Real Time Financial Analysis in Process Plants (Energy and Performance Information System)

Presenters Steve SussmanPresident, Kesler Engineering Value Added RtPM Solutions for Process Industry Dennis Lawless, Information Services, Citgo Inc. Corpus Christi, Texas Refinery

Why RtPM in Oil and Gas? Global competition is driving the need for Performance improvement Performance GAPS must be identified in real time while the opportunity can be ACTED upon

KEI Online Analytics You can’t improve what you can’t measure. – –KEI online analytics measures actual operational performance and calculates performance targets in real time. – –KEI analytics provides “Root Cause Analysis” and presents ways to reduce the performance gap. – –GAP Analysis justifies performance services Creates a record of hard dollar justification Creates demand for other performance solutions including human performance services.

Kesler Methodology Measures operational and financial performance. Compares to targets. Adjusts the targets dynamically using models. Calculates the financial opportunity gap. Actionable advisories Personalized Visualization Historical comparison for variability analysis.

RtPM Management Components

Citgo Refinery Project, by D Lawless Application Presents Actionable Engineering Best Practices Application Measures performance and identifies opportunities. Calculates financial impact. Adjusts targets on event. Management Team: Determines root cause of problems and proposes solutions. –Training –Organization –Automation/APC –Supply chain …

Citgo Refinery Scope of Supply –Crude and Vacuum Unit –Platformer –Coker –Plant wide steam systems –Cogeneration –KPI tracking –Environmental and safety reporting

Real Time Performance Analysis Energy Monitoring –Plant wide steam balance and optimization (AFE dependent) –EII calculations on line for plant or unit –Fuel, electricity usage, online targets and recommended savings –Fired Heater Monitoring Capacity Monitoring –Actual vs. target (permit limited) Asset management and safety monitoring / advisories Online reports in terms of KPI’s and Gross Margin Opportunity –Current Annual, Daily potential savings. –Cumulative Savings over time—day, week, shift, month, year, etc –Best Practice Recommendations on event

Application Architecture Leverage existing plant infrastructure –Visualization layer in OSIsoft Process Book or RT Portal (WEB) –Application Scheduling and Event notification –User Defined Rules/Calculations using OSIsoft ACE –Process models and algebraic equations using the Kesler Sentinel –Real Time and Historical Data in OSIsoft PI

Real Time Financial Analysis

Energy Aggregation Advisory

Plant Wide Steam System Advisories

Electrical Opportunity Advisory

Crude Unit Capacity Opportunity Advisory

Early use shows payback under 4 months Advisory to use spare compressor to reduce pressure in tower increases Capacity OOE calculates improvement (reduction of lost opportunity) of $8,000/day

Project Schedule –Proof of Concept Prototype Completed February, 2004 –Seek AFE approval for 2 units and Steam system adaptation May, 2004 –Primary Build Complete 2 nd Quarter, 2004 –Assessment of Benefits during 3 rd and 4 th Quarter, 2004 –Seek Secondary Build AFE and Implementation during 1 st Quarter, 2005

Real Time Financial Analysis Other Planned Improvements to EIS –Environmental Emissions Tracking and Reporting –Slow Down Tracking –Automation of Adhoc Energy Monitoring

Real Time Financial Analysis in Process Plants (Energy Information System)