Engineering Support for Refinery

Planning and Scheduling

Improve performance and margins
with aspenONE Engineering
Aspen Product Management
January 3, 2015

2010 Aspen Technology, Inc. All rights reserved

Agenda
Why Engineering Support for Planning
Engineering Best Practices
Integrated Petroleum Supply Chain Workflow
Key Activities
Why aspenONE Engineering
Next Steps

2010 Aspen Technology, Inc. All rights reserved

Why Engineering Support for Refinery

Planning and Scheduling

Improve and sustain refinery margins

Faster and better feedstock selection
Accurate planning and scheduling models
Agility in response to operational opportunities

Improve Refining Margins

with accurate planning models
through engineering models

2010 Aspen Technology, Inc. All rights reserved

Engineering Best Practices

Feedstock
selection

Capital project
assessments

agility

Plant
operations

decision support
for timely response

Planning
model
updates

for optimal
designs

Performance
Monitoring
of units and
equipment

for accuracy
2010 Aspen Technology, Inc. All rights reserved

Integrating Engineering Business Processes

Enables Best Practices
Asset Engineering Lifecycle and Workflow
Research and
Development

Conceptual
Engineering

Develop Process
Technology

Select Process
Technology

Basic
Engineering

Plant
Plant
Operations

Detailed
Engineering

Planning and
Scheduling

Identify Plant
Capital Projects

Produce Conceptual
Process Design

Produce Detailed
Process Design

Produce Conceptual
Engineering Design

Commission and
Handover Plant

Daily Plant
Operations

Produce Detailed
Engineering Design

Monitor and Guide

Plant Performance

Construct and Precommission Plant

Maintain
Equipment

FEED
Procure and Control Equipment,
Materials and Services

2010 Aspen Technology, Inc. All rights reserved

Select Crude Oils

and Feedstocks
Issue Operating
Targets

Planning and Scheduling Model Updates

Challenge

Impact
Challenge

Planners and
process engineers
work in silos

Reduced predictive
capability and
product quality

Engineering
models are needed
as input to update
refinery wide
planning models

Variation between
plan vs. actual

Easier updating of
planning and scheduling
models to reflect actual
plant performance

Lost Margins

Solution

Higher margins
with optimal yields and on-time,
on-spec performance

2010 Aspen Technology, Inc. All rights reserved

Unique to aspenONE
Collaborative workflow to update planning and scheduling models
Business
application

Workflow to

update planning
models using
rigorous models

Support
collaboration

between engineers
and planners

access by planners
and schedulers
through Excel

Ease of use

with calibration
tools and links
between models

2010 Aspen Technology, Inc. All rights reserved

Integrated Petroleum Supply Chain (IPSC)

Headquarters activity

Refinery activity

Constrained Forecast

Distribution Planning
Market Forecast

Market
Demand
Forecasting

Distribution & Exchange Plan

Refinery
Production targets

Refinery Planning

Production Plan

Production Schedule

Sales History
Market Forecast

Accounting
(SAP)

Actualised
movements

Refinery
Scheduling

Primary Distribution Scheduling

(depot inventory management)

Retail Demand
(by terminal)

Batch
nomination
Batch
confirmation

Scheduled Movements
to/from Refineries

Process Unit
Set-points

Blend
Scheduling
& optimisation

Blend recipes

Deals

Trading

Secondary
Distribution
Scheduling

Pipeline
simulation &
scheduling

2010 Aspen Technology, Inc. All rights reserved

Advanced Process Control

Integrated Petroleum Supply Chain (IPSC)

Headquarters activity

Refinery activity

Constrained Forecast

Distribution Planning
Market Forecast

Engineering Models Support

Planning & Scheduling
Market
Demand
Forecasting

Distribution & Exchange Plan

Refinery
Production targets

Refinery Planning

Production Plan

Production Schedule

Sales History
Market Forecast

Accounting
(SAP)

Actualised
movements

Refinery
Scheduling

Primary Distribution Scheduling

(depot inventory management)

Retail Demand
(by terminal)

Batch
nomination
Batch
confirmation

Scheduled Movements
to/from Refineries

Process Unit
Set-points

Blend
Scheduling
& optimisation

Blend recipes

Deals

Trading

Secondary
Distribution
Scheduling

Pipeline
simulation &
scheduling

2010 Aspen Technology, Inc. All rights reserved

Advanced Process Control

Example: A Recent IPSC Project

HQ
MOG
KPC Int Mktg

Ref MAA, MAB, SHU

Refinery
1
MAA

Refinery
MAB 2

Refinery
SHU 3

Shutdown
Days (3)

Demand,
Prices (1)

1. Mid-Term
Planning

XPIMS

Demand (2)

2. Short-Term
Planning

Sales, Target Inventory (4)

Global Targets: Sales, IRT, Capacity Inventory to Local Plan (10)
Plan Data

XPIMS

Aggregated
Demand (8)

IRT

Plan Data

PPIMS

Plan Data

PPIMS

Aggregated
Demand (8)

