The document discusses a technology session and workshop hosted by KBC and Petronas on January 16-17, 2018. It focuses on KBC's engineering simulation software suite called Petro-SIM, which aims to optimize operations and design for upstream and downstream oil and gas clients. The document provides examples of how Petro-SIM has helped clients evaluate strategic projects, capital projects, and optimize supply chain operations with more accurate modeling compared to traditional linear programming approaches.
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
SMR PRE-REFORMER DESIGN
Case Study #0618416GB/H
Contents
1. SMR Pre-Reformer Design
2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation
Technical Review and Commentary on Proposed Design
APPENDIX
A. Operating / Mechanical Data
B. Materials Specifications
C. Fabrication and Inspection Requirements
D. Weights
E. Nozzle Data
F. Instrument Connections
G. Manholes
Pre-reforming
Flow-schemes
Feed-stocks
Catalyst handling, loading & start-up
Benefits of a pre-reformer
Case studies
Effects upon primary reformer
Data analysis
Reactor temperature profiles
Catalyst management
Summary
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
Tube Wall Temperature Measurement On Steam Reformers - Best Practices
Temperature Measurement Techniques
Top – Fired Reformer
- Tube Temperature Measurement
- Background Temperature Measurement
Side – Fired and Terrace Wall Reformer
- Tube Temperature Measurement
- Background Temperature Measurement
Safety Considerations
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
SMR PRE-REFORMER DESIGN
Case Study #0618416GB/H
Contents
1. SMR Pre-Reformer Design
2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation
Technical Review and Commentary on Proposed Design
APPENDIX
A. Operating / Mechanical Data
B. Materials Specifications
C. Fabrication and Inspection Requirements
D. Weights
E. Nozzle Data
F. Instrument Connections
G. Manholes
Pre-reforming
Flow-schemes
Feed-stocks
Catalyst handling, loading & start-up
Benefits of a pre-reformer
Case studies
Effects upon primary reformer
Data analysis
Reactor temperature profiles
Catalyst management
Summary
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
Tube Wall Temperature Measurement On Steam Reformers - Best Practices
Temperature Measurement Techniques
Top – Fired Reformer
- Tube Temperature Measurement
- Background Temperature Measurement
Side – Fired and Terrace Wall Reformer
- Tube Temperature Measurement
- Background Temperature Measurement
Safety Considerations
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Summary of changes in burner specificationsKapil Batra
Our team at Furnace Improvement Services, New Delhi has compiled an interesting comparison of the changes in Burner Specifications in API-560 Fired Heaters for General Refinery Service over the years. Burner design has evolved a lot due to increasing restriction on NOx emissions. Because of the changes in burner design a lot of additions, modification and deletions have been made in the API 560 standard. We have covered from the 1st API edition made in 1986 to the latest 5th edition published in 2016. We intend to publish more such comparisons from API 560 standard. Please feel free to provide your feedback and comments.
A full package presentation about Hydrogen Production Unit including an overview about steam reformers, combustion reaction, moods of heat transfer, draft systems, reactors, chemicals used in HPU, and types of compressors. Moreover, it describes the process description, process variables, and opens the way for some possible improvements which can be implemented to develop the unit performance.
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
Steam Reformer Surveys - Techniques for Optimization of Primary Reformer Oper...Gerard B. Hawkins
Introduction
Background Radiation and Temperature Measurement
Reformer Survey Inputs
Other Troubleshooting Tools
Safety
Preparation
Onsite Data Collection
TWT Survey
Observation/Troubleshooting
Modelling and Analysis
Results/Outputs
Case Studies
Conclusions
Case Study 1
Case Study 2
Case Study 3
Conclusions
Need to remove poisons prior to entering downstream catalyst beds, including
Pre reformers
Primary reformers
HTS
LTS
Note : no Secondary - poisons do not stick as temperature is too high
Note that methanator is a purification step
Removes CO and CO2 which poisons synthesis catalyst
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Summary of changes in burner specificationsKapil Batra
Our team at Furnace Improvement Services, New Delhi has compiled an interesting comparison of the changes in Burner Specifications in API-560 Fired Heaters for General Refinery Service over the years. Burner design has evolved a lot due to increasing restriction on NOx emissions. Because of the changes in burner design a lot of additions, modification and deletions have been made in the API 560 standard. We have covered from the 1st API edition made in 1986 to the latest 5th edition published in 2016. We intend to publish more such comparisons from API 560 standard. Please feel free to provide your feedback and comments.
