refinery performance monitoring, evolved.€¦ · performance monitoring & reporting center...

REFINERY PERFORMANCE MONITORING,

EVOLVED.

P E RF OR MA NCE MO N IT O R IN G & RE P ORT IN G CE NT E R P r o p r i e t a r y a n d C o n f i d e n t i a l 2 of 27

This document was prepared by ZeoNet Inc.(ZeoNet), a company incorporated in the State of

Texas, which performs Management Consulting services. It is protected under the copyright

laws of the United States and other countries as an unpublished work. This report contains

information that is proprietary and confidential to ZeoNet which shall not be disclosed outside

the recipient's company or duplicated, used or disclosed in whole or in part without the express

written permission of ZeoNet.


Table of Contents

1.0 Introducing PMRC by ZeoNet ............................................................................................. 4

1.1 PMRC Concepts ......................................................................................................... 4

1.1.1 Dashboards and Hierarchies Connected to Underlying Data .......................... 5

1.1.2 Easily Able to Summarize Data Across Multiple Facilities ............................... 6

1.1.3 Summary Data Available for Any Day or Period.............................................. 6

1.1.4 Collaborate to Address Lost Profit Opportunities in Real Time ........................ 7

1.1.5 Combining Yields with Economics to Drive Behavior ...................................... 9

1.1.6 Statistically Driven Yield Accounting ..............................................................11

1.1.7 Backcasting Application .................................................................................14

1.1.8 Automated Month End Reporting ...................................................................17

1.1.9 Standardize Knowledge by Creating Monitoring Plans...................................19

1.1.10 Many More Customizable Features Tailored for Each Client .........................25

1.2 Minimum Technical Requirements .............................................................................26

2.0 About ZeoNet .....................................................................................................................27

2.1 Background ...............................................................................................................27

2.2 The Story Behind the Name .......................................................................................27

2.3 Contact Information ...................................................................................................27


1.0 Introducing PMRC by ZeoNet

PMRC (Performance Management and Reporting Center) is an innovative refinery and

petrochemical performance management system designed by Zeonet. A key element of this

solution is that it focuses on proactive performance monitoring through standard activities

grouped in monitoring plans that can be set up by the clients to meet their needs. It connects

performance information, such as yields, to targets and plans and allows the capturing of

deviations as they occur while posting action items to remediate any identified issues. In order

to achieve this, PMRC integrates the core data systems in a refinery or petrochemical plant to

produce a comprehensive view of results. Core systems include but are not limited to: 1)

Reconciled Material Balances by Site 2) Linear Program Planning Model Results 3) Scheduling

Package Results 4) Plant Historian Process Data and 5) Pricing. Because of the integration of

actual performance and plans, it also delivers a linear program modeling validation capability

also known as Backcast. The flexibility to create monitoring plans produces a foundational

based KPI system that drives operations toward profitability in a collaborative workspace. It

stores knowledge from across an organization and allows personnel to focus on the activities

that truly matter for bottom line results by visualizing at a glance how operations are performing

against a plan or a schedule. The solution itself is scalable and is created using industry

standard web based products, so it can be easily deployed across an enterprise to any number

of users. It comes with standard functionality, but can easily be adapted to fit any existing set of

KPIs or work processes.

1.1 PMRC Concepts

The following document details an example from a typical refinery. All of the views that follow

are screenshots based on an operating version of PMRC where data has been altered to

represent generic information. The starting point is a dashboard view that gives a quick

reference to visualize how the refinery is operating in real time. The screen shots will then show

how the dashboard comes to life and allows collaboration. At the end, we will show the

underlining capability to create and edit monitoring plans.


1.1.1 Dashboards and Hierarchies Connected to Underlying Data

Everything is connected to the underlying data – for example, clicking on the radar chart above

displays the underlying capacity data used in its generation:

Notice that actual capacity performance by unit is displayed against the planning target and

visually flagged so that performance can be quickly evaluated. Additionally, PMRC hierarchies

allow further drill down into the underlying data. Clicking on any unit in the above list will bring

up the reconciled mass balance for that particular unit, allowing a multi-tiered view of the data

that makes up the overall capacity KPI.


All of the actual capacity performance is based on a daily reconciled mass balance, which is

one of the bedrock data sources used by PMRC to develop KPIs and monitor performance

against plan.

1.1.2 Easily Able to Summarize Data Across Multiple Facilities

PMRC integrates data across multiple systems and multiple sites, allowing for overview screens

to be created to summarize and evaluate key performance parameters across the entire

enterprise.

As with all PMRC displays, drilling down into the underlying data for either refinery or the totals

is possible by clicking on the relevant section of the display. This allows the user to quickly

locate the data that is used to generate any overview across the sites.