PPIMS

Aggregated
Demand (8)

IRT (5)

Global Orion

PIMS to Orion
(11)

Inventory
Projections (9)

Inventory
Projections (9)

PIMS to Orion
(11)

Reuters, Platts, etc

Inventory
Projections (9)

PIMS to Orion
(11)

Finalised Feasible Shipments to Local Orion (7)

3. Refinery
Scheduling

Component & Product Prices (14)

DSS

Local
ORION/MBO

Supply Program
KPC Supply Ops

Local
ORION/MBO

Local
ORION/MBO

Shares Same DataBase

Published
Schedule (13)

Published
Schedule (13)

Orion Imports (12)

Published
Schedule (13)

Orion Imports (12)

Orion Imports (12)

Shipment Events (Vol, Prd, Dem, etc)

4. Operations
Execution

AtOMS
KPC Supply Ops

From IP.21:
process and lab
data

From IP.21:
process and lab
data

Nominations

Tank Info,
Products, Units

Tank and
Vessel
Movements
Data

Nominations

From IP.21:
process and lab
data

AtOMS

Tank and
Vessel
Movements
Data

Tank Info,
Products, Units

AtOMS

Tank and
Vessel
Movements
Data

Tank Info,
Products, Units

Line of Pallots

5. Production Accounting

Advisor
Data Loading

6. Operational Performance
Management

PS

EM

RBV

ODM

From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data

RefSys
To Oracle
Financials

From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data

Reconciled
Data
From IP.21: lab
data

Stream flows &

Qualities from
IP21

Advisor

Stream flows &

Qualities from
IP21

PSMA

From IP.21: lab

data

Reconciled
Data

RefSys

PSMA

2010 Aspen Technology, Inc. All rights reserved

10

From IP.21: lab

data

RefSys
To Oracle
Financials

To Oracle
Financials

Stream flows &

Qualities from
IP21

Advisor
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data

Reconciled
Data

PSMA

Example: A Recent IPSC Project

HQ
MOG
KPC Int Mktg

Ref MAA, MAB, SHU

Refinery
1
MAA

Refinery
MAB 2

Refinery
SHU 3

Shutdown
Days (3)

Demand,
Prices (1)

1. Mid-Term
Planning

XPIMS

Demand (2)

2. Short-Term
Planning

Sales, Target Inventory (4)

Global Targets: Sales, IRT, Capacity Inventory to Local Plan (10)
Plan Data

XPIMS

Aggregated
Demand (8)

IRT

Plan Data

PPIMS

Plan Data

PPIMS

Aggregated
Demand (8)

PPIMS

Aggregated
Demand (8)

IRT (5)

Global Orion

Engineering Support for Planning

and Scheduling is built into this project
PIMS to Orion
(11)

Inventory
Projections (9)

Inventory
Projections (9)

PIMS to Orion
(11)

Reuters, Platts, etc

Inventory
Projections (9)

PIMS to Orion
(11)

Finalised Feasible Shipments to Local Orion (7)

3. Refinery
Scheduling

Component & Product Prices (14)

DSS

Local
ORION/MBO

Supply Program
KPC Supply Ops

Local
ORION/MBO

Local
ORION/MBO

Shares Same DataBase

Published
Schedule (13)

Published
Schedule (13)

Orion Imports (12)

Published
Schedule (13)

Orion Imports (12)

Orion Imports (12)

Shipment Events (Vol, Prd, Dem, etc)

4. Operations
Execution

AtOMS
KPC Supply Ops

From IP.21:
process and lab
data

From IP.21:
process and lab
data

Nominations

Tank Info,
Products, Units

Tank and
Vessel
Movements
Data

Nominations

From IP.21:
process and lab
data

AtOMS

Tank and
Vessel
Movements
Data

Tank Info,
Products, Units

AtOMS

Tank and
Vessel
Movements
Data

Tank Info,
Products, Units

Line of Pallots

5. Production Accounting

Advisor
Data Loading

6. Operational Performance
Management

PS

EM

RBV

ODM

From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data

RefSys
To Oracle
Financials

From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data

Reconciled
Data
From IP.21: lab
data

Stream flows &

Qualities from
IP21

Advisor

Stream flows &

Qualities from
IP21

PSMA

From IP.21: lab

data

Reconciled
Data

RefSys

PSMA

2010 Aspen Technology, Inc. All rights reserved

11

From IP.21: lab

data

RefSys
To Oracle
Financials

To Oracle
Financials

Stream flows &

Qualities from
IP21

Advisor
From IP.21:
process and lab
data such as
flows, temp,
pressure, level,
inventory data

Reconciled
Data

PSMA

Refinery Plant Data enters IPSC via the

Engineering Models (see terms next slide)
To IPSC

Simplified Models
to Aspen PIMS &
Scheduler

Aspen RefSYS Flowsheets

Engineering Models for
Planning and Scheduling Support with
Data Reconciliation and Calibration

