Reliability Driven Asset Management Plant of the Year 2015 - Gbor - PowerPoint PPT Presentation

Reliability Driven Asset Management Plant of the Year 2015 - Gábor Bereznai - October, 18 2016, Rotterdam

Plant of the Year winners in 2010 2

Small in the world… Size of the logos are correlating to companies’ revenue. 3

But strong in the region… 6 production units 23 mtpa refining capacity 2.1 mtpa petrochemicals capacity >2000 filling stations 4

Business drivers around the Economical crisis Source: Wood MacKinsey, Global Refinery View, Refining in Europe, Africa and FSU 5

Diverging world in Donwstream business Global refining and petrochemical business outside of Europe is growing New, large scale, high-tech refineries and petrochemical sites in Asia and the Middle East are increasing product export to Europe The European downstream business is pressurised by worldwide trends and not supported by local politics and regulations EUROPE • Not growing with stagnating demand • Record low margins, crude runs at 23-year low UNITED STATES • Still significant overcapacity ASIA-OCEANIA • Becoming a net exporter of oil products • Decreased competitiveness, EU regulations • Strong put further pressure on European DS governmental • Huge investments targeting European support business markets • New refineries in China, • Favourable legislation (incl. tax India, Vietnam, etc. MIDDLE – EAST legislation) • Cheap feedstock, • Large new refining sites 4070 kbpd, $125bn • Additional ~2 mbpd refining capacity in New and ongoing 3 years (5x MOL capacity) investments CENTRAL AND • Targeting the European market SOUTH AMERICA • Strong demand growth • Favourable legislation for local 2750 kbpd, $60bn companies New and ongoing investments 2470 kbpd, $95bn New and ongoing investments 6

Delivering Business Value: 500M$+500M$ in five years 7

Production loss due to UPDT 2,500,000 Production loss [USD] [ 563 kEDC ] 2,000,000 1,500,000 1,000,000 [ 607 kEDC ] 500,000 0 2009 2010 2011 2012 2013 2014 Q1 UPDT: Unplanned Down Time due to instrumentation causes FIMS: Field Instrumentation Maintenance System Source: MOL SAP-PM Maintenance System, 2014 8

Layers of Protection Computerised Maintenance Evalution of Reliability Master Asset Maintenance Maintenance planning and Operative analysis Management Database execution sheduling Maintenance (MTBF, MTTR) Systems Failure modes Definition of Maintenance Risk evaluation Detailed Strategy Asset Strategy Group of Strategy optimisation and handling Reliability Assets to Evaluation Creation (Asset Policy) analysis Maintenance Condition Control Valve and Risk Based Vibration diagnostic, Monitoring Instrumentation Oil analysis, Thermo Inspection diagn., Systems digital comm. Off-line, diagnostic, Communicator Serial Off-line, diagnostic Off-line, diagnostic Corrosion Data Vibration data RFID / PDA database collection DCS systems Collectors diagnostic diagnosti On-line, On-line, c Equipements Statical equipements Rotating machines Field Instrumentations 9

CMMS integration SAP-PM server FIMS (AMS/PRM) user/ SAP-PM user expert AMS DM + AMS FIMS servers Refinery Information System On-line FIMS subsystem (AMS) Predictive DC MUX notifications can save 7k$-700k$ avoiding unit Alarm filtering in the outages. SAP-FIMS interface Intelligent instrumentations of the DC units CFV-087 10

DCS and Smart Instrumentation in MOL Refining MOL has 58 units in the Refining 95% equipped with DCS and Safety PLC. The number of the non-smart pneumatic transmitters are decresing. (19000) 11

Integrated Maintenance Systems AM - AMS - PRM protocols AM - AMS - PRM protocols (3382 pcs devices) (4135 pcs devices) 2500 2500 2114 2110 2000 2000 Devices [PCS] Devices [PCS] 1500 1500 1347 1000 1000 850 413 500 413 500 219 9 0 0 0 0 42 0 0 0 0 0 0 0 Honeywell AM Emerson AMS Yokogawa PRM Honeywell AM Emerson AMS Yokogawa PRM HART FFB Wireless HART HART FFB Wireless HART 2010 2015 12

Improved organisational model is needed to achieve the Refinery objective Business rational of organisational model change: Align the organisation with refinery objectives Improve cooperation and eliminate silo operation Put more focus on key areas in order to improve our efficiency and performance based on Solomon benchmark (maintenance, operational availability, energy efficiency) 15