1.1.3 Summary Data Available for Any Day or Period


PMRC uses date ranges to allow each display to flexibly look at selectable time periods. Many

displays show both a daily and MTD view, as well. Data can be exported to excel for further

manipulation, but generally the PMRC approach is to perform calculations and display relevant

data within the system itself to minimize data manipulation by the users.

1.1.4 Collaborate to Address Lost Profit Opportunities in Real Time

The following heat map graph visually tracks unit performance, and allows corrective actions to

drive profitable performance to be shared and tracked.

In this case, there is a deviation in performance on the 7th day in unit CDU2, which upon mouse

over shows that there is an associated action item.

Action items can be created and assigned to either the daily unit performance or to a table of

Lost Profit Opportunities (LPO), which PMRC uses to track deviations from planned

performance. This LPO display can be accessed in multiple ways while performing regular

refinery processes such as daily target reviews.


LPOs can be entered as they occur over selectable date ranges to push performance towards

the economic optimum. The system allows action items to be tracked against the LPO entry to

drive behavior. The calculate function allows a selected to line to be estimated based on data

available across multiple systems. Rate calculations are straightforward, but dollar values can

be estimated to customer specifications by the system based on its knowledge of planned and

actual performance data. All estimated values can be finalized once more details are known if

this activity is a part of a client’s work process. Several levels of categorization exist to allow

longer term charting and tracking to drive profit improvement over time.


1.1.5 Combining Yields with Economics to Drive Behavior

PMRC has the ability to quickly combine data from multiple sources to create powerful

economic visualizations. It has all the data related to actual performance (daily material

balance), planned performance (LP results), and economic activity (pricing), which allows the

following types of displays to be created:

Here you can instantly see the planned and actual margin performance for an operating unit

(whole plant or process unit). Even more powerfully, projections can quickly be generated for

the future and updated with actual data each day as it becomes available. The vision for PMRC

is to integrate with predictive capabilities as they are developed by the client – either through

simple algorithms or sophisticated models. The simplest algorithm, for instance, could be that

the unit will operate tomorrow as it did yesterday.

On the other side of the scale, targets from an optimizer could update the monitoring plan and

related display. In addition, cause propagation could be applied in order to recommend

remediating actions that fit the gap best.


As with all PMRC displays, everything is connected to the underlying data and tabular views are

available to allow quick analysis.

Tabular views are visually flagged to allow at a glance identification of deviations from plan. In

this case you can see the economic performance against plan for detailed crude and product

composition.


1.1.6 Statistically Driven Yield Accounting

PMRC automates and standardizes reporting that currently takes most organizations a large

amount of time, if it is even done at all. This shifts the organizational focus from gathering data

to analyzing data.

Here you can see daily performance of both volume and mass recovery versus a target. This

view is generated automatically, but provides the basis for more detailed automatic analysis.

For example, below is a view of volume gains versus plan for each production unit. At one

glance, users can understand where the unit performance is lagging expectations, and how

accurate the planning models are on a volume basis. These graphs are generated by the

system for any period in a matter of seconds, and the user can focus on analysis instead of

collating data from multiple sources. Displays such as the one below, can be built easily by the

client to leverage all information present in the PMRC database


One of the main features of PMRC is to allow detailed performance data from the connected

systems to become available to everyone. Below, Inventories, Shipments, Receipts, and

Refinery Balance (Volume & Weight) are quickly made usable to planning and operations

personnel.

Another collaborative feature within PMRC is the ability to allow process engineers to log better

values for flow rates within the unit material balances, which can be fed back to accounting.

This provides a structure for an accountability based reconciliation daily, all while keeping a


record of how flows are generated and adjusted. Note that these adjustments are by exception

only, and are used as an additional layer of accountability for the existing material balance

system. Engineers are able to edit the fields in the white columns in order to reflect information

they are aware of in the field that is not known by others.


1.1.7 Backcasting Application

Typically, the monthly backcasting process is tedious and time consuming for organizations due

to the amount of manual data collection required. PMRC greatly simplifies these activities, and

allows the focus to be on identifying improvement opportunities. Below is a monthly

reconciliation view, available on the push of a button:

As PMRC stores LP model case results, it allows multiple cases to be viewed simultaneously

with a custom excel upload capability.

The backcast margin and fence line comparison allows process units and blending to be

displayed side by side, with buckets available to quantify the observed margin losses across the

cases.