ASW Link

ASW
On Demand
Manual Data
Collection

AOD
Real Time 24/7
Automatic Data
Collection

RTO
Real Time 24/7 Automatic
Data Collection
APC
DMCplus

Real Time Data Base (IP.21, PI, PHD)

Plant DCS
2010 Aspen Technology, Inc. All rights reserved

12

From IPSC

Plant Targets
(APC setpoints)

Planning and Scheduling Support Workflows

Start with Aspen RefSYS*
Aspen PIMS and
Aspen Petroleum Scheduler

Workflow 1

Assay Tables for

Crude Distillation

LP Submodels
for Reactors

Excel

Excel

Case Study/Excel or
Swing Cut Utility

Case Study/Excel or
PIMS Support Utility

Aspen RefSYS Flowsheets

* The new name for Aspen RefSYS is Aspen HYSYS Petroleum Refining
2010 Aspen Technology, Inc. All rights reserved

14

Workflow 2

Planning and Scheduling Support Workflows

with PIMS to Petroleum Scheduler Integration
Aspen Petroleum
Scheduler

Aspen Petroleum
Scheduler

Workflow 3
V7.3 Utilities

SMC file transfer

Aspen PIMS

Workflow 1

Workflow 4

Aspen PIMS

Assay Tables for

Crude Distillation

LP Submodels
for Reactors

Excel

Excel

Case Study/Excel or
Swing Cut Utility

Case Study/Excel or
PIMS Support Utility

Aspen RefSYS
Flowsheets
2010 Aspen Technology, Inc. All rights reserved

15

Workflow 2

Engineering Support for Planning & Scheduling

Key activities

Crude Assay Distillation Tables

Reactor Submodel Updates

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16

Crude Assay Management

Challenge

Impact
Challenge

Characterizing
each crudes
properties and
composition is
time consuming

Errors can have

significant impact
on simulation
results

Blending crudes
into a single
feedstock
complicates setting
operational targets

Improved crude oil

blending to increase
accuracy and reduce
simulation times

Lost opportunity
crude oils

Solution

Lost Margins

Higher margins
Exploit opportunity feedstocks
and improve operating plans

2010 Aspen Technology, Inc. All rights reserved

17

What is Crude Oil Characterization?

Crude oil characterization converts crude oil lab data into high
fidelity simulation data = Aspen RefSYS Assay
Crude oils are tested in laboratories and lab results are reported.
Lab data is converted into detailed compositions using Aspen
HYSYS/RefSYS pure and hypo components. Bulk lab data is cut
into pure and hypo components which forms an Assay.
Crude Lab Data

Hypos
36-40*
40-50*
---*
200-210*
210-220*
----*
450-460*
460-480*
480-500*
----*
580-600*
600-650*
650-700*
700+*

2010 Aspen Technology, Inc. All rights reserved

18

Why is Crude Oil Characterization Important?

Petroleum refinery profit margins are under great pressure
Crude oil prices and product prices move independently
destabilizing profit margins

Feed and product costs must be well understood to protect

profit margins
Crude oil compositions must be well defined to correctly
price feed stocks and products

2010 Aspen Technology, Inc. All rights reserved

19

How does Crude Oil Characterization

Improve Profits?
Crude oil characterization data is used in three main ways:
Engineering models (Aspen HYSYS Petroleum Refining)
Planning models (Aspen PIMS)
Scheduling models (Aspen Petroleum Scheduler)

Engineering models confirm crude distillation units can

successfully process purchased crude oils
Planning models select optimal crudes oils for refinery
Scheduling models assure smooth and predictable delivery of
products

2010 Aspen Technology, Inc. All rights reserved

20

Where is Crude Oil Characterization Done?

Planning and Scheduling Support tools
Third party products

Flowsheet simulators
Aspen HYSYS Oil Manager
Aspen RefSYS MacroCut
Aspen Plus (ADA)

In house crude cutting programs

Large oil companies

2010 Aspen Technology, Inc. All rights reserved

21

Crude Oil Characterization Methods Used in

Aspen HYSYS and Aspen RefSYS
HYSYS
Oil
Manager

Lab Data:
Gravity,
Distillation,
etc.

RefSYS
Macro Cut
Input
Table
3rd party
assay managers

RefSYS
Assay
Manager

Other crude
cutting programs
RefSYS Macro Cut
Input Table
2010 Aspen Technology, Inc. All rights reserved

22

Feed
Stream
Model

Crude Oil Characterization Usage

Fractionation models re-assemble narrow range hypos
into wider range product cuts for PIMS assay tables

RefSYS cases
confirm crude
unit can
process crude

HYSYS
Oil
Manager

Lab Data:
Gravity,
Distillation,
etc.

RefSYS
Macro Cut
Input
Table

Feed
Stream
Model

HYSYS/RefSYS
Fractionation
Models

Yields
& Properties
for PIMS

3rd party
assay managers
Other crude
cutting programs

RefSYS
Assay
Manager

RefSYS Macro Cut

Input Table

Yields
& Properties
for Petroleum
Scheduler
2010 Aspen Technology, Inc. All rights reserved

23