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Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
ROMPETROL’S REAL TIME INFORMATION SYSTEM
a road from PLANT OPERATIONS FIELD DATA to MANAGERIAL DECISIONS
Regional Seminar Series
Ana-Maria CiuculanPI System AdministratorRompetrol
1 – October- 2009
© Copyright 2009, OSIsoft Inc. All rights Reserved. 2 Empowering Business in Real Time.
ROMPETROL’S REAL TIME INFORMATION SYSTEM:
a road from PLANT OPERATIONS FIELD DATA to MANAGERIAL DECISIONS
3 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Agenda
▪ The Rompetrol Group▪ Rompetrol Refinery Information System and the OSIsoft products
▪ OSIsoft products at Rompetrol Refinery ▪ PI data sources▪ System Architecture
▪ Why PI ?▪ Excel DataLink – Reports▪ Management Report – Storage Space▪ Management Report – Production▪ HTML visualization▪ Rompetrol Refinery – PI Process Book
▪ Crude unit▪ Crude oil – tanks▪ Operational KPI
▪ Sigmafine – Mass Balance –Model▪ Sigmafine –Data Inputs▪ Sigmafine –Data Outputs▪ Sigmafine –Products Transfers▪ Sigmafine – Mass Balance - Analysis▪ Sigmafine – Mass Balance – Graphic Model
▪ From Past to Future▪ Conclusions
4 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Rompetrol
▪ A leader in the regional oil field▪ A multinational company ▪ Activities in 13 countries ▪ Strong operational base in:
▪ The Black Sea region▪ The Mediteranean Sea region
5 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Rompetrol
– Through its 40 subsidiaries, The Rompetrol Group is mainly
active in the refining process with implications in
complementary projects, exploration and production,
distribution, industrial services, maintenance, project
management, logistics, industrial ecology and other related
services in France, Romania, Spain and South-Eastern
Europe.
– Other non-core businesses: air transportation, tourism,
safety and protection services.
6 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Rompetrol Refinery
• Designed and built between 1975-1977
• Romanian and foreign technology
• Rompetrol Refinery can process a wide variety of
crude.
• Refinery capacity = 5.300.000 tones/year.
• High quality control and information systems:
– DCS
– Information System =OSIsoft Plant Information
7 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
OSIsoft products at Rompetrol Refinery
• PI Enterprise Server ( 3.4.375.38) : 30000 tags
• PI Client Application:
– ComboPack Individual (PI ProcessBooK&PI Data Link) - 90
users
• Sigmafine Server: AF 1.3. & SF v4.4.0.123
• Sigmafine Client:
– PI AF Explorer: 1.3.0.1434
– AF Modeler Add-in: 1.1.1.1323a
• SRP
8 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
OSIsoft licences at Rompetrol
9 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
PI data sources
• Field instrumentation
– PLCs
– DCS for Production Area
– DCS for Utilities Area
– Tank Master for Crude Tanks
– Tank Master for Products Tanks
– NMR- online analyzer
• Manual Data Entry
– Lab – OLA
– Process Information - OLP
• Blending system
• Sigmafine
Information Gathered from
Different Sources
10 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Data sources and interfaces
Field instrumentation
Production Area DCS
PI NET
OLA OLP
Utilities Area DCS
Field instrumentation
Interface
Interface
Interface
Crude Tanks
ProductTanks
TankMaster
TankMaster
Interface Interface
Manual Data Entry
Manual Data Entry
InterfaceOnline
Analyser
Sigmafine Server
PI SERVER
Interface
11 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Overview: System Architecture
CLUSTER
PI SERVERACTIVE
PI NET
DCS (PI to PI)PLC (OPC Interface)
Motoare (OPC Interface)NMR
LabInterface
PI SERVER A PI SERVER B
PIRouter
1 2 3 4 5 6
7 8 9101112
AB
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
Eth
ern
et
A
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
C PI Private Switch
1 2 3 4 5 6
7 8 9101112
AB
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
Eth
ern
et
A
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
C PI Switch
1 2 3 4 5 6
7 8 9101112
AB
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
Eth
ern
et
A
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
C AFPE SW
AFPERouter
Tank
MasterProducts
Foxboro
Solaris
1 2 3 4 5 6
7 8 9101112
AB
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
Eth
ern
et
A
12x
6x
8x
2x
9x
3x
10x
4x
11x
5x
7x
1x
C 50000 SW
Tank MasterCrude
PI Router
PetromidiaOLA
PEM LANPIClients
Scanair
OLA
OLP
12 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Why PI ?