Peolpe behind the systems - Csaba Molnár-Valkó - October, 16 2016, Rotterdam 16

Man behind system Asset management system (AMS, PRM, FDM) Online equipment types Adding equipment / configuration ALERT setting / handling Valve diagnosis Pressure transmitter calibration Analytical instrument calibration Tranings / courses 17

Asset Management System AMS PRM FDM Asset Manager System Plant Resource Manager Field Device Manager 5 online plant : 8 online unit: 6 online unit: DCU MSA CL4 - - - GOK3 REF4 CL6 - - - CL5 GOK1 BEK5 - - - HDS HGY1 FCC - - - KBI HGY2 AV2 - - - REF100 PEM1 - - KGÜ - BK4 - Tags: Tags: Tags: ~ 2600 online ~1450 online ~ 1600 Online ~ 5000 offline 18 2010 2015

On-line equipment types - Transmitters - Pressure - Differential pressure - Level - Temperature - Flow transmitter - Valves - Control valave - ON-OFF valve (with positioner) 19

Adding device / Configuring Add new online device - Connecting new device to the system - Scanning and Denomination - Placing it in Plant structure - Setting all the 3-level alerts: - configaurated in the device - adjustable in the maintenance system - setting interface filter 20

Setting Alerts / Handling Device Alert handling DVC5000 (66 pcs parameters / 33 alerts) DVC 6200 (150 pcs parameters / 50 alerts) 21

Setting Alerts / Handling Setting Alerts in maintenance system 22

Setting Alerts / Handling Setting interface 23

Valve diagnostic ― ValveLink Online/Offline ― DTM based (Metso, Flowserve) ― Flowscan ― ValVue ― OVD 24

Pressure Transmitter Calibration Process - Adding device, scanning, denomination - Test-scheme assigning, placing in the Plant structure - Check Out - Calibration - Check IN - Report template assign - Report preparation 25

Analyser equipment calibration Process - Offline TAGS download from AMS to PDA - Device identification with RFID - Calibration (manual) - Check IN from PDA - Report generation - Notice posting to ERP 26

Skills / Competance A high level knowledge of systems (AMS, PRM, FDM) Database handling at user level Knowledge of specific devices Calibration knowledge Valve diagnostic on a really high level 27

Delivering Business Value from Digital Transformation Operational Maintenance Availability Efficiency Energy Yield Efficiency improvement - Tibor Komróczki October, 18 2016, Rotterdam

Digital Transformation of New & Next Downstream program Yield s Operational Safety & Asset optimization • Product quality integrity (PSM ) • Operating envelopes • Interlock statuses • Analyser reliability • NG (natural gas) and • Integrity Operating (Argus) fuel gas demand • Yield Accounting via Windows forecasting • Corrosion control Sigmafine (PI AF based) • Normal mode of control (HTHA) loops • Alarm management • APC control monitoring • Preventing coke steam • Diesel sulphur eruption Operational Maintenance Asset Reliability from optimization Availability Efficiency Proactive & Predictive • Coker yield optimization Energy Advanced Analytics • Energy monitoring and management • SAP PM Integration • Energy KPI breakdown Yield • Health Score in PI AF • Column energy efficiency dashboard Energy • improvement Hydrogen, utilities - energy balances • CBM on all rotating Efficiency • Flaring equipment • PSA – Pressure Swing Adsorbers • Chillers • Heat Exchangers • Electrical Infrastructur e

Ad Advan anced ced An Anal alytics cs an and IoT Oil & Ga Gas Downs nstr tream eam Increase productivity and efficiency across all major business units Condition based & through the best practices for data predictive harmonization maintenance Alarm Management System (alarm rationalization) – Inferential and Mode Base alarm , new alarm descriptive statistics logics Analyze control loops behavior Energy modelling Deeper understanding of optimization technological processes - Alternative crude oil usage as feed; yield optimization

Ad Advan anced ced An Anal alytics cs Intel elli ligence How can we make it happen? VALUE Cloud ud Analytic Ascendancy Model Prescriptive What will happen? Analytics Data Why did it happen? Predictive Analytics What happened? Diagnostic Analytics Descriptive Analytics DIFFICULTY Gartner, March 2012

Digit ital al tran ansfor ormati ation on Peo eople  Enablement of Contextual Data Based Decision Making & Management  Improving skill knowledge capture changing paradigms about data - Success ess leading by example Tec echno nology logy Proce cess ss  Reengineering the workflow around enhanced & consistent data