EV Intelligent DVR Solutions Refining

5th AnnualGlobalRefiningSummit2011 May18 20,2011 Rotterdam,Netherlands
IntelligentDataValidationand ReconciliationSolutionsforthe RefiningIndustry f d

MihaelaCristinaPopescu,HeadofPerformance Mihaela Cristina Popescu, Head of Performance Control,ArpechimRefinery,OMVPetrom Dr.RobertoLinares,VicePresident,VisiantPimsoft
Topics
BusinessPerformanceAspectsinRefining Refining Case RefiningCase ProductionAccountingandDataReconciliation (PADR)Requirements (PADR) Requirements PowerfulDataReconciliationConcepts Customer Benefits Using Sigmafine CustomerBenefitsUsingSigmafine YieldAccountingManagementPresentedby OMVPetrom OMV Petrom Conclusion
GlobalRefiningSummit Rotterdam,May18,2011 VisiantPimsoftInc.2011 Allrightsreserved.
BusinessPerformanceAspectsinRefining
Operational
o o o
Yield,Recovery,QualityTargets , y, Q y g ProductionRates ProcessConstraints(e.g.,environmental,physicallimitations) BestOperationalParameters(e.g.,LPs) ComparisonofPlannedvs.Actual MaterialLoss CostAllocation Cost Allocation InventoryPositions Taxes(e.g.,domesticvs.foreign)
GlobalRefiningSummit Rotterdam,May18,2011 3 VisiantPimsoftInc.2011 Allrightsreserved.
Planning
o o
Financials
o o o o
MarketDrivers
Environmental(GHG) Financial (Sarbanes Oxley Act) Financial(SarbanesOxleyAct) YieldAccountingStandards
o
APIStandard API Standard
RefiningMargins Security Theidealplatformfordatavalidationhastocomplywith emergingregulationsintherefiningindustry.
GlobalRefiningSummit Rotterdam,May18,2011
VisiantPimsoftInc.2011 Allrightsreserved.
RefiningCase
SourceofInformation
o o o o
ProcessHistorian Process Historian OilMovementSystem(OMS) VesselPositioningSystem(VPS) Vessel Positioning System (VPS) LIMS VCFaccordingtoAPI2004 OwnershipTracking ForeignandDomesticTracking MassBalance
GlobalRefiningSummit Rotterdam,May18,2011 5 VisiantPimsoftInc.2011 Allrightsreserved.
BusinessRules
o o o o
RefiningCase
Integration
o o
AutomaticDataCollection Automatic Data Collection IntegrationofOMSandVPSdataintoProduction AccountingSystem ExcelbasedforProductionAccountants Formaland/orWebbasedforRefineryUsers AutomaticReportingforMeasuredInformation
Reporting
o o o
SolutionMap
DataFlowforRefiningCase
Historian Sigmafine OMS
Aggregation/ Integration
Excel Reports
Vessel Positioning System
Rules
SQL Access
Report Logic
Webbased Reports
ProductionAccountingSolutionIntegration
TheBridgeBetweenBusinessandProcessData The Bridge Between Business and Process Data
Process Data
Lab Data
Movements Records
Planning Data
Scheduling Information
Global Refining Summit Rotterdam, May 18, 2011
MaximizingthePowerofYourMeasurements Maximizing the Power of Your Measurements

Sigmafineperformsflowssolvabilityanalysis. R Theflowisredundant,soitisbothmeasuredandsolvable. NR The flow is measured but not redundant so the measurement must be trusted Theflowismeasuredbutnotredundant,so themeasurementmustbetrusted. S Theflowisnotmeasured,butitisstillsolvable. NS The flowisnotsolvable.
SolvabilityandRedundancy
R NR
S NR
R
Themoreredundancy The more redundancy thebetter.Thisway, morevaluesmaybe crosscheckedto increaseaccuracy. increase accuracy
S S NR
GlobalRefiningSummit Rotterdam,May18,2011 9
R
MaximizingthePowerofYourMeasurements Maximizing the Power of Your Measurements

Sigmafineperformsflowssolvabilityanalysis. R Theflowisredundant,soitisbothmeasuredandsolvable. NR The flow is measured but not redundant so the measurement must be trusted Theflowismeasuredbutnotredundant,so themeasurementmustbetrusted. S Theflowisnotmeasured,butitisstillsolvable. NS The flowisnotsolvable.
SolvabilityandRedundancy
R R
S NR
R
*Byaddingameter totheflow,theflow becomesredundant. Asaresult,other meteredflowsalso becomeredundant.
*R
S S
R
GlobalRefiningSummit Rotterdam,May18,2011 10
R
FindingtheBestFitforYourModelandData Finding the Best Fit for Your Model and Data
54.2
Reconciliation
98.4 98 4
98.4 98 4
44.2
11
OptimalUtilizationofExistingMeters
Non Redundant Network

