IT for Refinery Operational Support

1
IT for Refinery Operational Support
Mike Brooks Global Refining, CIS
2
manufacturing model
Enterprise Network
Enterprise
WAN Router
Site Business Planning
Site Business Network
Process Historian
Optimizing Control
Production Control
Site Manufacturing Operations
Process Control Network
Supervisory Control
Supervisory Control
Area Supervisory Control
Operator Interface
Operator Interface
Discrete Control
Batch Control
Process Monitoring
Continuous Control
Basic Process Control
Field Instrumentation
The Process
Safety Critical
Protective System
3
Architecture for Refinery Real-time Interoperable
Systems
ARRIS
uniform.consistent.dependable.coherent.compatibl
e.congruous.constant
4
introduction to Chevron

• 2nd largest US integrated energy co.
• 59,000 Employees
• 2.5 mbpd production
• Operates in 180 Countries
• 2 mbpd in 21 refineries
• 26,500 fuels retail outlets

5
Chevron refining
Wholly Owned
JVs / Partnerships
Edmonton 30 - 13 mbpd
Pembroke Wales 220
Europort, Netherlands 30 - 400 mbpd
Burnaby 55
Richmond 245
Yosu, Korea 50 650 mbpd
Salt Lake 45
El Segundo 260
Karachi, Pakistan 12 50 mbpd
Pascagoula 325
Kalpolei 54
Port-o-PrinceMartinique 12 16.7mbpd
Map ta Phut, Thailand 32
130 mbpd
Abidjan, Ivory Coast 4 60 mbpd
Singapore 50 - 285 mbpd
Hamaca Venzuala 30 - 180 mbpd
Mombasa, Kenya 16 - 87.5mbpd
Lytton 50
230 mbpd (combined)

Kernell 50
Capetown, South Africa 105
Whangerai NZ - 13 100 mbpd
6
the refining business is about

• Health, Safety, Environment
• Reliability Utilization
• Improving value
• Optimizing
• Making the right decisions
• See capture opportunities

Wheres IT architecture ???
7
if you build it he will come

• Not an intrinsic technology problem!

8
technology follows
9
the flow of information
10
value of information flow
Independent business units

• ST, Marketing, Refining must be aligned

• Joint decisions to make, buy, supply

• Shared information about market needs, equipment
  manufacturing capability

11
architecture value opportunities
Within the refinery
Across all 8 refineries
Up down the value chain
12
current
Logs Reports
Accounting
LAB
Planning
Reliability
Trading
Management
Maintenance
Control
Historian
13
creating new value from existing systems

• To reach our goals needs
• user collaboration
• services interoperation
• Far more intimately
• thru the site(s) supply-chain

14
create value across refineries

• Best-in-class refineries
• Globalthe same everywhere
• Lower support costs
• shared training
• remote support
• Faster benefit capture
• common apps. roll-out
• consistency

15
create increased value in the supply chain
Produce
Deliver
Refine
Deliver
Retail
Pump
16
value-creating examples

• Transient opportunities
• Accept run a spot crude? Where, for most
  value, in an integrated energy company?
• Intermediate tradingWhy should we take cargo of
  alkylate? Room in the tank? Or why should we
  sell a tank?
• If equipment fails, what other decisions maximize
  profit?

17
go back to basics to expose new value

• Usersprimary/secondary
• Applicationswhat should they do?
• Dataownershipwhere do you find ithow you will
  use it

• The cornerstone is a single coherent
  data management policy

18
support work processes

• Architectural challenge to deliver to everybody
• Supporting applications must be specific to
  roles
• Primary users its their job 8 hours/day
• Casual users important, but not critical
• Applications belong to primary users

Asset management
Because it can doesnt mean we should !!
Control System
19
5 big interoperability issues

• Data Ownership
• Name Services
• Directory Services
• Metadata
• Connections

20
data ownership

• Source, System of Record
• ownership of definition, structure, content
• An application does work on data
• custodian of some data
• an application cannot own all data it uses
• All replicated data needs scrutiny
• Uncontrolled Replication is BAD

21
names metadata

• Each value has a unique label
• (point) tags, (relational) entityattribute
• Data now crosses boundaries it matters
• Names must be unique, explicit, clear
• cannot rename all data
• Need controller of Master Data
• common taxonomy where names are mapped into a
  shared model e.g., OpenOM

22
current
Logs Reports
Accounting
LAB
Planning
Reliability
Trading
Management
Maintenance
Control
Historian
23
connections
24
data context and integrity
Picture of Jack Nicholson Goes here
You want the truth, you cant handle the truth
Be careful with the truth everybodys truth is
not the same !!
25
data context and integrity

• Point data Tagname Tag PIC101PV
• The foundation context VTQ
• Atomic, intrinsic, inviolate, not optional
• Additional contextual info
• Shift, Week, Month, Campaign, Batch
• Intersection with relational systems
• Must propagate VTQ
• Complex remote networks
• Critical as functions descend

26
work process requirements

• Use cases are a MUST
• Nobody navigates or cares about multiple
  systems
• No big application solution
• All data in 1 system not workable
• Orchestration outside the applications
• Drive work behavior from events
• Publish/subscribe, ad hoc, escalation

... the goal is not to fit the worker to an
imposed process
27
(No Transcript)
28
arris

• Collaborative work processes enabled by, but
  separated from the IT underpinnings
• Secures data within primary systems
• Provides easy data exchange and sharing
• Users find information easily without knowledge
  of where it is stored

