Presentation from downstream track at KBC Europe Software User Conference June 2018

1. Implementing and supporting a multi-model, multi-site software
roll-out
Refining Technology & Engineering

2. Introduction
• Provide a high level summary of the program for the deployment of Petro-SIM
and the process models within the BP refining business.
• A program born from the need and desire to standardise the process modelling
tools in use
• The detailed program covers
– Model Evaluations
– Roll-out to refineries
– Models support
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Standard,
high quality UI
KBC
reactor
models
BP IP
KBC Petrosim

3. Context
• Process Models are widely used within BP
refining business
– Process Monitoring
– Unit troubleshooting
– Project development
– What-if analysis
– Commercial tools updating and assurance
• Diverse portfolio of refineries
– Different history
– Different levels of users’ proficiency in process
modelling
– Geographic and cultural differences
– Combination of in-house and third-party
applications
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• Objective
– Single simulation platform for all refineries
– Standard refining simulation process models
– Establish a common operating model
– Improve efficiency
– Utilise resources more effectively to support and
sustain the use of the process modelling tools
3

4. Expected Value
• Preserve current level of benefits brought by process modelling
• Improve efficiency and capabilities within the process modelling team and across
the refineries
• Shift focus of the modelling resources team to the creation of additional value
• Enable modelling and optimization of larger refinery systems and entire
refineries
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SustainabilityValueEfficiency

5. Program Outline
• Vendor Selection
– Evaluation of several vendor platforms
– Selected Petro-SIM for a detailed evaluation and Pilot study
• Phased Process Models Roll-out to all BP refineries
– Detailed Evaluation of each process model against documented requirements gathered
from current users and process experts. This included comparison against pilot plant data,
well accepted internal models and commercial units
– Roll-out to refineries
• Ongoing Support
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201920152014 2016 20182017
Platforms Evaluation Models Roll-out

6. Operating Model
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IT
Central Process Modelling Team
Site Model Owner
Site Model User
KBC Support
HardwareandLicensingsupport
ProcessModellingcompetence
andcapabilitydevelopment
CENTRALBUSINESS
KBC
HW and licensing
support
Central Engineering Team
Software
Hardware
Build and Maintain
model
How we use the model
Consumers of tools
and information

7. Roles and responsibilities
• Central Teams
– Process Modelling
 Configures and deploy the process models
 Drive the use of the process models
 Provide process modelling expertise throughout BP refining
– Engineering
 Establish best practices for unit performance test
 Support sites to close data quality gaps
 Use the models as part of their role
– IT
 SW distribution
 Computer support (installation and licenses issues, HW and SW issues)
 Support model database
• Refineries
– Site leadership
 Drives model adoption across refinery
– Site model owners
 Ensures accuracy of mass balance and other process data
 Keep model up to date
– Site model users
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8. Process Model Evaluation
Before being rolled-out each process model is subject to a detailed evaluation to
ensure it is fit for purpose and that its roll-out does not result in performances
“back-sliding” compared to existing tools.
• Detailed evaluation of each process model against:
– Functional Design Specification
– Pilot Plant Data
– Commercial Unit data
– Existing modelling tools in use
• Gaps identification
– Gaps are identified, documented and prioritised
– Regular meetings are held with KBC during the evaluation to discuss the identified gaps, to
work towards a resolution or to identify temporary workarounds
– Critical gaps prevent the model from being rolled-out
• Gaps resolution
– Work closely with KBC to close gaps and roll out updated models via most appropriate
channels (e.g. hot fixes, service Packs, inclusion in software development path)
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9. Roll-out to refineries
Standard work process for model roll-
out to refineries
• Data Collection
• Model configuration and calibration
• Users training
• Model hand-over to users
• User acceptance process
• Model support
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10. Process Model Structure
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Excel Model Interface
• Designed and supported
by PM Central Team
• Used For
• Unit monitoring
• Activity Tracking
• LP Generation
• Troubleshooting
• Used by
• Majority of model
Users
Flowsheet Base Case
• Configured and tuned by
PM central team and
Model owner
• Used For
• Detailed Tuning
• H&M balance
• Equipment and What-
if studies
• Used by
• Expert users
• Project Users
Model Inputs
Model Inputs
Model Outputs

11. Main Deliverables
• Petro-SIM simulation platform for general simulation processes
• Configured and calibrated models
• Excel model interface and integration with data work-up tool for data transfer
between data historian and KBC workbook
• Capability for using models
• Integrated support from RTE & IT&S
• Database for calibrations sharing
– Long term deliverable not included in the initial roll-out
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12. User Acceptance Criteria
Each delivered process model goes through an acceptance process which covers
several criteria:
• Data quality and data handling functionalities
• Model configuration
– Does the model represent all the required equipment, streams, properties, operating
conditions?
– Are operating modes represented?
• Model performance
– Products yields and products qualities vs. plant data
– Reactor performance vs. plant data
– Catalyst/unit performance tracking
– Step-out case against key process variables
• Model robustness
• Once accepted the model is owned by the refinery and is the single tool for all
use cases
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13. Model Life
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ModelOwner
CentralPM
teamModelUser
Model
Update
Needed
Configuration
update
(if required)
Data Selection
for calibration
Model
Calibration
Model
Published
Download
New model
Initiate
regular
model
assuranc
e
process
Review
model
performance
Model Fit
for
purpose?
KBC
Document
gaps due to
bugs or model
development
Review
bugs/model
improvements
Agree timeline
for fixes and
improvements
Agree timeline
for fixes and
improvements
No

14. Program Management
• BP-KBC monthly and weekly meeting
– Review status of open items for reactor models and Petro-SIM
– Review status of development activities
– Short-term resolution (Service Pack)
– Future releases
• Regular BP-KBC meeting during evaluation of each process model
• Regular BP internal meetings
– Track and report program progress
– Coordinate model rollout plans against (ever-changing) refinery time & resource constraints
– Stakeholder and management communication
• Weekly meetings between Process Modelling Engineers and Site Process
Engineers throughout model roll-out
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15. Successes to date
• Several models rolled-out to the refineries after successful evaluation
• Models rolled out so far well received by users
• Excel interface appreciated for its ease of configuration and flexibility
• Very positive relationship established with KBC to address gaps resolutions, bug
fixes, and general support during model implementation
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16. Challenges
• Work process often perceived by new users as complex
• Some non-standard unit configurations required customization of the Base case
and workbook
• For complex units speed of execution can be an issue
• Tuning of ULSD mode for DHTR-Sim complex
• Some Process model in their current state haven’t passed the evaluation phase
and will be re-evaluated in new releases
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17. Questions?
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