Additionally, a solver has been created to automate the creation of a volume balanced input for

backcasting models from the mass balance results for each time-period. This greatly

accelerates the business process associated with creating a usable backcast, reducing the time

commitment within the organization to produce this type of analysis. The solver currently runs

in a separate automated excel spreadsheet using the What’s Best Add-On.

Solver Based Reconciliation

The solver calculated reconciliation produces the “One Version of the Truth” for yields and

movements. It imports all existing movements in the material balance system of the refinery,

complemented by PI data if needed, and uses a simple Linear Programming technique to

produce a solution that minimize errors. The matrix imported from PMRC contains all

movements as columns, and each product as a row. The difference between the fence line

balance (Inventory change + shipments – receipts) and the process units or blending

movements should be 0, and the system will pay a penalty to break that rule. As illustrated

below, not only does the solver succeed resolving the problem, but it also adds movements that

were missing.

See Marked areas in “Raw Data” and “Post Solver” figures:

• Balance column is zeroed out: Liquid volumes are reconciled

• Missing movements have been added to balance rows

• Units that were seriously out of balance – see VDU’s, which do not have a reasonable

volume recovery.

• Off spec and slop make is now known as well as the origin

• Conditional formatting shows where data is slightly out of a boundary (ex: those that are

above the Max Sustained data).

This indirectly resolves balance issues when the site does not have meters, has bad meters, or

has flows that are difficult to measure.


Raw

Data

Post

Solver

MaterialTypeMaterialSubTypeMaterial Balance Fence LineRefineryCDU1-1CDU2-1 VDU1-1 VDU2-1 VDU3-1

Max Sustained 91900 94374 12510 10604 34403

Target LVR 99.9 99.9 99.9 99.9 99.9

Target TVR 99.9 99.9 99.9 99.9 99.9

Liquid Charge 194732 97895 95208 10833 10409 16535

Balance (Liquids) -3791 1688 -430 1003 884 -2355

Vol Recovery % 99.13% 99.56% 100.00% 109.26% 108.49% 85.76%

Liquids+ gas, vol% 102.25% 99.56% 100.00% 109.26% 108.49% 85.76%

FeedstocksCrude DCD1-1 -1748 -82776 -84524 -48856 -35668

FeedstocksCrude DCD4-1 -200 -43977 -44177 -21936 -22241

FeedstocksCrude NCD4-1 148 -20153 -20005 -5990 -14015

FeedstocksCrude OFSP-1 752 -324 428 -1799 -2547

FeedstocksCrude AC11-1 817 -39008 -38191 -17454 -20737

FeedstocksIntermediates PUDL-1 -7116 -4586 -11702

FeedstocksIntermediates FCCF-1 -15893 -1005 -16898

FeedstocksIntermediates HVYN-1 -14480 47 -14433

FeedstocksIntermediates LSRG-1 -3099 349 -2750 29764 27054

FeedstocksPurchased Blendstock FeedsIBUT-1 1653 -3344 -1691

FeedstocksRecovered Oil SLOP-1 -2097 45 -2052 -1860 75 75 200

FeedstocksRecovered Oil TRAN-1

Products 1-Liquid Petroleum GasPROP-1 -121 4185 4064

Products 1-Liquid Petroleum GasWGAS-1 89 89 45 44

Products 1-Liquid Petroleum GasCNSO-1 734 734

Products 1-Liquid Petroleum GasALKF-1 -8369 -8369

Products 1-Liquid Petroleum GasC3PL-1 6879 6879

Products 2-Gasoline BlendstocksMHCH-1 644 241 885

Products 2-Gasoline BlendstocksCATG-1 20341 -1133 19208

Products 2-Gasoline BlendstocksLREF-1 -325 1734 1409

Products 2-Gasoline BlendstocksOLEF-1 8827 145 8972

Products 2-Gasoline BlendstocksLFCC-1 2412 -832 1580

Products 2-Gasoline BlendstocksNBUT-1 305 -2595 -2290

Products 2-Gasoline BlendstocksALKY-1 43 -616 -573

Products 2-Gasoline BlendstocksHREF-1 2170 10671 12841

MaterialType MaterialSubType Material Balance Fence Line Refinery CDU1-1 CDU2-1 VDU1-1 VDU2-1 VDU3-1