Excel Reports before PI DataLink Excel Reports – with PI Data Link
⚫ A huge number of reports delivered by e-mail
⚫ Various data sources
⚫ Inconsistencies between figures
⚫ Large volume of calculations
⚫ Performance computing module
⚫ One database for data process
⚫ The information is updated in real time
⚫ Formulas predefined
An overview of the entire refinery process data in real time:
Production Parameters:
•Temperature
•Pressure
•Flows
•Level
Equipment Health and Period of On-line Operation
❖ONE DATA BASE for reports
❖REAL TIME updates
13 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Management Report – Storage Space
Reziduu
Spatiu liber
Pompabil
Nepompabil
Stocuri&Capacitati de stocare
Motorine
Date PI nereconcilate
8/28/08 2:00 PM
Benzine
Materii Prime
27035
26913
160258
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare Titei
= 214206 tone
0
598
460
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
METANOL = 1058 tone
75
215
788
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
Motorina super euro 5 =
1078 tone
1620
10445
13273
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
Motorina super euro 4 =
25338 tone
415
1010
1137
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
Benzina Premium E 4 =
2561 tone
1593
4543
4586
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
Benzina naturala tip 92 =
10722 tone
2230
7971
5261
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
Benzina euro plus fara
plumb = 15462 tone
1694
10661
14061
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare Motorina
Stoc Total = 26416 tone
4426
14916
13102
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
Benzina Stoc Total =
32444 tone
1085
389
14654
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
COMPONENTI MOT.EURO4
= 16128 tone
600
3051
1787
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Capacitate stocare
REZIDUU DE VID DA =
5438 tone
VISUALIZATIONS Based on PI DATA
14 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Management Report – Production
Supus instalatii 8/28/08 4:00 AM 8/29/08 4:00 AM
HB
784 784 784
2,351
802 802 802 2,406774 764 756
2,294
-
500
1,000
1,500
2,000
2,500
3,000
Sch.1 Sch.2 Sch.3 8/28/2008
MOP(PIMS) Program (Orion) Realizat
DAV
4,243 4,243 4,243
12,730
4,333 4,333 4,333 13,0004,429 4,430 4,429
13,288
-
2,000
4,000
6,000
8,000
10,000
12,000
14,000
Sch.1 Sch.2 Sch.3 8/28/2008
MOP(PIMS) Program (Orion) Realizat
RC
468 468 468
1,403
517 517 517 1,550468 468 467
1,403
-
200
400
600
800
1,000
1,200
1,400
1,600
1,800
Sch.1 Sch.2 Sch.3 8/28/2008
MOP(PIMS) Program (Orion) Realizat
HPM
924 924 924
2,773
953 953 953 2,860946 918 919
2,782
-
500
1,000
1,500
2,000
2,500
3,000
3,500
Sch.1 Sch.2 Sch.3 8/28/2008
MOP(PIMS) Program (Orion) Realizat
HPR
411 411 411
1,234
490 490 490 1,470481 485 485
1,450
- - - -- - - -- - - --
200
400
600
800
1,000
1,200
1,400
1,600
Sch.1 Sch.2 Sch.3 8/28/2008
MOP M (PIMS) Program M (Orion) Realizat M
MOP P (PIMS) Program P (Orion) Realizat P
HDV
1,413 1,413 1,413
4,239
1,433 1,433 1,433 4,3001,447 1,485 1,487
4,418
- - - -- - - -- - - --
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
Sch.1 Sch.2 Sch.3 8/28/2008
MOP(PIMS) Program (Orion) Realizat DMOP(PIMS) Program (Orion) Realizat M
HIGH VISIBILITYof
ACTUAL PRODUCTIONvs
PLAN&SCHEDULES
15 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
From EXCEL to HTML
Management Report
EXCELPI DATA LINK
HTML
❖AGGREGATED OVERVIEW
❖BETTER INFORMED
❖CORRECT DECISION
16 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
HTML visualization
• High speed for report upload
• Graphic visualization
• Multiple possibility for accessing data :
– INTRANET (done)
– INTERNET (in progress)
– SMART PHONE (in progress)
• Increasing the visibility of the information through
the company systems
• Getting the required INFORMATION for the analysis on
TIME
• SUPPORT for the INFORMED DECISIONS
Engineers Report
Management Report
Valuable informationIn Real TimeTo Any Place
17 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Rompetrol Refinery – PI Process Book
EASY TO NAVIGATEBETWEEN
THE DISPLAYS
18 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Crude unit
REAL TIME VIEW
BEST MONITORING
19 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Crude oil – tanks
REAL TIME DATA CRUDE UNIT FEEDSTOCK
20 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Sigmafine – Mass Balance -Model
• 756 elements– 320 Flows
– 88 Nodes
– 53 Gas Meters
