How OTS Improve the start-up of RNEST, the newest

Petrobras Refinery. Planning, implementations difficulties,

training and attainable results

Herbert Campos Gonalves Teixeira

PETROBRAS Research and Development Center - CENPES

2014 Software Global Customer Conference - September 30 - October 2

PETROBRAS comprises
about 300 subsidiaries
Total Investments:
US$ 29 billion

PETROBRAS - AN INTEGRATED OIL AND

GAS COMPANY PRESENT IN27
COUNTRIES
15 Refineries Installed Capacity:
2.125 million bpd
Natural Gas Production:
620 thousand boe per day

Employees: 54,204

Biodiesel plants: 5
Ethanol plants: 10 plants

Net Operating Revenues

US$ 120.1 billion

Oil Production:
2.583 thousands barrels per
day (bpd) of oil and LPG
4,500 thousands barrels per
day (bpd) of oil and LPG in
2025

Gas stations: 6,485

Natural Gas Sales:

62.4 million m3/d
Wind plant: 1
Fertilizer plants: 2

Thermoelectric Energy
Plants : 15
Installed Capacity : 2,412 MW

Proved Reserves :
16.1 billion barrels of oil
and gas equivalent (boe)
Dec 2004

2014 Software Global Customer Conference - September 30 - October 2

KNOWING BETTER THE REFINERY

REFINARIA DO NORDESTE - RNEST

UFCG

11/03/2014

2014 Software Global Customer Conference - September 30 - October 2

RNEST Localization at Pernambuco.

We are constructing
five new refineries.
One in Rio de Janeiro
and four in northeast
Petrobras has a
complex of
12 refineries, a
processing shale oil
unit, Petrochemicals,
and Fertilizers plants
distributed throughout
the Brazilian territory
2014 Software Global Customer Conference - September 30 - October 2

RNEST - Overview
Investment: US$ 17,316 billion
Objective: To meet the demand of diesel in northern and
northeastern of Brazil.
Jobs in Construction: 44 000
Jobs in operation: 1500
Start of construction: September 2007
Start of operation: November 2014

2014 Software Global Customer Conference - September 30 - October 2

RNEST
Produo de 20% do Diesel
consumido
Brasilm2
Total
Area: 6,3 no
million
Capacity: 230.000 bpd
9 % of national production
Two train of 115.000 bpd each

2014 Software Global Customer Conference - September 30 - October 2

RNEST JOBS Construction Curve

2014 Software Global Customer Conference - September 30 - October 2

Pier Terminal
2014 Software Global Customer Conference - September
30 - October 2

Each train consist

of Crude
Distillation and
Vacuum Unit
(CDVU), Delay
Coke (DCU),
Hydrogen
Generation (HGU),
Naphtha HDT Unit,
Diesel HDT Unit,
2014 Software Global Customer Conference - September 30 - October 2

Utilities Units:
SNOX Unit, Acid
Sulfuric Unit,
Storage and
Transference,
CAFOR (Steam
Generation, Electric
Power Generation,
Water Treatment
System)
2014 Software Global Customer Conference - September 30 - October 2

Petrobras want to know the problems that the Oil and

Gas industries face to use dynamic simulation in plant
design, operational assessments and operator training
before we buy it.

During our refinery project phase we ask the

engineering companies how they are using
dynamic simulation
2014 Software Global Customer Conference - September 30 - October 2

Difficulties in the use of Dynamic Simulation:

We normally use static simulation for
operational evaluation because the
time to customize the dynamic
simulation
We can not guarantee that the model
is adherent to actual plant because it
is necessary to test the plant to verify
the model
We question if it is possible to have a
model that is robust enough in all
operational region to evaluate
operability,
controllability
and
rejection of disturbances of the plant
2014 Software Global Customer Conference - September 30 - October 2

We ask for dynamic simulators suppliers what are

the benefits of dynamic simulation
IOM Dynamic Simulation Suite: From Design to Training!
Validate
Design

PROCESS
DESIGN

Checkout
Controls

Train
Personnel

Improve
Performance

DCS
CONFIGURATION

INITIAL
START

PLANT
OPERATION

Although there is conflict between Suppliers and

Engineering company: the truth is out there.
2014 Software Global Customer Conference - September 30 - October 2

So Petrobras decided for a Major Automation Contract

(MAC) that include OTS
Our presentation shows, what is truth that we have found
out, and consist of:
operational
procedure

Attainable
results

Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

Train
Personnel

Improve
Performance

DCS
CONFIGURATION

INITIAL
START

PLANT
OPERATION

PROCESS
DESIGN

2014 Software Global Customer Conference - September 30 - October 2

OTS Scope of Supply Rigorous Dynamic Simulation models:

From Design to Training!
Validate
Design

PROCESS
DESIGN

Checkout
Controls

Train
Personnel

Improve
Performance

DCS
CONFIGURATION

INITIAL
START

PLANT
OPERATION

Crude and Vacuum Unit, DCU, HGU, Naphtha HDT,

Diesel HDT, SNOX Unit, Acid Sulfuric Unit, Storage
and Transference, CAFOR (Steam Generation,Electric
Power Generation, Water Treatment System)
2014 Software Global Customer Conference - September 30 - October 2

