Real Time Financial Analysis in Process Plants

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

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

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

4. 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.

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

6. RtPM Management Components

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

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

9. 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

10. 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

11. Real Time Financial Analysis

12. Energy Aggregation Advisory

13. Plant Wide Steam System Advisories

14. Electrical Opportunity Advisory

15. Crude Unit Capacity Opportunity Advisory

16. 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

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

18. Real Time Financial Analysis • Other Planned Improvements to EIS • Environmental Emissions Trackingand Reporting • Slow Down Tracking • Automation of Adhoc Energy Monitoring

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