the journey into integrated refinery information system

© 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

http://inamos/

http://inamos/


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

http://s1256.photobucket.com/user/Emil_Emili/media/Stara Ri/Rafinacijaiotpremabenzinapredrat_zps34474abb.jpg.html



About MOL Group

Oil and Gas Company

3


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



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



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



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:


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


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

9

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



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


PI System integration architecture

11



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


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


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


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


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


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


RESULTS AND BENEFITS BUSINESS CHALLENGES SOLUTION

Summary

18

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


Contact Information

19

Sergej Horvat

[email protected]

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

mailto:[email protected]

mailto:[email protected]

© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015 20

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the journey into integrated refinery information system

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