Data validation & reconciliation in Oil & Gas Refineries
Applying Sigmafine in Oil & Gas - Downstream
Refining world is facing challenges of uncertain oil price in the foreseeable future, new fuel specifications, limited investments which puts pressure on the existing capacity. The capability of efficiently using existing resources requires more careful decisions both in planning and in operations. Availability is not enough for data driven decisions: consistency and accuracy are imperative requirements to achieve better sensitivity and judgment: data quality matters! The implementation of Sigmafine has fulfilled our customers’ vision: The implementation of a single platform for production accounting tool to be used by financial accounting, operational departments and planning & logistic.
Sigmafine, the state-of-the-art data validation and reconciliation software, puts in relation raw process data, material transactions and business data in one model constrained by first principles equations, to get a refined set of consistent and more accurate information to support your decisional process.
Sigmafine is currently used in major refineries worldwide to drive the daily business, material accounting, inventory reporting, integration with ERP and business intelligence till supporting corporate governance.
Production and Yield Accounting
Sigmafine is daily used in production and yield accounting of refineries with many production units, tank farms and thousands of flow meters.
Sigmafine supports the daily work of the accountant in identifying inconsistencies, bad values or gross errors. By including multiple source of information (historicized data, laboratory data, external inputs) in one single integrated environment, empowers accountants to get one version of the truth, spending time in analyzing cause of deviations rather than data entry into a system.
Accurate monitoring of energy intensive equipment is critical to improve usage and decrease emissions. Sigmafine is actively used to provide KPIs based on reconciled data solving mass and energy balance of the plant and/or of the equipment under monitoring, such as furnaces, relevant heat exchangers or big rotating equipment supported by rigorous thermodynamic modeling.
Sigmafine KPIs are provided on dashboards to enable operators and engineers to take timely 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 of crude or intermediate inventories in terms of material quantity is crucial for better planning and yield estimation (evaluate mixtures feeding the units, optimize inventory allocation, etc.).
Sigmafine composition tracking analysis supports the planning department with up-to-date estimation of material allocation.
A further step is the quality tracking analysis that provides in addition an estimation of physical properties of mixtures (e.g. density, viscosity, flash point, Sulphur content etc.), stored in inventories or fed to the process units. Operations can monitor the properties and choose better routing to improve mixture characteristics and minimize out-of-spec semi-finished or finished products and planning decide how to better allocate the inventory based on mixture properties.
- Production and yield accounting
- Composition and quality tracking of crudes and semi-finished materials
- Movement Management
- Energy management and emission monitoring
SAP Integration Comprehensive Metallurgical Accounting
Sigmafine comes with an Integration Framework component allowing data exposing to external systems and facilitating integration with most common ERP systems, including SAP. Most common SAP modules integrated with Sigmafine are:
- PPPI: post reconciled figures of Productions, Consumptions & Losses and compare with Planned/Business figures
- SD: download from SAP inbound raw material receipts and outbound final product shipments
- WM / MM: align physical or logical SAP inventories with Sigmafine ones
Improved data quality in the Oil & Gas Refinery Industry are primarily associated with:
- Production accounting automation and validation>;
- Validated and auditable estimates of raw materials, intermediates and products inventories>;
- Validated KPIs for improved process control and optimization systems
Many customers have achieved, through the single Sigmafine implementation, automation of the daily production accounting, performance monitoring, yield accounting, loss monitoring as well as the direct connectivity and distribution of results throughout the organization this official information which are safeguarded and auditable. Additional benefits such as improvements in production planning and logistic can also be realized.
Sigmafine References in Refining
|Hunt Refining: Learn how Hunt Refining used Sigmafine mass balance and Integration framework to perform accurate refinery performance KPIs automatically||Used for yield accounting; loss control / systems integration||Automatic plant/production/yield accounting and inventory; Systems integration; corrected refinery performance calculation; automatic daily monitoring or meters, process units, refinery performance||Learn More|
|Iplom Refinery: Are you experiencing difficulties determining the refinery yields due to frequent changes in crude campaigns? Download this Iplom presentation where the single Sigmafine platform supported real time plant performance KPIs, automatic campaign aggregation and refinery dissemination.||Performance monitoring, real-time validated KPIs, adaptive digital model||Gasoil-diesel yield improvement of 1% or a 230 barrel7day increase in capacity||Learn More|
|MOL a Hungarian conglomerate uses Sigmafine, e.g. at Slovnaft Refinery, to automatically improve the process data quality used for financial accounting the solution is unified to confirm the site and business perspective, scalable, transparent, auditable with web based enterprise reporting.||Production accounting, loss management accounting, enterprise reporting.||Reduction in effort; Systematic loss identification and quantification, consistent, enterprise wide accounting||Learn More|
Marco Lanteri, Milan Office, Industry Principal for Refining