A full package presentation about Hydrogen Production Unit including an overview about steam reformers, combustion reaction, moods of heat transfer, draft systems, reactors, chemicals used in HPU, and types of compressors. Moreover, it describes the process description, process variables, and opens the way for some possible improvements which can be implemented to develop the unit performance.
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
Steam Reformer Surveys - Techniques for Optimization of Primary Reformer Oper...Gerard B. Hawkins
Introduction
Background Radiation and Temperature Measurement
Reformer Survey Inputs
Other Troubleshooting Tools
Safety
Preparation
Onsite Data Collection
TWT Survey
Observation/Troubleshooting
Modelling and Analysis
Results/Outputs
Case Studies
Conclusions
Case Study 1
Case Study 2
Case Study 3
Conclusions
Need to remove poisons prior to entering downstream catalyst beds, including
Pre reformers
Primary reformers
HTS
LTS
Note : no Secondary - poisons do not stick as temperature is too high
Note that methanator is a purification step
Removes CO and CO2 which poisons synthesis catalyst
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Conference: 23rd ICE/IEEE ITMC Conference
(ICE2017).
Madeira, Portugal – June 27-30, 2017
Title of the paper: An Approach to Production
Scheduling Optimization
A Case of an Oil Lubrication and Hydraulic Systems
Manufacturer
Authors: Artem Katasonov, Toni Lastusilta, Timo
Korvola, Leila Saari, Dan Bendas, Roberto Camp,
Wael M. Mohammed, Angelica Nieto Lee
if you would like to receive a reprint of the
original paper, please contact us.
Using Agile Approach with Fixed Budget ProjectsSynerzip
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Akili's 20+ years of Oil & Gas projects has
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• Production volume forecasts
• Pricing scenarios
• Resulting revenue forecasts
• Lease operating expense
• Cash flow, debt, and interest
• Capital planning
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digital applications and capabilities needed to achieve operational excellence: applications and capabilities that derive their value from knowledge of how the plant has operated in the past combined with its current and future potential; and an actionable optimum path to achieving and sustaining that potential.
Optimization in the conceptual or feasibility stage provides:
Specifications for the Licensor Process Design Package (PDP) before design begins and opportunities to minimize utilities capital costs
Each individual business with their own unique assets and supply chain optimizing their decisions according to their incentives, abilities and working culture. The latest developments in Planning (Petro) and AI use cases.
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Thereby providing actionable insights into production activities that can drive convergence in decision-making and action across organizational silos.
The future involves refining industry is becoming more efficient regardless of technology choice. Reduce cost, improve value chain and be responsive with a digital twin
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Petro-SIM presentation
1. KBC/Petronas Technology Session
and Round Table Workshop
Proprietary Information
16-17th January 2018
Confidential Information
Petro-SIM
Empowering clients with simple solutions today to address
the complex challenges of tomorrow
2. KBC/Petronas Technology Session
and Round Table Workshop
Proprietary Information
16-17th January 2018
Confidential Information
Technology Introduction
3. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 2018
Technology Introduction
• Vision
To create an end-to-end technology platform that
revolutionizes supply chain optimization in downstream and
production optimization in upstream across the lifecycle of
an asset
• Mission
To empower our clients with the simple solutions today to
address complex challenges of tomorrow
4. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 2018
Technology in Industry
• What are clients looking for from a technology platform?
