Promise of Digital Transformation • Agile and flexible • Synchronized business and plant systems • Supply chain synchronization • Optimized operations based on real- time economics • Highly integrated operations and maintenance • Autonomous operations • Nearly unmanned operation, intervention by exception • Connected, networked, access anywhere • Predictive and prescriptive alerts • Right information, content, context • Safe, Secure and Clean 0 100 200 300 400 500 1950 1960 1970 1980 1990 2000 2010 2020 2030 Control loops per operator Digital Control Systems IIoT
Digital Transformation Challenges of Digital Transformation Information is not readily available, lack of mobile and cloud support Existing systems are poorly integrated, information islands Lack of digital vision and strategy, uncoordinated initiatives Sub-optimal business processes with limited automation Uncoordinated initiatives, lack of cross functional teams and collaboration $ Limited and unclear return on investment
Agency for Natural Recourses and Energy, Feb. 2014 Reducing Crude Cost and Energy Cost, and Increasing Operation Efficiency are Immediately Required Japan Refining Industry Example Moving Direction : Increasing Operation efficiency at Plant Japan Refineries are less efficiency due to 1) Less capacity 2) High operation cost to Compare to Korea Refineries Delta of Operation cost to Korea, $2.78/BBL is consist $1.54/BBL of Maintenance cost and Energy cost. It is mandatory required to reduce the cost of maintenance and energy by increasing operation efficiency. Japan Refineries average operation cost is $2.78/BBL high to Korea There is the difference on Maintenance and Energy cost Others Other than Maintenance Maintenance Energy Difference between J23 & K Difference between J5 & K
5 Road to Operational Excellence Operational Excellence is a multi-year journey Vulnerable Accepting Structured Disciplined Innovative Strategic Intent Risk Minimization Reliable Profitability Quality/LEAN Production Maximise Asset Value Business Growth Operational Design Process Integration Performance Optimisation Managed Performance Business Process Focus on Basics
7 Supply Chain Optimization Asset Operations and Optimization Operational Risk Management Asset Management and Integrity Key areas for Operational Excellence Transformation Digital Technologies Safe, Reliable and Profitable Operations
Synaptic Business Automation Portfolio IT OT Business & Domain Knowledge Sensing & Measurement Control & Monitoring Planning & Accounting Modeling & Simulation Big Data & Analytics Cloud & Edge Computing Maintain License to Operate Increase Margins Optimize Capital Usage Integrated Performance Management (Synaptic Performance Indicators)
Solution Portfolio Simulation and Modeling Data Analysis Performance Dashboard Operational Excellence Profit improvement by subject matter ISA LEVEL 4 Business planning & logistics ISA LEVEL 3 Production operation management ISA LEVEL 2 Manufacturing control Enterprise Resource Planning (SAP) Trading and Planning System Operations Management Asset Performance Analytics Supply Chain Scheduling Production Accounting Analyzer Maintenance Asset Maintenance Mgmt Energy and Utility Systems Off-site & Terminal Management Data Historian Laboratory Information Management System Unit Performance Assurance Process simulation Advanced thermodynamics Refinery Reactors Pipeline networks and flow assurance Flare System Optimization Cyber Security Industrial Networking Control & safety system (DCS & SIS, SCADA, PLC) ISA LEVEL 1 Field Sensors Blend Ratio Control Process Analyzer Field Instruments Process Control Base Layer PID Tuning APC/RTO Advanced Regulatory Controls Combustion Optimization Field Device Maintenance Plant Security Operations Safety Production/Supply Chain Energy Asset Multifunctional Plant Lifecyle Mgmt Master Plan Study Pre-FEED Dynamic simulation Oil Movement Control Downtime Analysis Terminal Automation Movement Monitoring Modular Procedural Automation Override Safety Advisor Alarm Management Safety Function Monitoring Workflow Management Sequence of Events Recorder Alarm Reporting and Analysis Alarm Master Database Permit to Work Management of Change Incident Management Work Instructions Shift Handover Logbook Mobility Energy Real-Time Optimizer Energy Monitor Energy Multi-period Planning PETRO Risk Prediction Asset Performance Mgmt Cloud-based Energy Mgmt Utility System Simulation Heat Exchanger Monitoring Heat Exchanger Sys Opt. Blend Property Optimization OTS Equipment Sizing and Costing
