DR (Data Reconciliation)

System Upgrade Case Studies

Based on information submitted to the Inlibra User Group by Yeochun NCC and Honam Petrochemical.
 CustomerUpgrades

Li t f I lib
ListofInlibracustomerimplementationsandupgradesfromotherproducts:
t i l t ti d d f th d t

SKCorp.(formerYukong)refinery Korea,1998
NamhaeChemical(fertilizerplant) Korea,1998
GSCaltexRefinery(formerLGCaltexRefinery)
GS C l R fi (f LG C l R fi ) Korea,1999
K 1999
SKEvertech(formerSKOXYChemicals,petrochemical) Korea,2000
KOGAS(LNG) Korea,2000
HonamPetrochemical
H P t h i l Korea,2003
K 2003 Sigmafine to Inlibra
SigmafinetoInlibra
SamsungTotalPetrochemical Korea,2004
QingdaoPetrochemical China,2005
YeochunNCCPetrochemical
Yeochun NCC Petrochemical Korea,2005
Korea 2005 Sigmafine to Inlibra
SigmafinetoInlibra
SKIncheonRefinery Korea,2005 SigmafinetoInlibra

LGChemicals(Daesanplant) Korea,2005
LotteDaesanPetrochemical
Lotte Daesan Petrochemical Korea,2006
Korea 2006
LGPetrochemical Korea,2006
KPPetrochemical Korea,2007
SamnamPetrochemical
Samnam Petrochemical Korea,2009
Korea 2009 Sigmafine to Inlibra
SigmafinetoInlibra

TherearenolongeranyactiveSigmafineusersleftinKorea,thebirthplaceofInlibra.
UpgradeCaseStudy 1.YeochunNCC

PRO_DR:ProductionDRSystem

StreamMassBalanceDR
HydrocarbonMassBalanceDR
UtilityMassBalanceDR
FuelGasMassBalanceDR
PlantMassBalanceDR
Tank
D il /10Mi U d t
Daily/10Min.Update Inventory
DailyTotalUpdate
PIS OIS
(PI) (Oracle)
E
EventBase
B LIMS
EventBase DailyBase

NPT_DR:NaphthaDRSystem UNIT_DR:UnitProcessDRSystem

SourceNaphthaMonitoring Prod.DRUPGRADE
Feeding&YieldMonitoring TotalProcessDRModeling
TankCompositionUpdate TankInventoryandCompositionMonitoring
SourceNaphthaYieldPrediction
Source Naphtha Yield Prediction ActualYieldEvaluation
Actual Yield Evaluation
 Upgrade Case Study 1. Yeochun NCC

Improvements Results

Detecting gross errors Increased work efficiency, shortened data validation time

Multiple Period Reconciliation capability Shortened by 80% the execution time by allowing running daily DR for
whole month
Multi-User Support Increased usability by permitting sharing DR data by multiple users.

Integration of DR data into one database Contributed to work efficiency improvement of 50%

Adding inter-model connection capability Contributed to work efficiency improvement of 50%

Connection capability within one model Work efficiency increased, data validation time shortened

Third party system interfaces Efficiency increased, users gained ability to configure new interfaces.

DR execution performance Contributed to shortening work time by 50%.

Logical Stream capability Work efficiency increased, data usability increased

Ability to access earlier periods data from current Work efficiency increased and data validation time shortened.
period windows
Trending capability Work efficiency increased and data validation time shortened.

Retention of sufficient precision (3 decimals) to permit Eliminated manual steps.

exact balance for Accounting
Performance improved when changing Current Period Contributed to shortening work time by 50%.

Model Summary feature Work efficiency increased and data validation time shortened.

Final evaluation Considering improvements in work efficiency, data validation,

execution speed, overall work time shortened 50%.
 Upgrade Case Study 1. Yeochun NCC

Upgrade

H/C Model Summary after

pg
upgrade to Inlibra
Hydrocarbon Model
(Sigmafine)

A significant reduction in
visual complexity using
Summary Models and
Logical Streams New Fuel Balance Model
Upgrade Case Study 1. Yeochun NCC

Interactive Model Communication

Multi-Period Reconciliation

Trending and Evaluation

Upgrade Case Study 1. Yeochun NCC

Easy Plant Summary

Multi-User and DB Integration

RTDB & RDB Interface

 Upgrade Case Study 1. Yeochun NCC

TANK YARD : Total

T t l Tank
T k Inventory
I t and
d Product
P d t Balance
B l Monitoring
M it i
 Upgrade Case Study 1. Yeochun NCC

PLANT SUMMARY : Mass Balance Monitoring by Plant

 UpgradeCaseStudy 2.HonamPetrochemical

DR I l
DRImplementationHistory
t ti Hi t
.2003Q3 :DR(DataReconciliation)started
Sigmafine(OSIsoft)purchased
g ( )p
.2004Q1 :DRsysteminitiated
ERP&PISGoLive~
.2005Q3(JunetoAug) :DRsystemupgradeinitiated
ReplacedwithInlibra(seenextslideforadvantagesgained)
.2005Q4:NewDRsystem(Inlibra)initiated
StandardizedasdailyERPproductionbalancetool
UpgradeCaseStudy 2.HonamPetrochemical

Advantages Realized

Sigmafine
g Inlibra
FileDBsharingandrevisionlimited,script RDB(RelationalDB)andGUIusage,data
method. sharedandrevisionpossibleregardlessof
Directrevisionimpossiblewithscriptcoding. numberofusers.
RevisionandquerypossiblyonePC,one
user.