Accurate Meter
Redundant Network
Accurate Meter
Less Accurate Meter
12
ErrorDetection
WhichNetworkCanDetectaMeasurementError? Which Network Can Detect a Measurement Error?
Accurate meter failure
Non Redundant Network. There is no possibility of detection
Redundant Network. An imbalance can be detected
13
MeterPerformance
ErrorIdentification Error Identification
Pure Gas E 1750 1600 1400 1200 1000 800 600 400 200 0 02-Sep-01 00:00:00 SLO East 250 C0F1230.AD 1649.4 C0F1230.SF Not Reconciled B2F1003.AD 400.5 400 5 B2F1003.SF Not Reconciled B2F2003.AD 402.47 B2F2003.SF Not Reconciled F0F1013B.AD 19.939 F0F1013B.SF Not Reconciled Pure Gas W 1750 1600 1400 1200 1000 800 600 400 200 0 11-Nov-01 00:00:00 C0F1109M.AD 89.787 ton/h C0F1109M.SF Not Reconciled ton/h C0F1116M.AD 76.712 ton/h C0F1116M.SF Not Reconciled ton/h C9F1004.AD 181.66 m3/h 3/h C9F1004.SF Not Reconciled m3/h SLO West 250 20F0101.AD 1571.4 20F0101.SF Not Reconciled 12F1003.AD 422.08 422 08 12F1003.SF Not Reconciled 12F2003.AD 428.68 12F2003.SF Not Reconciled F0F1013A.AD 0. F0F1013A.SF Not Reconciled
Bias
Drift
30.59 Day(s) 11-Dec-01 14:02:56 20F1109.AD 99.745 m3n/h 20F1109.SF Not Reconciled m3/h 20F1116.AD 89.789 m3/h 20F1116.SF Not Reconciled m3/h 29F1004.AD 192.7 m3/h 3/h 29F1004.SF Not Reconciled m3/h
100.59 Day(s)
11-Dec-01 14:02:54
200
200
150
150
100
100
50
50
0 02-Sep-01 00:00:00
100.59 Day(s)
Meter Error
11-Dec-01 14:03:04
0 02-Sep-01 00:00:00
100.59 Day(s)
11-Dec-01 14:03:05
14
OptimumMaintenanceofRefineryMeters
TakingActiontoImproveMeterPerformance Taking Action to Improve Meter Performance
15
ImprovingtheOverallPicture
HigherConfidenceinRefineryData Higher Confidence in Refinery Data
30% 25% 20% 15% 10% 5% 0%
Overall DX1 Trend ( Q4 2008 - Q1 2010)
16
OilLossMonitoring
BeforeandAfterSigmafine Before and After Sigmafine
Error Elimination Meter Improvements
Better Decisions
17
OilLossMonitoring
Loss Accountability Loss Accountability 5 4 3 2 1 0 -1 -2 -3 Sigmafine available
(%)
ja n04 m ar -0 4 m ai -0 4 ju l-0 4 se p04 no v04 ja n05 m ar -0 5 m ai -0 5 ju l-0 5 se p05 no v05 ja n06 m ar -0 6 m ai -0 6 ju l-0 6 se p06 no v06 ja n07 m ar -0 7 m ai -0 7
18
OilLossMonitoring
Feb/01 - Jan/02 (Loss % Cumulative = 1.09%)
10.0% 8.0% 6.0% 4.0% 2.0% 2 0% 0.0% -2.0% -4.0% -6.0% Loss % 3 Month Rolling Loss % Cumulative
Benchmark
Mass Balance Before Sigmafine
Oil loss (%) After Sigmafine Implementation

Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
SF Losses
1.08 1.20 1.00 0.80 0.60 0.40 0.20 0.00 Jun/02 Jul/02 Aug/02 Sep/02 Oct/02 Nov/02 %
0.48 0.23 0.30 0.12
0.53
SF monthly
SF cumulative
19
ASignificantBiasCausesFinancialLoss A Significant Bias Causes Financial Loss
CustodyTransferErrorDetection
20
AccountingFuelConsumption
5,000 4,500 4,000 3,500 3,000 , 2,500 2,000 1,500 1,000 500 14Oct 15Oct 16Oct 17Oct 18Oct 19Oct 20Oct 21Oct 22Oct 23Oct
OptimizationofEnergyUseRequiresInformation Optimization of Energy Use Requires Information

