- 1. Process improvements. By having real-time situational awareness, operators and engineers are able to resolve issues before they become large, expensive problems. These include
- • Detecting issues that increase variance in actual production rates versus planned targets; then correcting those issues, some of which included correlation analysis, process improvements, and optimizing distributed control system (DCS) control loops. This resulted in just over a 0.5% gain in barrels of oil produced.
- 2. Increased operating margins through reductions in refinery operating-related expenses by transitioning from a calendar-based to a condition-based or run-time-based maintenance program in which the EIDI monitors real-time equipment performance.
Averting replacement of new equipment because of improved maintenance practices frees up capital for other refinery investments. The team estimates the following savings:
- • Increased equipment availability, with an expected uptime of more than 98%. Online calculations will immediately identify assets that are not performing adequately, require checking, need repairs, or are taken out of service. Based on experiences at the South Texas refinery, the increased equipment availability reduced operating costs by 6% annually.
- • Total lost production resulting from lack of equipment availability is estimated at $35 million annually, based on previous experiences at the South Texas refinery.
- • By avoiding unscheduled equipment failures, maintenance expenses and associated labor costs are estimated to decrease at each facility by 4% annually, based on South Texas refinery savings.
- • By having the EIDI identify the assets most prone to failure, budgeting will become much more data driven, resulting in more accurate methods of deploying capital to replace or repair critical assets. The expected savings is 6% per year in each refinery/ plant's maintenance budget.
- • Major outages will be able to be flexibly scheduled, based on market conditions, rather than by rigid scheduling or equipment failures. The South Texas refinery found this resulted in 1% annual revenue growth.
3. Reduced operational expenditures (ОРЕХ) through energy savings.
Having real-time visibility to energy consumption will enable the following:
- • Track actual energy costs for each barrel of energy produced.
- • Identify which assets are consuming the most energy or excessive energy and correcting the underlying problems.
- • Reduce steam traps caused by broken pipes, tubes, vessels, and so forth.
- • Reduce compressor energy usage caused by equipment fouling, water contamination, and so on.
- • The expected reduction in energy costs per refinery/plant is 4% per year.
- • In addition, the validation of fuel and utility custody transfers (gas, power) is estimated to save 1% per year.
- 4. Increased margins through supply chain savings. Directly integrating real-time production and operations data into the corporate software system will have the following expected outcomes:
- • Tracking raw material and energy consumption in that system, making it available for accounting personnel
- • Transmitting equipment status to the corporate maintenance system so that the work-order process is much more efficient
- 5. Reduced ОРЕХ through improved management, technical staff productivity, and reduced travel costs. Division managers, vice presidents, knowledge workers, and others will have real-time visibility into their fleet operations from dashboards accessible from desktop or mobile devices. Knowledge workers will reduce their time spent collecting data from disparate siloed systems by 20% to 25%. In addition, engineers, research and design (R&D) personnel, and others would not need to travel to the sites to diagnose and fix problems. The estimated travel cost savings per facility is $100,000 annually.
- 6. ОРЕХ savings through reduced cost of EIDI deployment.
The South Texas refinery created an asset database with hierarchical object templates. These asset templates contain online calculation and notification alert capability. By reusing these templates, much of the EIDI configuration time for each site can be reduced by 40%.
7. Reduce capital expenditure (CAPEX) and ОРЕХ through decreased software costs for new use cases. Some new analysis use cases may occur where it is more feasible to place similar data into a separate EIDI system, such as monitoring condenser performance for the entire fleet. With the EIDI asset template capability, new asset databases can be generated very quickly. In addition, actual plant data is replicated to a new EIDI in near real time. Using a separate EIDI is beneficial in cases where software development or significant data retrieval queries are needed, so as not to compromise the performance of actual plant control networks.