System Workflow integration Provided by Supply Chain Management Integration Example ERP/ SAP Production Planning • Tank Inventory Management • Movement Management • Ship loading/ unloading Offsite DCS (ATG, SLMS) Onsite DCS Historian Data Base Tank Inventory/ Transaction LIMS Process Value and Lab Data (density etc.) Data Reconciliation Mass Balancing Plant Model Movement/Inventory Gap Analysis Movement /Inventory Transaction Record Planning & Scheduling Report for production Movement Mass balance, Accounting Oil Movement System Production Accounting Production Monitoring Feedstock Supply Production Scheduling Product Off Take Scheduling Data Input of Plant availability, Scheduling and Operation Management Production Execution DCS HMI OPC Server Production Instruction report Production Process Production Monthly Plan Tank Inventory Baseline Production Accounting System Real time measurement Lab data Confirmed Sales/ Purchase Order Movement work Instruction Real time loading /unloading quantity Tank inventory & properties Operation Information System KPI Dashboard Manual Entry (unit capacity, etc.) Missing movement Process Value Workflow Composer VP Production Supervisor Co-pilot VM-PA VM-SCS PETRO Yokogawa oil Movement System Yokogawa DCS CENTUM Exaquantum/PIMS Lab-Aid Supply Chain Optimization Asset Operations and Optimization Operational Risk Management Asset Management and Integrity Platform for Advanced Control and Estimator
Asset Operations and Optimization APC Onsite DCS Dynamic RTO Plant Data Historian Unit Online Gain Generator & Optimizer Production/Offsite Scheduler Plant Wide Monthly Plan Offline Case Study Simulation Refinery Reactors KBC RXs-SIM Olefin-SIM AROM-SIM Offline Dynamic Simulation Daily Base Plant Wide Optimizer Automated Data Connection Semi-Automated Data Connection This Function will fill the gap between Scheduler and actual operation including economical optimization Monthly Base Planning Target Semi-Optimized Scheduler Target for Operation LP Shift Vector Generation for Planning and Scheduler model Petro-SIM PETRO VM-SCS Platform for Advanced Control and Estimator Petro-SIM Petro-SIM Petro-SIM Dynamic Plant Wide Optimized Scheduler Target Exaquantum/PIMS CENTUM Supply Chain Optimization Asset Operations and Optimization Operational Risk Management Asset Management and Integrity Platform for Advanced Control and Estimator
Operational Risk Management Data-driven plant operation model for shift team excellence Shift handover, operations logbook, operator instructions and Field Mobile Process Data Analytics Alarm management Operator decision support Work instructions Procedural automation Incident/near miss management Control room design OTS • Model Broker • Petro-SIM Operations Management/SH Process Data Analysis Exaquantum/SER Exaquantum/ARA Exaquantum/AMD Advanced Operator Graphics Exapilot Operations Management/WI OmegaLand OTS Operations Management/IM Control Room Design Supply Chain Optimization Asset Operations and Optimization Operational Risk Management Asset Management and Integrity
15 Operations Management (Daily Operation Execution) Work Instruction Operations Management Shift Handover Operation Log Permit to work Incident Management Management of Change Production Scheduling System Shift Supervisor Ops. Task Dispatch Panel Operator Task Exec Record Result Operation Log PIMS Alarm Critical Alarm Log Key process params LIMS Quality Data 3rd Party Database Other data During shift operation During Handover Create Instruction for action Operations Management Supply Chain Optimization Asset Operations and Optimization Operational Risk Management Asset Management and Integrity
16 Operations Management (Process Safety Management) Work Instruction Shift Handover Operation Log Permit to work Incident Management Management of Change CMMS Panel OP Mnt. Mgr. Work Order Mnt. Technician Mnt. Request Mnt. Notification Status update Status update Technician Shift Supervisor Engineer Technician Raise Review Approve Complete e.g. Permit to Work business process Report Investigat e Implemen t Validate Closure Plant personnel Technician HSE team HSE team HSE Manager e.g. Incident Mgmt. business process MOC also has similar process Operations Management Operations Management eServ Supply Chain Optimization Asset Operations and Optimization Operational Risk Management Asset Management and Integrity
Synaptic Business Automation underlies a process of co-innovation and collaboration with customers that leverages Yokogawa’s domain knowledge and digital automation technologies to create sustainable value.
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