FuelConsumption,Oct2010 Sigmafine
Legacy System
24Oct 25Oct 26Oct 27Oct 28Oct 10Oct 11Oct 29Oct 1Oct 2Oct 3Oct 4Oct 5Oct 6Oct 7Oct 8Oct 9Oct 12Oct 13Oct
21
MonitoringRefineryPerformance
ValidationofKPIs Validation of KPIs
Current/Shift/Running Plan Reconciled vs. Theoretical Yields Running Plan KPIs
22
PerformanceMonitoring
ValidatingYieldData Validating Yield Data
Reconciled Yields
Theoretical Yields
23
IncreasingYieldProfitability
PerformanceManagementImprovement Performance Management Improvement
Exampleofdieselyieldimprovements
o
Analyzinghomogeneousdatarelatedto sweet crudes: Analyzing homogeneous data related to sweetcrudes: 2003actualaveragedieselyield 37,4% 2004actualaveragedieselyield 39,6% Averageactualdieselyieldincreasedduebothtoinvestmentson ld l ld dd b h plantsandtoperformancemanagement. Historicalanalysisondieselyieldshowedthattheaverageincrease duetoperformancemanagementamountwasabout0.8%inthe d f b h period20032004. ThisledtoaprofitincreaseestimatedinUS$1 millionperyear.
24
LowYieldDetectionAfterCatalystImprovement
UnmaskingHiddenProblems Unmasking Hidden Problems
Data Quality Improvement: Profits

Mass balance yield - FCC (Fluidized Catalitic Cracking Unit)
110
105
*Data reconciliation group identified LCO flow meter fault *During this p g period it was believed that LCO yield had increased.
M Mass balance yield (%)
100
95
Flow meters maintenance required by reconciliation group Unit shut down Different catalyst loaded
90
85
**LCO flow meter repaired Actual **Actual LCO yield equal to the value previously to the catalyst change
**Lower light HC and more decanted Lower oil produced = Less profits
17-02-2005 09-03-2005 29-03-2005 18-04-2005 08-05-2005 28-05-2005 17-06-2005 07-07-2005 27-07-2005
80
28-01-2005
Date
Global Refining Summit Rotterdam, May 18, 2011 25 VisiantPimsoftInc.2011 Allrightsreserved.
LowYieldDetectionAfterCatalystImprovement
UnmaskingHiddenProblems Unmasking Hidden Problems
Eliminated loss corresponding to US$ 23.5 million per y $ p year

M a s s b a la n c e y ie ld - F C C (F lu id iz e d C a ta litic C r a c k in g U n it)
110 105
Mass balance yield (%)
*Data reconciliation group identified LCO flow meter fault *During this period it was believed that During LCO yield had increased.
100
95
Flow meters maintenance required by reconciliation group Unit shut down Different catalyst loaded
90
85
80
2 8 -0 1 -2 0 0 5 1 7 -0 2 -2 0 0 5 0 9 -0 3 -2 0 0 5 2 9 -0 3 -2 0 0 5 1 8 -0 4 -2 0 0 5 0 8 -0 5 -2 0 0 5
**LCO flow meter repaired **Actual LCO yield equal to the value previously to the catalyst change **Lower light HC and more decanted oil produced = Less profits
2 8 -0 5 -2 0 0 5 1 7 -0 6 -2 0 0 5 0 7 -0 7 -2 0 0 5 2 7 -0 7 -2 0 0 5
D a te
26
ReconciliationCoupledwithOptimization
ValidatingBlendingOptimization Validating Blending Optimization

Cost Integration C tI t ti with Reconciled Data Optimizer Result
62,77 US$/m3
63,84 US$/m3
1,00 US$/m3
difference
Measurement Problem Hydrotreated Diesel Flow
x 15 000 m3 15.000 15.000,00 US$/batch x 40 batches/month 600.000,00 US$/month x 12 month/year 7.200.000,00 US$/year
27
DetectingOperationalErrors
FindingUndetectedProblems Finding Undetected Problems

Volum etric entrainmof the aromatic removalaromtotal amount byunit, total V l Financial t i t i tl f th ti l it t losses ent losses from the unit, atic rem oval month t l am ounts by m Jun-2006 to Jun-2006 to m ay-2007. from onth from may-2007. 1000 160000 900 140000 800 120000 700 100000 600 500 80000 400 60000 300 40000 200 20000 100 0 0
13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 07-02-2007 08-04-2007 08-04-2007 07-06-2007 07-06-2007
Solvent entrain nment, m3 Loss, US S$
Data reconciliation group detected rubber solvent entrainment from solvent unit to gasoline unit.
Date Date
28 VisiantPimsoftInc.2011 Allrightsreserved.