Main challenges:

Familiarize operators with the DCS interfaces

Train operators to start and stop the plant
Improve operator response in emergencies
Diagnosis, adjustment and maintenance of
process, control and instrumentation
Enable a faster plant startup and product
specification

2014 Software Global Customer Conference - September 30 - October 2

Planning for each unit:

Kickoff Meeting 3 month after Basic Engineering phase

Documentation consolidation for OTS 6 month during detail
engineering phase
Model Acceptance Test (MAT) 6 month after documentation
considated
Factory Acceptance Test (FAT) 6 month after MAT
Site Acceptance Test (SAT) 2 month after FAT or 6 month
before startup

Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

Learning Lessons:

Basic Engineering has enough information for beginning the

model
It is necessary intermediate milestone for model verification
before MAT
It is possible with adequate tools to retune the Model with
information of consolidated documentation different from basic
engineering. It increases the engineering cost but it is worthwhile
and it is important for robustness of model
The model integration to DCS and SIS take more time than we
plan. It is necessary to develop tools to improve DCS and PES
integration
Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

Learning Lessons:

Delay in DCS and SIS configuration results in delay in OTS

DCS/SIS integration phase
During FAT, we find inconsistency on both system: OTS model
and DCS/SIS configuration
Remember, the work never finish. Until the plant startup, we will
find necessaries modifications on model and DCS/SIS
configuration and system integration. Train your own team and
include this task in MAC cost because you need OTS integration
team until the plant startup

Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

Learning Lessons:

It is necessary to have a pedagogical team to prepare the

operator training. Engineers are not the best people to deal with
this task.
Didactic material is a very important for operator training

Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

Benefits already experienced:

Identifies errors of safety, control and automation logic

Checks for configuration errors
Verify instruments ranges and size
Tune the control loops adequately and realistically
Recognize controllers interactions and controller
strategy misconception

Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

We train the operator

using the concept of
Independent Protection
Layers (IPLs)
by IEC-61511
IPLs are often depicted as an
onion skin.
Each layer is independent in
terms of operation.
The failure of one layer does
not affect the next.

RESPONSE
Plant and Community Emergency Response
LIMITATION
Deluge systems, fire sprinklers, toxic gas detection,
alarms, emergency shutdown systems
BARRIERS
Explosion barriers, Barricades, Dikes
MITIGATIVE
Pressure Relief Valves, Vacuum Breakers,
Flame arrestors, Rupture Disks
PREVENTIVE
Safety Instrumented Systems
Safety-related alarms, other protective systems
and alarms (economic and catastrophic
environmental)
SUPERVISORY
Critical alarms, operator response,
and operator supervision
CONTROL
Basic Process Control Systems
Process alarms, Operating Procedures
I

INHERENTLY SAFER

2014 Software Global Customer Conference - September 30 - October 2

The concept of Independent Protection Layers (IPLs) by

IEC-61511
Pedagogical methods elaborated

Automatic
Control
and
impact of manual operation.
Alarm procedures.
Safety system failure impact.

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

The actual behavior of OTS comes with rigorous

Dynsim tune with the correct parameters of each
equipment

2014 Software Global Customer Conference - September 30 - October 2

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All startup procedure of each equipment shall be

exhaustively trained, mainly if they high level of
automation

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

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All equipment is checked for oversizing in all

operational conditions (startup, minimum to
maximum operation point)

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

2014 Software Global Customer Conference - September 30 - October 2

All operator was trained in all API-520 scenario and

risk that have been identified during Hazop.

2014 Software Global Customer Conference - September 30 - October 2

Results:

Each operational procedures has been verified.

Reduce significantly the number of error of DCS and
SIS configuration
Time consuming for loop test was 25% of the schedule
plan.
Product specification in a short time avoid intermediate
storage inventory and reprocessing. Estimate gain U$ 5
million only for CDU.
Decrease the expected number of trip.
Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

Conclusions and Petrobras truth:

Dynamic Simulation is consolidated technology that

shall be used in the complete lifecycle of new plant
project
As more rigorous, more result is attainable
Take the necessary time in the model development.
It is necessary and it is possible to have more and
better tools to configure and tune the model to
decrease engineer cost of model phase

Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2

Conclusions and Petrobras truth:

It is possible to decrease DCS/SIS configuration cost

when use dynamic Simulation.
With proper tools, we can use dynamic simulations
during design phase to decrease capital and operational
cost of our project.
Dynamic Simulation elevates the safety analysis to a
more important and impressive level.
OTS needs more than dynamic simulation. A
pedagogical preparation deeply enhance the results.
Planning

Implementation
difficulties

Validate
Design

Checkout
Controls

PROCESS
DESIGN

DCS
CONFIGURATION

operational procedure

Attainable
results

Train
Personnel

Improve
Performance

INITIAL
START

PLANT
OPERATION

2014 Software Global Customer Conference - September 30 - October 2