A single source and version of the truth
Expert uses for non-expert users
Optimised engineering workflows that reduce the time and
effort from identified problem to implemented solution
A means to exploit the synergies between different groups
to enhance team work and the effective utilization of
resources
5. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 2018
KBC’s Technology Platform Value Proposition
• In operations
Create realistic plans, identify the gap between the plan and the actual
to convert it into an actionable plan on a routine basis that allows our
clients to achieve realistic production goals
• In design
Compare different design scenarios over the life of an asset to reduce
design margin and improve the accuracy of forecasting and planning
• Overall
Create a winning experience for our clients which they are excited to
share with each other
6. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 20186
KBC Engineering Simulation Software Suite Overview
7. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 20187
Petro-SIM in Downstream
NHTR-SIM Ref-SIM
AROM-SIM
Olefin-SIM
DHTR-SIM
VGOHTR-SIM
ISOM-SIM
HCR-SIM
RHDS-SIM
ALK-SIM
FCC-SIM
DC-SIM
VIS-SIM
8. KBC/Petronas Technology Session
and Round Table Workshop
Proprietary Information
16-17th January 2018
Confidential Information
Downstream Industry Challenges
9. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 20189
Downstream Focus Areas
Strategic Focuses
• Strategic
Projects
• Design and
Capital Projects
• Equipment &
Technology
Purchasing
Supply Chain
Optimisation
• Crude & Product
Purchasing
• Planning &
Scheduling
Meeting
Production Goals
• Automation
• Unit & Equipment
Performance
Management
• Catalyst
Selection &
Monitoring
• Offline
Optimization
10. KBC/Petronas Technology Session
and Round Table Workshop
Proprietary Information
16-17th January 2018
Confidential Information
Strategic Focuses
11. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201811
Downstream Questions and Challenges
Strategic Projects
Design & Capital
Projects
Equipment &
Technology
Purchasing
• Should you invest, why, how much, and where?
• What is the project ROI, did we achieve it, why or
why not?
• How do you decide where and on what to spend
capital?
• What is the impact of current and future operations on
current equipment performance and our strategy for
reliability, availability, and maintenance?
• Should we invest in upgrading existing technology or
introducing new technology?
12. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201812
Traditional Approach
• Simplistic, linear representations of
reaction units that is not material or heat
balanced
• Very narrow range of applicability
• Does not consider complex interactions
between process units
• Point Solution
KBC’s Approach – Refinery Wide Modelling
• Rigorous, nonlinear kinetic models
• Can handle wide variation in changes to inputs
• Provides a granular understanding of critical
relationships between process units
• Can support all aspects of the lifecycle of a
project
Strategic Focuses
13. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201813
Case Study – Strategic Projects
Client Situation
Client was looking to evaluate the performance of a unique crude in an existing refinery in order to understand their current
capability to process it and future improvements required to capitalise on the new crude
Project Implementation Approach
• Historically, this type of project would have been done using an LP model, but in this case, the client did not have confidence in the ability of the LP to
handle such a unique
• The client created individual reactor and unit models for each process unit
• The client then created an integrated refinery wide model of each of the process units modelling each area to the level necessary to capture potential
constraints
• The client then ran multiple different operating cases with different blend ratios of the new crude to determine trade-offs to capital spend to operating
margin
Key Findings and Recommendations
• The client was able to evaluate multiple capital and non-capital options
to determine the most profitable scenarios
• The client took the results of the study and moved forward with two
options that they sent for detailed engineering estimates.
Indirect client quote:
Looking back now that we have been processing this new crude profitability,
everything Petro-SIM said would happen has happened. As a result, we’ve been
prepared for how to operate to achieve maximum profitability. This is something the
LP never would have been able to do.
Results The client was able to successfully and profitably implement a strategy for processing the new crude
14. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201814
Case Study – Strategic Projects
Client Situation
Client was looking to conduct an internal profit improvement initiative. Critical issues for them revolved around poor
fractionation in certain process units. They also wanted to evaluate the introduction of new process units.
Project Implementation Approach
• Historically, this type of project would have been done using an LP model, but in this case, the client did not have confidence in the ability of the LP to
handle such a unique
• The client created individual reactor and unit models for each process unit
• The client then created an integrated refinery wide model of each of the process units modelling each area to the level necessary to capture potential
constraints
• The client then ran multiple different operating cases looking at both non-capital and capital improvement options
Key Findings and Recommendations
• The client was able to put together key results and recommendations for their refinery from options involving zero capital expenditure to major capital
project.
• The results from the study were then actioned by the refinery leading to new operating strategies as well as a couple capital projects
Results The client was able to determine a range of short to long term options to improve profitability
15. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201815
Case Study – Design & Capital Projects
Client Situation Client was looking for a tool to help them evaluate and quantify changes to their largest refinery.