Max Sustained 91900 94374 12510 10604 34403

Target LVR 99.9% 99.9% 99.9% 99.9% 99.9%

Target TVR 99.9% 99.9% 99.9% 99.9% 99.9%

Liquid Charge 194732 194732 97421 95358 11375 10929 31307

Balance (Liquids) 0 1688 1688 -96 -94 -11 -11 -31

Vol Recovery % 99.13% 99.13% 99.90% 99.90% 99.90% 99.90% 99.90%

Liquids+ gas, vol% 102.25% 102.25% 99.90% 99.90% 99.90% 99.90% 99.90%

Feedstocks Crude DCD1-1 -82776 -82776 -47846 -34930

Feedstocks Crude DCD4-1 -43977 -43977 -21837 -22140

Feedstocks Crude DCD5-1

Feedstocks Crude DCD8-1

Feedstocks Crude NCD4-1 -20153 -20153 -6034 -14119

Feedstocks Crude AC11-1 -39008 -39008 -17827 -21181

Feedstocks Crude ACD1-1

Feedstocks Crude ACD3-1

Feedstocks Crude RCD1-1

Feedstocks Crude RCD2-1

Feedstocks Crude WTIM-1

Feedstocks Crude OFSP-1 -324 -324 -2110 -2988

Feedstocks Intermediates PUDL-1 -4586 -4586

Feedstocks Intermediates FCCF-1 -1005 -1005

Feedstocks Intermediates HVYN-1 0 47 47

Feedstocks Intermediates LSRG-1 0 349 349 29484 26579

Feedstocks Purchased Blendstock FeedsIBUT-1 -3344 -3344

Feedstocks Purchased Blendstock FeedsMPBG-1

Feedstocks Recovered Oil SLOP-1 0 45 45 -1767 68 68 1491

Feedstocks Recovered Oil TRAN-1

Products 1-Liquid Petroleum GasPROP-1 4185 4185

Products 1-Liquid Petroleum GasWGAS-1 45 44

Products 1-Liquid Petroleum GasCNSO-1

Products 1-Liquid Petroleum GasALKF-1 0 0

Products 1-Liquid Petroleum GasC3PL-1

Products 2-Gasoline BlendstocksMHCH-1 0 241 241

Products 2-Gasoline BlendstocksCATG-1 0 -1133 -1133

Products 2-Gasoline BlendstocksLREF-1 1734 1734

Products 2-Gasoline BlendstocksOLEF-1 145 145

Products 2-Gasoline BlendstocksLFCC-1 0 -832 -832

Products 2-Gasoline BlendstocksNBUT-1 -2595 -2595

Products 2-Gasoline BlendstocksALKY-1 -616 -616

Products 2-Gasoline BlendstocksHREF-1 10671 10671

Cleandata

Import


Once completed, the volume reconciled balances can be imported into PMRC for direct

comparison and analysis.

Once again flags are used to quickly highlight areas where further investigation may be

required. The entire process of creating a volume reconciliation for backcast effort is reduced to

minutes rather than days or hours. This allows the users to focus on improving models and

profitability, rather than collecting data. The process here can be tailored to any existing

reconciliation process to account for any uniqueness or proprietary features a client may wish to

include.

1.1.8 Automated Month End Reporting

PMRC reduces the time sink within organizations devoted to generate monthly summary reports

by automating many standard reports. Below is an example of a monthly scorecard view:


As each section is expanded, more details become available:

The system provides a collaborative workspace to capture any comments related to

performance against targets, which can be gathered into the final reporting process for the

month. This saves time and allows results to be presented more accurately and with the proper

context. A few additional KPI views serve to drive this concept home and show the potential

within PMRC for report automation:


Any topic can be analyzed with multiple views and displays. New data displays are easy to

create using industry-standard Microsoft products (.Net, SQL, Visual Studio) integrated with an

advanced web UI layer (Telerik). PMRC can be customized to fit around any existing reporting

process, the key is the automation of data collection, which is accomplished by functional and

robust data integration.

1.1.9 Standardize Knowledge by Creating Monitoring Plans

One of the most powerful concepts contained within PMRC is the ability to standardize the way

processes are monitored across an organization. Knowledge retention can be difficult for

companies to manage. Often as employees change positions or exit an organization not all of

the accumulated knowledge is transferred successfully. PMRC monitoring plans can alleviate

these issues while providing a very focused view on performance versus target for a broad

range of operational activities.

The following screenshots demonstrate the Actual versus Plan (AVP) target sheet capability of

PMRC:


The following monitoring plan displays data from multiple sources and facilitates collaboration

as performance is analyzed versus target. In this case the current is from the plant historian,

the daily is the last reconciled accounting balance, and the target comes from the LP plan.

Should the plant have a scheduling system, more accurate targets would come from it; if not, a

manual override would give the capability to alter the plan for 1 or more days. Comment

sections are available as needed, and an instruction column is provided to allow operating

instructions to be communicated. All edits are tracked, and system generated results can be

manually overwritten if needed. Notice that throughout the system, PMRC uses the same visual

widgets and coloring schemes. Learning to use the system takes a few hours of introduction,

not days or weeks.