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 07-02-2007 08-04-2007 08-04-2007 07-06-2007 07-06-2007
Potential profit depends on the difference between rubber solvent and gasoline prices
Date Date

13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 13-04-2006 12-06-2006 11-08-2006 10-10-2006 09-12-2006 07-02-2007 07-02-2007 08-04-2007 08-04-2007 07-06-2007 07-06-2007
Total solvent entrainment: 14 % of feed Total annual losses: US$ 0.7 million
Date Date
LossofCapacityVersusNominalCapacity
BiasDetectionofaMeter Bias Detection of a Meter
Loss of processing capacity US$ 25.7M/year 25 7M/year

Carga U283A
5800 5600
Carga Proce essada (m3)
5400 5200 5000 4800 4600 4400
01-09-07
15-09-07
29-09-07
13-10-07
27-10-07
10-11-07
24-11-07
08-12-07
22-12-07
05-01-08
19-01-08
02-02-08
16-02-08
01-03-08
15-03-08
29-03-08
12-04-08
26-04-08
10-05-08
24-05-08
07-06-08
21-06-08
05-07-08
19-07-08
02-08-08
16-08-08
30-08-08
13-09-08
Carga medida C did
Carga R C Reconciliada ili d
31
27-09-08
CustomerPresentation
YieldAccountingManagement by byMihaelaCristinaPopescu ae a s a opescu OMVPETROM
32
Conclusions
SatisfyingGlobalRefineryNeedsintheFieldofPADR Satisfying Global Refinery Needs in the Field of PADR

Territories
Sigmafinebased solutions Sigmafine basedsolutions deliversignificantbenefitsto refiningcustomersworldwide. Solutionshavetobeadaptive, keepingthecustomer requirementsinmind. requirements in mind Sigmafinetechnologiesare designedtosatisfycurrentand designed to satisfy current and futurebusinessrequirements.
NorthAmerica Europe&Russia Asia&Pacific LatinAmerica MiddleEast&Africa

6% 17% 28%
21% 28%
33
Thankyou! Thank you!

MihaelaChristinaPopescu,Mihaela_Cristina.Popescu@petrom.com Dr.RobertoLinares,roberto.linares@visiant.com Dr Roberto Linares roberto linares@visiant com
34

EV Intelligent DVR Solutions Refining

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5th AnnualGlobalRefiningSummit2011 May18 20,2011 Rotterdam,Netherlands

IntelligentDataValidationand ReconciliationSolutionsforthe RefiningIndustry f d

APIStandard API Standard

RefiningMargins Security Theidealplatformfordatavalidationhastocomplywith emergingregulationsintherefiningindustry.

AutomaticDataCollection Automatic Data Collection IntegrationofOMSandVPSdataintoProduction AccountingSystem ExcelbasedforProductionAccountants Formaland/orWebbasedforRefineryUsers AutomaticReportingforMeasuredInformation

Vessel Positioning System

Global Refining Summit Rotterdam, May 18, 2011

MaximizingthePowerofYourMeasurements Maximizing the Power of Your Measurements

MaximizingthePowerofYourMeasurements Maximizing the Power of Your Measurements

Non Redundant Network

Less Accurate Meter

WhichNetworkCanDetectaMeasurementError? Which Network Can Detect a Measurement Error?

Accurate meter failure

Non Redundant Network. There is no possibility of detection

Redundant Network. An imbalance can be detected

Overall DX1 Trend ( Q4 2008 - Q1 2010)

Mass Balance Before Sigmafine

Oil loss (%) After Sigmafine Implementation

0.48 0.23 0.30 0.12

ASignificantBiasCausesFinancialLoss A Significant Bias Causes Financial Loss

Global Refining Summit Rotterdam, May 18, 2011

OptimizationofEnergyUseRequiresInformation Optimization of Energy Use Requires Information

Global Refining Summit Rotterdam, May 18, 2011

Global Refining Summit Rotterdam, May 18, 2011

Global Refining Summit Rotterdam, May 18, 2011

Global Refining Summit Rotterdam, May 18, 2011

Data Quality Improvement: Profits

M Mass balance yield (%)

Data Quality Improvement: Profits

Eliminated loss corresponding to US$ 23.5 million per y $ p year

Mass balance yield (%)

Global Refining Summit Rotterdam, May 18, 2011

Data Quality Improvement: Profits

Measurement Problem Hydrotreated Diesel Flow

Global Refining Summit Rotterdam, May 18, 2011

Data Quality Improvement: Profits

Solvent entrain nment, m3 Loss, US S$

Data Quality Improvement: Profits

Solvent entrain nment, m3 Loss, US S$

Data Quality Improvement: Profits

Solvent entrain nment, m3 Loss, US S$

Loss of processing capacity US$ 25.7M/year 25 7M/year

Carga Proce essada (m3)

5400 5200 5000 4800 4600 4400

Carga medida C did

Carga R C Reconciliada ili d

Global Refining Summit Rotterdam, May 18, 2011

Global Refining Summit Rotterdam, May 18, 2011

SatisfyingGlobalRefineryNeedsintheFieldofPADR Satisfying Global Refinery Needs in the Field of PADR

NorthAmerica Europe&Russia Asia&Pacific LatinAmerica MiddleEast&Africa

Global Refining Summit Rotterdam, May 18, 2011

Thankyou! Thank you!

Global Refining Summit Rotterdam, May 18, 2011

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