Sigmafine: A Flexible Platform to Validate Process and Business Information

Transcription

1 Sigmafine: A Flexible Platform to Validate Process and Business Information Roberto Linares, Visiant Pimsoft Massimo Galli, Visiant Pimsoft OSIsoft s Brasil Regional Seminar 2010 Sao Paulo, October 28,

2 What is Sigmafine? Sigmafine is a Data Reconciliation and Validation tool created 20+ years ago for production accounting in the refining industry The reconciliation rule uses a least-squares minimization algorithm to find the solution of process networks Support several types of balances and analyses Mass, Component, Volume, Energy, Crude Tracking 2

3 Production Accounting Needs Good Data Production Accounting needs the transformation of raw data into production information Auditable methodologies Compliance with standards due to regulations or contractual reasons API 1980, API 2004 AMIRA ASTM Regulations and methodologies are updated API 2004 (e.g., requires pressure corrections, <2% effect) Production accounting meters don t exist! Data has to be aggregated, transformed and exposed to users Before data gets published, it has to be validated 3

4 From the Operational Perspective Many measurement and operational problems are not noticed until is too late Custody meter bias Unaccounted waste Incorrect line-up Downgrade of products Unidentified and unnecessary recycling operations Incorrect calculation factors Manual entry errors All of these above potentially can cause financial losses Up to tens of millions of dollars, depending on the processed inputs and outputs 4

5 Sigmafine as a data validation platform The validation platform offers also advanced analysis techniques to: Balance and reconcile the process network Calculate imbalances Detect meter biases Increases the confidence before data is published and used by other systems: Planning and Scheduling Maintenance ERP (e.g., SAP) Plus the operational benefits: Loss and waste reduction Process Knowledge Management 5

6 Yields accounting in refining 6

7 Refinery yields monitoring and optimization 7

8 Intelligent Movement Management 8

9 % Oil Loss estimation program Accounted Loss tonnes % On Input Crude Measurement 0 0.0% 0.00% API drainage evaporation 2, % 0.03% Flares % 0.00% Tank Evaporation % 0.00% Flare pilots & purge 0 0.0% 0.00% Crude Water Method 10, % 0.14% Inert Gas Blanket 0 0.0% 0.00% Refinery Liquid Effluent 0 0.0% 0.00% Process fugitives 0 0.0% 0.00% Cooling towers 0 0.0% 0.00% 0 0.0% 0.00% 0 0.0% 0.00% 0 0.0% 0.00% 0 0.0% 0.00% 0 0.0% 0.00% 0 0.0% 0.00% Mass Balance Follow up Sigma Fine Monthy Loss % Cumulative Inputs Losses % Inputs Losses % Jun/ , ,08 Jul/ , ,71 Aug/ , ,51 Sep/ , ,50 Oct/ , ,46 Nov/ , ,47 1,08 0,23 0,12 SF Losses 0,48 0,30 0,53 Jun/02 Jul/02 Aug/02 Sep/02 Oct/02 Nov/02 1,20 1,00 0,80 0,60 0,40 0,20 0,00 SF montly SF cumulative Accounted Loss 13,361 16% 0.18% Unaccounted Loss 68,864 84% 0.91% Total Loss 82, % 9

10 Component Balance in LNG 10

11 Recovery Calculations in Metals and Mining 11

12 Leak Detection in Water Distribution 12

13 Meters performance monitoring Pure G as E Bias C 0F12 30.A D C 0F12 30.SF B 2F10 03.A D B 2F10 03.SF B 2F20 03.A D B 2F20 03.SF F0F1013B.A D F0F10 13 B.SF Pure G as W F01 01.A D F01 01.SF 1 2F10 03.A D F10 03.SF 1 2F20 03.A D F20 03.SF F0F1013A.A D 0. F0F10 13 A.SF Sep-01 00: 00 : D ay (s) 11-D ec :02 : Drift 0 11-N ov :00 : D ay(s ) 11-D ec :02 :56 SLO East C 0F1109M.AD ton/h C 0F1109M.SF ton/h C 0F1116M.AD ton/h C 0F1116M.SF ton/h C 9F10 04.A D m3/h C 9F10 04.SF m3/h SLO W es t F11 09.A D m3n/h 2 0F11 09.SF m3/h 2 0F11 16.A D m3/h 2 0F11 16.SF m3/h 2 9F10 04.A D m3/h 2 9F10 04.SF m3/h 0 02-Sep-01 00: 00 : D ay (s) 11-D ec :03 :04 Meter Error 0 02-Sep-01 00: 00 : D ay (s) 11-D ec :03 :05 13

14 Performance dashboards Yields comparison (teo, hourly, shift, campaign) KPIs representation Current Running plan general info 14

15 Enterprise reporting 15

16 Sigmafine at Visiant Pimsoft Visiant Pimsoft, a longstanding OSIsoft partner since 1996 Offices in Italy (Milan, Turin) and the US (Houston) Operating worldwide directly and through network of Sigmafine valueadded resellers Our Mission is to provide customers with state-of-the-art data validation technologies and services based on industry standards and proven best practices Offering Sigmafine suite of products Industry specific solutions Tech Support Training, Consultancy, Auditing Turnkey projects and application management 16

17 Sigmafine Industries 200+ Customers 20+ multi-sites customers 17

18 Industry-specific value added applications Oil and Gas & Petrochemicals Metals & Mining LNG Power Water Production accounting Crude Metals accounting Energy contents balance Fuel management Leaks detection Composition Pile management Cargo unload verification Energy balance Yield reconciliation Oil movement management Recovery optimitation Quality monitoring (Wobbe factor) Turbine efficency calculations Meters Validation Data Validation Meters Performance Monitoring Losses idenftification 18

19 The PI System and Sigmafine Sigmafine is a data validation and reconciliation solution adding further value to your PI System Sigmafine relies on OSIsoft PI infrastructure Same administration tools Asset database technology (AF) Consistent client tools (PI-ProcessBook, Excel addin) Seamlessly integrated to the PI System Not another application island Same users tools and user experience Easier system administration Committed to OSIsoft roadmap SF on AF2 already on Beta 19

20 Sigmafine on a path of continous improvements Keep the application aligned with the latest data reconciliation techniques based on the research and development in this field Protect the investments of our customers following IT state-of-the-art technologies Introduce innovative paradigms Keep the platform updated with the latest industry-specific standards Listen to our customers needs to continue the development of new value added components Leverage investments through reusability 20

21 Visiant Pimsoft

22 Sigmafine User Network Sigmafine Newsletter is Published Quarterly Sigmafine Web Site is Coming Soon Knowledge Base for the Sigmafine Users: Access to Technical Papers, Bulletins and Marketing Materials Promotion of Sigmafine Seminars Sigmafine Users Conference

23 Muito Obrigado. Any questions?