The maintenance and creation of monitoring plans has been standardized and simplified within

PMRC.


The system houses a standardized list of activities by equipment and product, and can be

extended across any business function. Overall, though, any plan and its activities can be

imported in a new plan.

This allows the capture and storage of knowledge from across an enterprise, allowing key

personnel to focus on what is actually important to monitor for any process.


Data sources are defined without the need for additional back-end coding, and can be drawn

from any system that has been integrated into PMRC.

This allows the creation of a new monitoring plan from any existing plan or component in the

library.


The following example demonstrates how flexible the system is. A new plan is created, and any

of the existing templates can be dragged to the new plan as a starting point.


In this example, a furnace is added to the new plan hierarchy. It comes pre-populated with the

library monitoring components for a standard furnace. The task of mapping the new

instruments and reconciled rate data is greatly simplified, and is handled within the PMRC

monitoring plan structure. The benefit is that once a comprehensive plan is generated, it can

easily be scaled across multiple sites or businesses. Client solutions can use the existing

structure within PMRC or add their own proprietary data, and setup is kept to a minimum.


1.1.10 Many More Customizable Features Tailored for Each Client

PMRC comes out of the box with a great deal of functionality, but one of its best features is the flexibility it offers to adapt as business conditions change. As the business is monitored collaboratively and in more detail, inevitably discoveries are made. The ability to add new KPI displays or adjust monitoring plans allows for a system that adapts to the competitive environment, and will drive behavior towards an economic optimum. Additionally, many clients have well developed business process and proprietary models which can be incorporated into a successful implementation of PMRC. ZeoNet begins each project with a roadmap that addresses each of the core data sources required to fully realize PMRC, and works with each client to customize a solution that makes sense for their business. Projects can be staged to start with the basics and add functionality as competence with the new tools grow within the organization.


1.2 Minimum Technical Requirements

• Microsoft SQL Server 2012 Standard Edition (64-bit)

o Supported Operating System

▪ Windows 7, Windows Server 2008 R2, Windows Server 2008

Service Pack 2, Windows Vista Service Pack 2

• 32-bit systems

o Computer with Intel or compatible 1GHz or faster

processor (2 GHz or faster is recommended.)

• 64-bit systems

o 1.4 GHz or faster processor

▪ Minimum of 1 GB of RAM (2 GB or more is recommended.)

o 2.2 GB of available hard disk space

o .NET 3.5 SP1 is a requirement for SQL Server 2012

o .NET 4.0 is a requirement for SQL Server 2012

o For more in-depth details on requirements:

https://msdn.microsoft.com/library/ms143506(v=SQL.110).aspx

• .Net Framework 4.5

• HTML 5.0

• CSS 3.0

• Telerik UI for ASP.NET AJAX R3 2016 SP2 (version 2016.3.1027)

• Telerik Reporting R3 2016 SP1 (version 10.2.16.1025)

• Microsoft Internet Information Server (IIS) 6.0 or later (For PI Web Services)

https://msdn.microsoft.com/library/ms143506(v=SQL.110).aspx


2.0 About ZeoNet

2.1 Background

CEO Rony Jammar founded ZeoNet, Inc. in 2000. Rony’s vision for ZeoNet is to provide the

right expertise at the right time and at the right price to assist Oil & Gas Downstream clients to

improve their profitability. His goal is to provide a comprehensive and fit for purpose set of skills

to his clients, whether for a small strategy study or a large system implementation such as

PMRC. Our team consists of some of the best and most experienced professionals in the

industry, with a core network of roughly 30 consultants with deep knowledge of refining and

petrochemical work processes and systems. ZeoNet's core competencies include Information

Technology and System Implementation, Program Governance, Planning, Scheduling,

Optimization, Process Improvement and Design, Change Management, and Marketing. Our

team understands how the industry works, and they routinely integrate processes, data, and

systems effectively and sustainably. PMRC is in many ways a natural result of the knowledge

and experience ZeoNet has gathered by implementing solid work processes and improvements

throughout the industry.

2.2 The Story Behind the Name

The invention of the first zeolite catalyst in the 1960’s for use in gasoline manufacturing

revolutionized the process and continues to do so as more efficient catalysts are developed

today. As the origin of the name ZeoNet, a contraction of “zeolite” and “network” refers to this

significant event in the history of industrial and chemical engineering. Our network of experts

serves as a catalyst for transformation.

2.3 Contact Information

For additional information about ZeoNet or PMRC contact:

Tom Ferguson Zeonet [email protected] https://www.zeonet.com

mailto:[email protected]

https://www.zeonet.com/

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