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1 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
The Pursuit of Reliable Data
OSIsoft Asia Technology Conference 2007
The Pursuit of Reliable Data
OSIsoft Asia Technology Conference 2007
M Faisal ZainalAdvanced Process Control (APC) EngineerPETRONAS Penapisan (Melaka) Sdn Bhd.
Prakash KumarPrincipal Engineer, Advanced Process Control (APC)
PETRONAS Penapisan (Melaka) Sdn. Bhd.
2 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
AGENDAAGENDA
• Introduction• Our Aspiration• Data Utilization• Issues and Challenges• PP(M)SB Way of Data Management• Benefits• Conclusion
3 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
INTRODUCTIONINTRODUCTION
• PETRONAS Penapisan (Melaka) Sdn Bhd is a subsidiary of PETRONAS.
• Consist of 2 refineries:– PSR-1 (process 100MBD of sweet crude)– PSR-2 (process 135MBD of sour crude)
• Use Solomon Benchmarking to identify current ranking with peers:– PSR-1; 1st in the world (74 refineries)– PSR-2; 3rd in the world (74 refineries)
Refinery utilization
4 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
PRODUCTSBUFFERPROCESSING UNITS
TYPICAL PROCESS FLOWTYPICAL PROCESS FLOW
Vacuum Distillation
Unit
Treating Units
FEED
Atmospheric Distillation unit
Sour Crude
Gasoline
Diesel
Kerosene
Cracking Units
Asphalt
Coke
Reforming Units
LPG
Blending
Component
5 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
ASPIRATIONASPIRATION
0102030405060708090
100
Normal Operation ImprovedOperation
ProfitOperation Cost
YIELD
MAXIMIZEMAXIMIZEPROFITPROFIT
MINIMIZEMINIMIZEOPERATIONAL COSTOPERATIONAL COST
MAXIMIZEMAXIMIZEPRODUCT YIELDPRODUCT YIELD
PROFIT = PRODUCT YIELD – OPERATIONAL COST
6 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
HOW TO ACHIEVE OUR GOAL??HOW TO ACHIEVE OUR GOAL??
RELIABLEDATA
RELIABLEDATA
CLOSE MONITORING
MASS BALANCE
ENERGY & LOSS
TESTRUN RESULS
DAILY AUTOMATED
REPORT
ADVANCED CONTROL MODELING
TO SWEAT PROCESS UNIT
7 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
HOW DATA IS USED?HOW DATA IS USED?
OPERATION PLANNING-Monitor crude availability-Mass balance
FEED TECHNOLOGY-Daily monitoring-Monthly reporting-Troubleshooting
OPERATION-Daily report-View current process condition-To ensure process stability-Troubleshooting
SIX SIGMA-Optimization project
PROJECT-View historical data for future expansion
PROCESS UNIT TECHNOLOGY-Daily monitoring
OPERATION-Daily monitoring-To monitor product specification
SCHEDULER-Monitor blending components’ availability
PRODUCT
8 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
Tool for SUCCESSTool for SUCCESS
• Data availability at desktop• Timeliness• Easy access – anytime,
anywhere• High data processing speed
9 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
WHAT WE HAD YESTERDAYWHAT WE HAD YESTERDAY
Control System (Refinery-2) Control System(Refinery-1)
PI Server
Oil Accounting
Lab results
ORACLE
FIREWALL
USERS
Business Network
OPC OPC OPC
Process Control Network
Interface
10 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
ISSUES & CHALLENGESISSUES & CHALLENGES
• High Utilisation– Greater appreciation of
historical data– More users
• High Server Loading– More complex computations– More frequent computations
• CAPEX Project support– The need for remote access
11 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
PP(M)SB WAY OF DATA MANAGEMENTPP(M)SB WAY OF DATA MANAGEMENT
Redundant system to overcome high downtime
Hi-spec server to overcome high server loading
Distributed Data Management System (DDMS) to handle complex computations
RtWebPart in enabling remote access
Control System (Refinery-2) Control System(Refinery-1)
PI Calc-Server
Oil Accounting
Lab results
ORACLEPI Primary Server PI Secondary Server
N-Way Buffering N-Way Buffering
FIREWALL
RtWebPart
N-Way Buffering
USERS
OPC OPC OPC
REMOTE USERS
12 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
BENEFITSBENEFITS
High Availability Data
Better server performance and reliability
Distributed data management
system
Redundant system
Minimal downtime and low loading
Easy access of reliable data
Master the process unit through recorded past event-driven data
OptimizationInitiative
(by Six Sigma, Technologist)
Value creation
Increment Increment on system on system capabilitycapability
Increment Increment on process on process
capabilitycapability
13 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
TYPICAL VALUE OF BenefitsTYPICAL VALUE OF Benefits
DataExtraction
DataDataExtractionExtraction
AnalysisModellingAnalysisAnalysisModellingModelling
ImplementAPC
ImplementImplementAPCAPC
Advanced ControlAdvanced ControlImplementationImplementation
CycleCycle
Example (Reforming Unit)RM3.5mil/yr value creation
18 MB18 MBOf DataOf Data
14 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
ConclusionConclusion
• Data drives value creation.
• The key requirement for a data historian system is continuous data availability.
15 OSISoft Asia Technology Conference 2007M Faisal Zainal, PETRONAS Penapisan (Melaka) Sdn Bhd
THANK YOUTHANK YOU