Project Implementation Approach
• A joint KBC and client team was assembled to construct the model
• The client built individual calibration models that connected directly to the PI process historian for bringing in current operating data
• The client preferred this rigorous approach to modelling their refinery because
• They were able to model the entire process in the same software
• The model represented a more detailed tool than their LP, Scheduling tool, or Excel
• The client liked the ability to easily import many different crudes to support the studies they intended to do
Key Findings and Recommendations
• The client was able to put together key results and recommendations for their refinery
• The model was also used to update the LP leading to improved future decision making around optimization
• The results from the study were then actioned by the refinery leading to new operating strategies as well as a couple capital projects
Results The client was able to determine a range of short to long term options to revamp their refinery
16. KBC/Petronas Technology Session
and Round Table Workshop
Proprietary Information
16-17th January 2018
Confidential Information
Supply Chain Optimisation
17. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201817
Downstream Questions and Challenges
Crude & Product
Purchasing
Planning &
Scheduling
• Given the variability of crude qualities and prices as
well as product values in the market today, how do
you ensure that you are buying the right crudes and
making the right blend of products to sell?
• How do you determine the optimal supply plan for
your facility?
• How do you translate from optimal supply plans to
realistic operating plans?
• How do you ensure that the results from an LP
capture the real facility constraints and mimic the
performance of a facility?
• How do you validate the results for a given supply
and operating plan?
18. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201818
Supply Chain Optimisation
LP Models
LP Data Generation Models
Refinery Wide Models
• Perform rapid optimization
• Validate and Maintain LP submodels
based on rigorous simulation models
• Provide higher fidelity and accuracy
• Same models used for capital planning and
margin capture
Smart Unit Performance Monitoring
• Track LP submodel performance against
model and plant
ONE OF KBC’S CLIENTS PUT IT THIS WAY: “THE LP CAN TELL YOU WHERE TO GO BUT NOT NECESSARILY
HOW TO GET THERE. PETRO-SIM CAN.”
19. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201819
Case Study – Multi Refinery Data Generation
Client Situation
Client was looking for a way to implement a consistent and best practice based methodology for developing LP data across
multiple refineries. Across their multiple sites, the client was originally using different modelling approaches; files were not
managed centrally and were often duplicated or even lost; there were significant delays in transmission of data; and
miscommunication was a growing problem
Project Implementation Approach
• The client employed flowsheeting best practices across all their refineries
• Standard topology
• Standard stream and file naming
• The client chose to have everything centrally stored and managed through the Petro-SIM database using an Excel based interface to control the data
generation activities.
Key Findings and Recommendations
• Centralised modelling department makes cases and data easy to manage and ensures that site unit engineers can focus on day to day operations
• Better communication
• Reduced IT costs as calculations are done remotely
Results
Petro-SIM has rich variety of methods to helped the client to exchange data, collaborate with their
co-workers, integrate their own technology, and build complex applications
21. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201821
Downstream Questions and Challenges
Automation
Unit & Equipment
Performance
Management
Catalyst Selection &
Monitoring
Offline Optimisation
• How do you ensure that your control
strategies are tuned, accurate, and
readily updated to ensure stable
performance?
• Are you actively and routinely being
proactive to ensure current and future
performance management?
• Does your campaign include process,
energy, and mechanical considerations?
• How do you validate vendor estimates?
• Do you independently verify and track
agreed performance standards?
• To what extent are your unit engineers
focused on short term optimization?
22. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201822
Meeting Production Targets
How can you determine whether a
facility is achieving optimal operation?
How can you determine what
improvements can be made?
How can you develop implementation
strategies to act on improvement
ideas?
• Process Models can tell you where you
should be able to operate
• Comparing existing operation against
desired operation identifies gaps in
performance
• Process models empower you to develop
implementable strategies to address
identified improvements
How can you ensure that engineers are
making the most efficient use of their
time?
• Smart unit performance monitoring allows
unit engineers to track improvements and
identify and troubleshoot concerns before
they impact overall operation
23. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201823
Case Study – Meeting Production Goals
Client Situation Client was looking significantly improve the performance and profitability for one of their major US refineries.
