)– PSR-2; 3rd in the world (74 refineries)

Refinery utilization


PRODUCTSBUFFERPROCESSING UNITS

TYPICAL PROCESS FLOWTYPICAL PROCESS FLOW

Vacuum Distillation

Unit

Treating Units

FEED

Atmospheric Distillation unit

Sour Crude

Gasoline

Diesel

Kerosene

Cracking Units

Asphalt

Coke

Reforming Units

LPG

Blending

Component


ASPIRATIONASPIRATION

0102030405060708090

100

Normal Operation ImprovedOperation

ProfitOperation Cost

YIELD

MAXIMIZEMAXIMIZEPROFITPROFIT

MINIMIZEMINIMIZEOPERATIONAL COSTOPERATIONAL COST

MAXIMIZEMAXIMIZEPRODUCT YIELDPRODUCT YIELD

PROFIT = PRODUCT YIELD – OPERATIONAL COST


HOW TO ACHIEVE OUR GOAL??HOW TO ACHIEVE OUR GOAL??

RELIABLEDATA

RELIABLEDATA

CLOSE MONITORING

MASS BALANCE

ENERGY & LOSS

TESTRUN RESULS

DAILY AUTOMATED

REPORT

ADVANCED CONTROL MODELING

TO SWEAT PROCESS UNIT


HOW DATA IS USED?HOW DATA IS USED?

OPERATION PLANNING-Monitor crude availability-Mass balance

FEED TECHNOLOGY-Daily monitoring-Monthly reporting-Troubleshooting

OPERATION-Daily report-View current process condition-To ensure process stability-Troubleshooting

SIX SIGMA-Optimization project

PROJECT-View historical data for future expansion

PROCESS UNIT TECHNOLOGY-Daily monitoring

OPERATION-Daily monitoring-To monitor product specification

SCHEDULER-Monitor blending components’ availability

PRODUCT


Tool for SUCCESSTool for SUCCESS

• Data availability at desktop• Timeliness• Easy access – anytime,

anywhere• High data processing speed


WHAT WE HAD YESTERDAYWHAT WE HAD YESTERDAY

Control System (Refinery-2) Control System(Refinery-1)

PI Server

Oil Accounting

Lab results

ORACLE

FIREWALL

USERS

Business Network

OPC OPC OPC

Process Control Network

Interface


ISSUES & CHALLENGESISSUES & CHALLENGES

• High Utilisation– Greater appreciation of

historical data– More users

• High Server Loading– More complex computations– More frequent computations

• CAPEX Project support– The need for remote access


PP(M)SB WAY OF DATA MANAGEMENTPP(M)SB WAY OF DATA MANAGEMENT

Redundant system to overcome high downtime

Hi-spec server to overcome high server loading

Distributed Data Management System (DDMS) to handle complex computations

RtWebPart in enabling remote access

Control System (Refinery-2) Control System(Refinery-1)

PI Calc-Server

Oil Accounting

Lab results

ORACLEPI Primary Server PI Secondary Server

N-Way Buffering N-Way Buffering

FIREWALL

RtWebPart

N-Way Buffering

USERS

OPC OPC OPC

REMOTE USERS


BENEFITSBENEFITS

High Availability Data

Better server performance and reliability

Distributed data management

system

Redundant system

Minimal downtime and low loading

Easy access of reliable data

Master the process unit through recorded past event-driven data

OptimizationInitiative

(by Six Sigma, Technologist)

Value creation

Increment Increment on system on system capabilitycapability

Increment Increment on process on process

capabilitycapability


TYPICAL VALUE OF BenefitsTYPICAL VALUE OF Benefits

DataExtraction

DataDataExtractionExtraction

AnalysisModellingAnalysisAnalysisModellingModelling

ImplementAPC

ImplementImplementAPCAPC

Advanced ControlAdvanced ControlImplementationImplementation

CycleCycle

Example (Reforming Unit)RM3.5mil/yr value creation

18 MB18 MBOf DataOf Data


ConclusionConclusion

• Data drives value creation.

• The key requirement for a data historian system is continuous data availability.


THANK YOUTHANK YOU

The Pursuit of Reliable Data - OSIsoft · M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd 1...

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