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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


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


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.


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


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


OSIsoft licences at Rompetrol


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


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


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


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


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


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


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


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


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


From EXCEL to HTML

Management Report

EXCELPI DATA LINK

HTML

❖AGGREGATED OVERVIEW

❖BETTER INFORMED

❖CORRECT DECISION

../../../Rompetrol Documents and Settings/Groups/Refinery/Control Procese/CP-Shared/RapHTML/Rap_SPV/Rap_SPV.htm


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




Rompetrol Refinery – PI Process Book

EASY TO NAVIGATEBETWEEN

THE DISPLAYS


Crude unit

REAL TIME VIEW

BEST MONITORING


Crude oil – tanks

REAL TIME DATA CRUDE UNIT FEEDSTOCK


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


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


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


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


Sigmafine – Mass Balance - Analysis

DAILY BASES ANALYSIS

24H, WEEKENDS


Sigmafine – Mass Balance- Graphic

Model


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


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


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


WE ARE LOOKING FORWARD TO

ANSWER ALL YOUR

QUESTIONS

Regional Seminar Series - cdn.osisoft.com · Regional Seminar Series Ana-Maria Ciuculan PI System...

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