Project Implementation Approach
• Generated operational improvement ideas based on consulting typical experience
• Ranked ideas on an experienced based review
• Developed a refinery wide model to test the top ideas and identify additional opportunities
• Used the refinery wide model to generate “playbooks” to assist technical operation decisions
Key Findings and Recommendations
• The refinery was able to take several key recommendations and further develop and implement the delivered playbooks to improve their operational
performance
Results The client was delivered over 10 Million $/year in evaluated benefits
24. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201824
Case Study – Unit Performance Monitoring
Client Situation
Client was looking to build Smart Unit Monitoring Application in Petro-SIM to replace mass balance spreadsheets and
enhance KPI reporting.
Project Implementation Approach
• Taking existing calibration models, the client setup connections to their data historians
• The process model was adapted to incorporate KPI calculations
• Automatic and in-built trending was created for each application to be viewable through the Petro-SIM Explorer
Key Findings and Recommendations
• The KBC Approach provided
• Standardization across the organization for for mass balancing, data validation and catalyst performance monitoring
• Collaboration across their organization as all the data is held on a central server that anyone can access using the KBC Explorer or 3rd part BI
reporting tools, which allows multiple end users can access and review the results at the same time
• Improved Model Performance
• Kinetics model and LP model accuracy can be tracked
• More frequent updates lead to improved LP, Scheduling, and Petro-SIM refinery wide models
Results
The client is working through a multi-year project to implement these applications for all major
process units
26. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 2018
KBC Capabilities That Address the Problem
• Strategic Focuses
Refinery Wide Modelling provides refinery context
Refinery Wide Modelling supports economic assessment studies
Refinery Wide Modelling evaluates projects effectively to achieve the desired outcome
EFFECTIVE USE OF PROCESS MODELLING IS A KEY COMPONENT IN EVALUATING CAPITAL SPEND
• Supply Chain Optimisation
LPs derived from rigorous kinetic simulation models support crude purchasing, operations planning, and selling products
Refinery Wide Modeling supports LPs in delivering realistic operational strategies
RIGOROUS SIMULATION MODELS COMBINED WITH TRADITIONAL LPs PROVIDE THE IDEAL SOLUTION FOR
BALANCING SPEED WITH ACCURACY TO SUPPORT REFINERY PLANNING
• Meeting Production Goals
Refinery Wide Modelling benchmarks refining operations performance
Refinery Wide Modelling identifies gaps between where refineries are today and where they could be
Smart Unit Performance Monitoring sustains identified improvements
REFINERY WIDE MODELLING SUPPORTED BY SMART UNIT PERFORMANCE MONITORING DRIVES CONTINUED
OPERATIONAL IMPROVEMENT
28. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201828
Why Petro-SIM?
Consolidation
Collaboration
Standardization
Integration
• Distillation Models
• Reactor Models
• Unit Monitoring Applications
• Centralized database for file management
• Subscription model for Assays, Calibrations, Unit
Monitoring, Workflows, Reports
• Common approach to material and component balancing
• Standard approach to catalyst and equipment monitoring
• A single version of the truth
• Ability to monitor actual data vs simulated vs LP vs Plan
• Ability to add standard tools to focus on reliability and
energy
29. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201829
Petro-SIM Benefits
Improved Data
Quality
Improved
Productivity
Improved Decision
Making
• Data reconciliation puts all data on the same basis
• Data reconciliation identifies questionable meters and lab data
• Calculations are all performed on a consistent basis
• Catalyst performance can be monitored in a consistent manner
for all units
• LESS TIME spent maintaining out of date tools or building new tools
• LESS TIME spent on generating data for reports or requests
• MORE TIME spent analyzing data to determine trends in the operation
• MORE TIME spent identifying potential problems
• Process engineers can use established and maintained tools to
quickly assess problems
• Process engineers will have MORE TIME to troubleshoot issues and
improve operations
• Reactor model and LP model accuracy can be tracked and improved
• More accurate LP models and Scheduling tools lead to better crude
choices and better product planning
30. KBC/Petronas Technology Session
& Round Table Workshop
Proprietary Information 16-17th January 201830
Petro-SIM: Beyond Engineering Simulation Technology
Underpin
Business
Processes as
the Decision
Support Tool
Revolutionize
the way teams
collaborate and
exchange
information
More effective process modeling practices
drive better decision making Better decision making drives improved profitability while
maintaining strong health and safety practices