Slide 1
SSE-03
Integrated Yield Accounting and
Off-sites Solution
John Hernandez
Invensys Operations
Management
October 15-16, 2012
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
Agenda
• Yield Accounting Domain
• Purpose and Benefits
• Leveraging Integration
• Partnership
• Highlights and case studies
• Conclusion
Slide 3
Where Yield/Production Accounting Lives
Target Area for
Production Accounting
Synchronization
Business
Performance Management
Plan vs. Actual
Goals
Results
Production
Performance Management
Monthly Production
Accounting
Backcasting
Reconciled
Performance
VALUE
Schedule
Sched vs. Actual
Hourly Balance
Operations Monitoring
Operations
days ago
Reviews, Reports
hours ago
Limits & Boundaries
Operations
Management
Process Control &
Optimization
weeks ago
Goals and Targets
Performance Management
Daily Accounting
Logistics
Quarterly/Monthly
Plan
Plan vs. Actual
Reconciled Performance
Slide 4
Business/Yearly
Plan
Business Results
now
Execution
Integration
hours ahead
days ahead
months ahead
Decisions
Why Yield Accounting?
• Objectives
– Provide an improved material, yield and unit cost management system that
complies with best practices of data reconciliation and production accounting
methods
• Issues
– Leading refining and petrochemical companies in the world require
constantly tighter control over unaccounted material losses
– Data gathering and ensuring the quality of data is a time consuming process
leaving very little time for analysis
– Multiple versions of data exist across organizations without a consistent set
of figures
– Comingled ownership of processed materials
– Yields & Loss reporting for environmental (HSE) impact as well JV financial
transaction
Slide 5
Key Questions
• How much time do we spend on closing the balance each day and is
it manual-entry intensive?
• Is our yield accounting solution integrated to our tank inventory and
movement monitoring system(s)?
• How quickly can we produce month-to-date and month-end balance
reports?
• Why doesn’t our yield accounting package allow for quick analysis
and drill-down to find the problem?
• Does our package allow a view into the historical data without having
to go to another application?
• Is it easy for us to account for different ownership of materials across
the process? (Comingled ownership)
Slide 6
Value Proposition for Integrated Yield
Accounting
• Scope
– Unit by Unit Hourly/Shift Mass and Utility Balance Reconciliation
– Refinery wide Daily Mass and Utility Balance Reconciliation
– Refinery wide Monthly Mass and Utility Balance Reconciliation & Accounting
• Benefits
– Loss Control and reduction:
• Current unaccounted losses at a typical Refinery = 1.5%
• As a result of Data reconciliation, assume that 0.5% is properly accounted
• Price Differential between loss and product mix = $20 per barrel
– Potential Benefits = 250,000 x 330 x 0.005 x 20 = $8.5 MM per year
Potential Benefits at a Typical Refinery - $8.5 MM per year
Slide 7
Yield Accounting- Benefits
- Profitability
- Early detection of Meter gross error
- More consistent and accurate flow data in PI, for use in
monitoring spreadsheets, LP yields etc.
- Reliability
- Generates values for unmeasured flows or meters that are
out of service or unreliable
- Lets the organization know which meters are reliable
- Productivity
- Ensures that instrument staff only work on meters that are
broken
- Eliminates the need for PE to do steady state mass balances
Slide 8
Yield Accounting Integration with
Off-sites
Process Unit DVR
Offsites Inventory and Movement Management
Slide 9
Yield Accounting Integration with
Off-sites
Integration
Slide 10
Yield Accounting Integration with
Off-sites
Plant wide Reconciliation
Slide 11
Invensys’ Partnership for Yield Accounting
Key Criteria for Partnership
– Technical capability
– Usability and Flexibility
– Seamless Integration to Tank and Inventory data
– Field proven
MESEnter
ErrorSolver
Slide 12
ErrorSolver Flowsheet Environment
Slide 13
Quick Visibility to Key Information
Hover for Process and Stream Details
Slide 14
MESEnter’s ErrorSolver Highlights
• Easy Graphical User Interface and Navigation
• Integration capability with PI, Infoplus, and others based on industry
standard protocols
• Established in several large customer sites for several years
• Has replaced Sigmafine and Production Balance in some sites
• Competitively priced
• Low/No maintenance
Slide 15
Upgrade Case Study
Yeochun NCC
Mr. D. K. Kim,
Deputy General
Manager of
Yeochun NCC
says:
ErrorSolver
offered us
functionality that
was simply not
present in our
original
software,
Sigmafine
-- including the ability to create logical summary models and additional,
user-definable constraints. ErrorSolver composition tracking
functionality also provides valuable feedstock movement detection and
quality tracking. The switch to ErrorSolver improved our work
efficiency, data validation, and execution speed, so that overall, our
material balance work time was shortened by half. On a normal day, we
spend less than an hour balancing the plant, and we can trust the
values we get back from ErrorSolver.
Slide 16
Upgrade Case Study
LG Chemicals
Mr. S. K. Jang
of LG
Chemicals,
Korea, says:
We had tried other material balance solution(Honeywell PB) and
were frustrated by how poorly they worked and how much effort
they required to create and maintain. We were surprised and
pleased to find out that there was another way. ErrorSolver saves us
hours each day and gives us results we could not have obtained
using other solutions.