DRexecutionandqueryonlypossibleon DRexecutionandquerypossibleformultiple
dailybasis.Workhoursincreaseatmonth days.Efficiencyincreasedformonthend.
end.

Trendsupportmissing.DRerrorscanonlybe Trendingofmultipleperiodssupported.DR
examinedonaonedaybasis.
Configurationdiagramapproach:Entire
plantbuiltinonelargeflowdiagram.Each
subareadrawnintinydetail.
errorscanbeanalyzedonamultidaybasis
byviewingmeasuredandreconciledvalue
trends
trends.
Configurationdiagramapproach:Model
eachpartofplantseparatelyandusemodel
connectors.Increasedefficiencyandeaseof
confirmingbalance.
g
 UpgradeCaseStudy 2.HonamPetrochemical

P
ProcessFlow
Fl
Dailyproductionbalanceclosingprocedure(usingInlibraDR)
Inlibrausedformaterialbalancereconciliationofrawflowmeterdata

(BusinessInformation
(Business Information
Warehouse) Step1
Step5
BW DCS
(DistributeControlSys)
ERP DailyProduction
y RTDB
(EnterpriseResourcePlanning) (RealTimeDataBase)
Closing
Step4

PIS Step2
((PlantInformation
l f i DR
System)
(DataReconciliation)

Step3
InlibraDR
UpgradeCaseStudy 2.HonamPetrochemical

Daily production balance closing procedure (using Inlibra DR)

Dailyproductionbalanceclosingprocedure(usingInlibraDR)
1
DCS DistributeControlSystem

Flowmeter
Flow meter
Unbalanced,rawflowmeterdata
Flowmeter
fromtheDCSisthemajorinputto
Flowmeter theprocedure.
Flowmeter
Flowmeter

Step1 Interface

2 RealTimeDataBase

DCSdatainoneminutesnapshot
intervalsisretrievedfromthe
realtimedatabase.
 UpgradeCaseStudy 2.HonamPetrochemical

InlibraDR Step2 Interface

3
RealTimeDataBase
DRSystem(Inlibra) 4 DRSystem(Inlibra) 5 DRSystem(Inlibra)

NaphthaTrackingexecution(CT) Basedonprocesschange, Performdailyorperiodbased

Foreachtank,Naphtha confirmorrevisepropertiesof DR.
Densityisusedtocalculate eachstream(e.g.designvalues
mass (MT) from volume
mass(MT)fromvolume. like temp press )
liketemp.,press.)
 Upgrade Case Study 2.HonamPetrochemical

InlibraDR

6
DRSystem(Inlibra) DRSystem(Inlibra) DRSystem(Inlibra)

Confirmmainproductsyields Confirmreceiptandshipment Confirmingredientbalance

fromDRresults(Summary discrepancy(ReceiptSaleModel) discrepancy(BalanceModel)
Model)
UpgradeCaseStudy 2.HonamPetrochemical

St 3
Step3 Interface

7 PlantInformationSystem

AfterconfirmingDRresultsforeach
plant,transferbalancedatatoERP.
(GR/GIvalues=GoodsReceipts,GoodsIssued)

MonomerPlant:GR/GI
Monomer Plant : GR/GI
PolymerPlant:GI

Step4
p Interface

8 ERP(SAP)

FinalizeGR/GIperproductionorder
andperformunitcostcalculation
UpgradeCaseStudy 2.HonamPetrochemical

Step5 Interface

9 BW BusinessInformationWarehouse

Collectiondatafromthe
BW
(Business productiondatacube(PIS&ERP
Information Data)andproducereports
Warehouse)

Future Project
FutureProject Interface

10 EIS ExecutiveInformationSystem
<Future Project>
<FutureProject>
DailyBaseexecutiveinformation
EIS systemplannedfor2007.
ImplementRTE concept
 Upgrade Case Study 2.HonamPetrochemical

Inlibra graphics example

Inlibragraphics

NaphthaTracking
UpgradeCaseStudy 2.HonamPetrochemical

Confirm/revise
designvalues
 UpgradeCaseStudy 2.HonamPetrochemical

DRexecution
UpgradeCaseStudy 2.HonamPetrochemical

Result
validationafter
DRbalance