– 95 Liquid Meters
– 19 Processes
– 6 Receipt Points
– 21 Shipment Points
– 154 Tanks
• 180 Layers
• Strapping tables
• Density tables
• Material tablesONE CONSISTENT
MODEL
for REFINERY
21 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Sigmafine –Data Inputs
➢ Measured Mass
➢ Measured Volume
➢ Density
➢ Temperature
➢ Tank Level
➢ Strapping tables
➢ Density tables
➢ Material tables
➢ Volume correction factor (VCF)
➢ Products Transfers
MANUAL DATA INPUTS
Sigmafine Model
PI SYSTEM
❖ONLINE DATA
❖MANUAL DATA INPUTS
22 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Sigmafine –Data Outputs
➢ PI Tags :
➢ Reconciled Mass
➢ Any reconciled Value
➢ Inventory Report
➢ Yields Report
➢ Measurements Report
➢ Loss Report
*xls Reports
Sigmafine Model
PI SYSTEM
❖ANALYSIS
❖FEEDBACK
❖DECISION
23 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Sigmafine –Product Transfers
StartTime EndTime Source Destination MeasuredMass
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\ReceiptPoint_Conpet_Titei Refinery Model\Node_Titei 14097000
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_DILB Refinery Model\ShipmentPoint_AFPE 6211000
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_GPL_REZ_OUT Refinery Model\ShipmentPoint_GPL 927000
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_Cocs_CX_OUT Refinery Model\ShipmentPoint_Cocs 1435000
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_GILB Refinery Model\ShipmentPoint_AFPE 2085000
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\ReceiptPoint_Gaze naturale Refinery Model\Node_Gaze_naturale_IN 48000
3/1/2008 4:00 3/3/2008 2:00 Refinery Model\Node_Sulf_RS_OUT Refinery Model\ShipmentPoint_Sulf 185000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\ReceiptPoint_Conpet_Titei Refinery Model\Node_Titei 2069000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_DILB Refinery Model\ShipmentPoint_AFPE 4394000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_Calor_Extra Refinery Model\ShipmentPoint_Calor_Extra 25000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\C-99 Refinery Model\ShipmentPoint_Calor_Economic 69000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_GPL_REZ_OUT Refinery Model\ShipmentPoint_GPL 1382000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_Cocs_CX_OUT Refinery Model\ShipmentPoint_Cocs 562000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_GILB Refinery Model\ShipmentPoint_AFPE 1214000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\ReceiptPoint_Gaze naturale Refinery Model\Node_Gaze_naturale_IN 33000
3/3/2008 4:00 3/4/2008 2:00 Refinery Model\Node_Sulf_RS_OUT Refinery Model\ShipmentPoint_Sulf 75000
*xls FILE
DAILY INPUTS
MANUAL DATA
24 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Sigmafine – Mass Balance - Analysis
DAILY BASES ANALYSIS
24H, WEEKENDS
25 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Sigmafine – Mass Balance- Graphic
Model
26 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
What we had and what we have ?
2004
BEFORE PI IMPLEMENTATION AFTER PI IMPLEMENTATION
COLLECTING DATA = TIME CONSUMING ACTIVITIES
MORE TIME FOR ANALYSES
LIMITED HISTORY LONG TIME DATA HISTORY
DELAY BETWEEN THE FACTS AND FEEDBACK
REAL TIME INFORMATION , REAL TIME ACTIONS
A HUGE MANUAL DATA INPUTS FOR REPORTS
HIGH QUALITY DATA INPUTS FOR REPORTS
ERRORS on NUMBERS ACCURATE DATA
LIMITED DATA ACCESS HIGH DATA AVAILABILITY
DATA from PI SYSTEM
=
QUALITY, AVAILABILITY, INTEGRITY
REAL TIME
27 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Future Directions
PI System
⚫ Upgrading the PI system to ensure a PI solution for other sites
⚫ Develop new applications for other areas:
– Tanks Farm
– Product Loading Terminal
– Utilities Area
Sigmafine
⚫ Improving the production Mass Balance Model
⚫ Develop and implement a model for the Utilities
❖PI SYSTEM for ANOTHER SITE
❖SIGMAFINE MASS BALANCE
❖SIGMAFINE for UTILITIES
❖RT WEBPARTS
❖ACE MANUAL DATA INPUTS
28 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
Conclusions
PRODUCTION AREA
MANAGEMENT
TECHNICAL
STAFF
CONTROL
SYSTEM
DECISIONS
VARIOUS
DATA SOURCES
PI SYSTEM
Reports
INFORMATION
CORRELATE
THE PRODUCTION
WITH THE BUSINESS NEEDS
M
O
N
E
Y
REAL TIME
RAW DATA RAW DATA
ON TIME
29 Empowering Business in Real Time. © Copyright 2009, OSIsoft Inc. All rights Reserved.
WE ARE LOOKING FORWARD TO
ANSWER ALL YOUR
QUESTIONS
Thank you
© Copyright 2009 OSIsoft, Inc.
777 Davis St., Suite 250 San Leandro, CA 94577