Applying Sigmafine in Oil & Gas – Downstream
The refining world is facing challenges due to the uncertainty of oil prices, new fuel specifications, and limited investments, all of which put pressure on existing capacities. To overcome these challenges, oil and gas refineries must use resources carefully and make informed decisions in planning and operations. Data availability is not enough; that data must also be consistent and accurate to empower strategic decision making. To achieve data accuracy and consistency, major refineries around the world are implementing Sigmafine, a single production accounting platform used by financial accounting, operations departments, planning and logistics.
Sigmafine is state-of-the-art data validation and reconciliation software that relates raw process data, material transactions, and business data in one model constrained by first principles equations. The result is a refined, consistent, and accurate set of data that supports informed decision processes. In addition, refineries are using Sigmafine to drive daily business, account for material, report inventory, and integrate with ERP and business intelligence to support corporate governance.
Production and Yield Accounting
Sigmafine is used daily in refineries with many production units, multiple tank farms, and thousands of flow meters to deliver accurate production and yield accounting. Sigmafine supports accountants by identifying inconsistencies, bad values, and gross errors. By including multiple source of information (historicized data, laboratory data, external inputs) in a single integrated environment, Sigmafine empowers accountants with a single source of truth, letting them spend time analyzing the causes of deviations rather than entering data into a system.
Accurately monitoring energy-intensive equipment is critical to improving usage and decreasing emissions. Sigmafine provides KPIs based on reconciled data, solving mass and energy balances within the plant and for monitored equipment, including furnaces, relevant heat exchangers, and big rotating equipment supported by rigorous thermodynamic modeling. Those KPIs are available on dashboards to enable operators and engineers to quickly take action and save energy. Moreover, since data are historicized and fully auditable, Sigmafine supports energy managers’ duties in complying with energy directives and standards such as ISO 50001:2011.
Supporting Planning and Operations
Knowledge about crude or intermediate inventories’ material quantity is crucial for better planning and yield estimation (e.g. evaluating mixtures feeding the units and optimizing inventory allocation). Sigmafine’s composition tracking analysis supports planning departments with up-to-date material allocation estimates.
Quality tracking analysis provides an additional estimate of the physical properties of mixtures (e.g. density, viscosity, flash point, and sulphur content) that are stored in inventories or fed to the process units. Operations can monitor properties and choose better routing to improve mixture characteristics and minimize out-of-spec semi-finished or finished products. This reporting empowers planning to better allocate inventory based on mixture properties.
- Production and yield accounting
- Composition and quality tracking of crude and semi-finished materials
- Movement management
- Energy management and emissions monitoring
Integrating Sigmafine with SAP
Sigmafine comes with an integration framework component, allowing data to interface with external systems, including SAP. The most common SAP modules integrated with Sigmafine are:
- PPPI: Post reconciled figures of productions, consumptions, and losses compared with planned/business figures
- SD: Download inbound raw material receipts and outbound final product shipments from SAP
- WM/MM: Align physical or logical SAP inventories with Sigmafine inventories
The Benefits of Improved Data Quality
Improved data quality in the oil and gas refinery industry is primarily associated with:
- Validating and automating production accounting
- Validating auditable estimates of raw materials, intermediates, and product inventories
- Validating KPIs for improved process control and system optimization
The Business Impact of Implementing Sigmafine
Customers who have implemented Sigmafine have achieved:
- Daily production accounting automation
- Equipment & site-wide performance monitoring
- Yield accounting
- Loss monitoring
- Results distribution throughout the organization
- Improved production planning and logistics
Sigmafine References in Refining
Customer: Hunt Refining Company
Abstract: Learn how Hunt Refining used Sigmafine’s mass balance and integration framework to perform accurate refinery performance KPIs automatically.
Used for: Yield accounting and loss control/systems integration
Benefit: Automatic plant/production/yield accounting and inventory; systems integration; corrected refinery performance calculation; automatic daily monitoring of meters, process units, and refinery performanceLearn More
Customer: Iplom Refinery
Abstract: Are you experiencing difficulties determining refinery yields due to frequent changes in crude campaigns? Download this Iplom presentation to learn how Sigmafine supported real-time plant performance KPIs, automatic campaign aggregation, and refinery dissemination.
Used for: Performance monitoring, real-time validated KPIs, and an adaptive digital model
Benefit: Gasoil-diesel yield improvement of 1%, or a 230 barrel 7-day increase in capacityLearn More
Customer: MOL - Slovnaft Refinery
Abstract: MOL, a Hungarian conglomerate, uses Sigmafine at Slovnaft Refinery to automatically improve the quality of process data used for financial accounting. The solution is unified to confirm the site and business perspective, scalable, transparent, and auditable with web based enterprise reporting.
Used for: Production accounting, loss management accounting, and enterprise reporting
Benefit: Reduction in effort; systematic loss identification and quantification; consistent, enterprise-wide accountingLearn More