Slide 17
Upgrade Case Study
Honam Petrochemical
DR Implementation History
-.2003 Q3 : DR (Data Reconciliation) started
▶ ‘Sigmafine’(OSIsoft) purchased
-.2004 Q1 : DR system initiated
▶ ERP & PIS Go-Live ~
-.2005 Q3 (June to Aug) : DR system upgrade initiated
▶ Replaced with ErrorSolver (see next slide for advantages gained)
-.2005 Q4 : New DR system (ErrorSolver) initiated
▶Standardized as daily ERP production balance tool
Slide 18
Upgrade Case Study
Advantages Realized
Slide 19
Honam Petrochemical
ErrorSolver Installations
List of ErrorSolver customer implementations and upgrades from other products:
 SK Energy Refinery (former Yukong, Ulsan plant) – Korea, 1998
AspenTech Advisor to ErrorSolver
 SKC (former SK OXY Chemicals, Petrochemical, SM plant) – Korea, 2000
 KOGAS (LNG Plant) – Korea, 2000
 Honam Petrochemical(Yeosu plant, Ethylene plant)– Korea, 2003
Sigmafine to ErrorSolver
 Samsung Total Petrochemical (Ethylene plant & Aromatic plant) – Korea, 2004
 Qingdao Petrochemical (Refinery) – China, 2005
 Yeochun NCC Petrochemical(Ethylene plant) - Korea, 2005
 SK Energy Refinery(Incheon plant) - Korea, 2005
Sigmafine to ErrorSolver
Sigmafine to ErrorSolver
 LG Chemicals (Daesan plant, Ethylene plant) - Korea, 2005
 Honam Petrochemical(Daesan plant, Ethylene plant) – Korea, 2006
 LG Petrochemical (Yeosu plant, Ethylene plant) – Korea, 2006
Honeywell PB to ErrorSolver
 KP Petrochemical (PX & TPA plant) – Korea, 2007
 Samnam Petrochemical (TPA plant) – Korea, 2009
Sigmafine to ErrorSolver
 Daehan Petrochemical (Ethylene plant) – Korea, 2010
 Titan Petrochemcial (Ethylene plant) - Malaysia, 2012
There are no longer any other active product users left in Korea
Slide 20
Off-sites TIS
Tank Inventory System
• Uniform approach to managing gauging
systems (Varec, Saab, L&J, Enraf, …)
• Strapping table database
• ASTM/API table volume & density
corrections
• Extended calculations (e.g. DIN51757)
• Flow-rate calculations from level changes
• Level & tank operational states & alarms
• Standard tank detail, pool &
midnight inventory reports
TIS provides the basic data of the
actual state for all other Offsites
Modules
 TIS bridges the tank gauging with the
MES/ERP layer
Slide 21
Off-sites OMM
Order Movement Management System
• Management, real-time monitoring & reporting
for all orders/movements.
• Handles all standard movement types (tank,
unit, & transport source/ destinations),
blending operations, and other complex orders
• Can handle co-mingling (multiple ownership)
• Validates input data and overall movement
data based on all available meters & gauges
• Optional Product composition tracking (PCT)
and quality integration (TQI) modules
• OMM interfaces with scheduling and stock/yield
accounting systems
OMM bridges the gap between movements
scheduling, operations and oil accounting
OMM monitors active movements, manages
scheduled activities and archives past
actions
Slide 22
Off-sites Differentiating Value
•TIS/OMM/MAS streamlines
inventory & movement
management
•$MMs potential from better
inventory accounting, stock
loss programs, plan vs. actual
analysis, and tank farm asset
utilization
•Provides accurate & reliable
data to ErrorSolver
Slide 23
Shell Netherlands Arena Project (Off-sites)
“Arena has provided us with a more stable system with reliable data,
both instantaneous and historical. This information we can use
entirely as we need and want. As a result we not only have available
to us all up-to-date information really needed by us, but also
information that was not available to us in the pre-Arena times.
Although it did not change our work, it allows us to work more
efficiently as a result of the improved tools and information
available to us.”
Ria Keizer
Crude Oil Accountant
Slide 24
Off-sites Installations
100 Sites
Operational or
In Progress:
TIS
OMM
DBS
BOSS
MAS
AMADAS
BTM
Slide 25
© Invensys
102
61
87
84
32
5
7
Why Invensys’ Integrated Yield Accounting
Solution?
Slide 26
•
The Off-sites integration greatly reduces manual entry or manual
transference of data from one system to another
•
Graphical process modeling environment – better navigation
•
Logical modeling capability – interactive reporting mechanisms
•
Automatic missing movement detection from tank information
•
Composition tracking function
•
User defined balance constraints
•
Reconciliation for multiple periods individually
Differentiators
• Direct integration to tank inventory and
movements packages
• Logical models as well as process
Potential Benefits at a
$8.5 MM per year or
more
balance models
• Versatile equation builder: calculate inferred transactions and support
logical models
• Tracking Simulation function calculates composition and component
quality for critical areas of the model
• Automatic detection of missing movements from tank inventory
information
• Proven track record with many installations for both the yield
accounting and the Off-sites components.
Slide 27
Thank You
Slide 28