29
learn from the past

• Great architectures occurred in the past
• Failed because
• Cannot easily change
• Proprietary pieces, all hand-carved

Standards ? Agility
30
bp data model map
Capability
Operation
Construction
Procurement
Engineering
Material Specifications
Piping Specs. Material Master Catalog
Tool Catalog
Materials Model
Crude Assays MSDS
Spare Parts Lists Stores InventoryReliability
Data
Maintenance Procedures Job plans As maintained
eqpt. data As operated reliability data
Operations Procedures Equipment Alarm
Configuration Operating Envelopes
Equipment Model
Vendor Catalogs
Bill of Material
As-installed Equipment Data
Trade skills register Root Cause Analysis Data
Contracted Services Contracts
Personnel Model
Vendor Engineering Contracts
Operator Unit knowledge
Service Contracts
Work requests TAR plans PM program Inspection
schedule Maintenance roster Equipt.
Calibration Equipt. Capability Forecast
Shift roster Daily plans Stock progressions
Price sets
Design Requirements
Purchase Requests
Construction Schedule
Plant Model
Tag Monitoring Locations Process Data Tank
inventories Lab results Bill of Lading
Transfer Advices Operator Logs
TAR reports Fault data w Op Params Component
tracking Inspection records Work Order History
Work Permits
Calculations Project PIDs
Purchase Orders Invoices
As-built PIDs HAZOP minutes
Actuals Model
31
bp data model map
Capability
Operation
Construction
Procurement
Engineering
Material Specifications
Piping Specs. Material Master Catalog
Tool Catalog
Materials Model
Crude Assays MSDS
Spare Parts Lists Stores InventoryReliability
Data
Maintenance Procedures Job plans As maintained
eqpt. data As operated reliability data
Operations Procedures Equipment Alarm
Configuration Operating Envelopes
Equipment Model
Vendor Catalogs
Bill of Material
As-installed Equipment Data
Trade skills register Root Cause Analysis Data
Contracted Services Contracts
Personnel Model
Vendor Engineering Contracts
Operator Unit knowledge
Service Contracts
Work requests TAR plans PM program Inspection
schedule Maintenance roster Equipt.
Calibration Equipt. Capability Forecast
Shift roster Daily plans Stock progressions
Price sets
Design Requirements
Purchase Requests
Construction Schedule
Plant Model
Tag Monitoring Locations Process Data Tank
inventories Lab results Bill of Lading
Transfer Advices Operator Logs
TAR reports Fault data w Op Params Component
tracking Inspection records Work Order History
Work Permits
Calculations Project PIDs
Purchase Orders Invoices
As-built PIDs HAZOP minutes
Actuals Model
OpenOM Standards (based on MIMOSA, OPC, ISA95,
etc.
32
draft ISO 18435 diagram
Resources Material / Personnel
Assets Equipment / Facilities / Serialized
Components Sensors / Software / Documents
33
integration evolution
Database Centric
Point-to-Point
Message Bus
RdB
Message-Based InfoBus

• Distributed Scales
• Event-Driven
• Impact on IT
• Transaction-based

• Replicated Data
• Latencies, synch.
• MOC Costs

• Non-scaleable
• Add/change costs

The work process is embedded in IT underpinnings
Courtesy of Dave Woll, ARC
34
distributed offers advantages, but
Remember the DCS

• Common utilities, power supply, air,
• Secure support the facilities, remote access,
  local support
• Management of change, maintenance

Technically possible practically unrealized
35
another way
IT underpinnings still strangle work processes
36
what if you could?


Loosely Coupled

• Isolates work processes
• Controls impact on IT infrastructure
• Centralized functions

37
Service-Oriented Architecture
(implemented using Web Services)

• Opportunity to remove the work process
  from the IT underpinnings

38
value condenses to three benefits
1
Lower costs Simper integration Eliminate
duplicate systems Build once leverage Time-to-ma
rket
2
New value creation Optimal decision-making at the
confluence of disparate, functionally separate
systems
3
New architecture Capable of business agility
changing business models (w/o massive IT help)
39
soa
allows decomposition of applications into
services
reusable building blocks
Reusable services enable a nimble IT
infrastructure that can adapt to meet changing
business needs
40
soa maturity model
41
the forum
42
a hub an intersection

• Exchange distribute the truth
• Content source (data, docs, drawings, reports)
• Access to single version of the truth not
  ownership of the truth
• One front door for data in/out of refinery
• Workflow via events escalation
• Respects application usage

43
a hub creates value

• At the confluence of functions
• Analysis occurs decisions get made
• Common functions reside e.g. reports
• Holds web parts from application vendors
• Capture knowledge at this intersection
• Agility quickly adapts to new needs

44
query and predictive analysis
How do we ask questions about data from multiple
systems without previously building the
questions into SQL schema ??
45
Business Continuity Plans

• More important
• Business critical
• Manage availability
• Needs resiliency
• Around systems not just CPUs

46
top IT concerns in 2000

• Benefits
• increased productivity
• competitive advantage
• reduced cost to solve problems
• Getting the most from Corporate Data
• integration of diverse databases
• tools to analyze data trends
• universal access to systems
• indexing sorting information
• unified method for searching diverse data systems
• Sandy Reid - Editorial Director INFOWorld Jan00

47
MikeBrooks_at_Chevron.com
Thank you