Docstoc

suncor2

Document Sample
suncor2 Powered By Docstoc
					Oil Sands - Upgrading
Synthetic Crude
     - Mix of Naphtha, Kerosene, Gas Oils




                                            2
 Industry Projected Oil Sands Production
  Millions of barrels per day                                5 Million + bpd
      5



      4



      3



      2



      1



      0
             2004
                       $$$  2006   2010   2015        2020               2030
                                                 Source:CAPP, RIWG, Alberta Chamber of Resources



But.........., that’s a lot less than World Consumption of >100 Mbpd!!
Natural Gas – Produce more than we use
Suncor’s Production/Value Chain




   Vision
   1/2 million barrels per day
Market Access




Existing
Proposed
(new or expanded)




                    6
Sarnia Refinery – 70,000 bpd
(Sarnia, ON)
• gasoline, kerosene, jet, diesel, asphalt, petrochemical feedstocks
• industrial, commercial, retail markets (85,000 bpd products)
Sunoco Retail / Wholesale
Network in Ontario




 Suncor’s Sunoco branded retail network is separate and unrelated to Sunoco, Inc. in the United States
   Sunoco in the United States is operated by Sunoco Inc. of Philadelphia, PA.
Commerce City Refinery – 90,000 bpd
(Denver, CO)

• Acquired CoP 2003; Valero 2005
• gasoline, jet, diesel, asphalt
• industrial, commercial, retail
Phillips 66® Retail
Network in Denver




 * Suncor Energy (U.S.A.) Inc. is an authorized licensee of the Phillips 66 brand and marks in the state of Colorado.
Suncor’s Integrated Production
Renewable, Sustainable Energy ...

• Emergence of ‘both/and’ instead of ‘either/or’ approach
• Early entry into the Wind Energy business
• Entry into the Ethanol business
Suncor’s Renewable Energy – Ethanol
     (Sarnia, ON)
   • Canada's largest ethanol plant
   • 200 million liters/year
   • Offsets 300,000 tonnes of CO2 annually
   • Investigating new Biofuel opportunities
   • Plans to build #2
Suncor’s Renewable Energy - Wind
     (AB, SA, ON)
 • Four wind farms = 147 MW
 • Offsets 284,000 tonnes of CO2 annually
Suncor’s Growth Projects

       Project          When            Production

   Millennium               2004        260,000 bpd
   Cornerstone (ERP)        2006      Business Processes
   Genesis / Odyssey        2006       DeSulfurization
   Ethanol                  2006        200 M liters/yr
   Coker / Extraction       2008
   Firebag 3 (Insitu)       2009       350,000 bpd
   Firebag 4,5,6
   Voyageur (UG3)
                           2010
                            to 2012     550,000 bpd
   Ethanol #2               ??          400 M liters/yr
So, Why am I telling you all this.........???


Ask yourself.............., In Your Company:


      What Generates the Wealth?
                        How? Who?

       Suncor’s Wealth Generation Chain:
Just Doing It is no longer enough...


                   Facility Efficiency



                                         Reliability Based
                                          Maintenance
         Initial Capital
        Expenditure for
       Plant Equipment

                                                  Value to customer is          Efficiency
                                                  area between curves           Threshold




                                             Preventive and
                                          Reactive Maintenance


                CAPEX            OPEX                                    Time

               Driving to Operational Excellence
Why the Conflict with IT... ??
     - Inherent, Fundamental Differences ...

                             IT       Manufacturing
Priority is different ...
          System & Data Integrity     SAFETY – Human & Plant
Security is different ...
   Protect the (central) System       Protect the End Device
Environment is different ...
    Response Not Time Critical        MUST work in Real Time
System Management is different ...
      Easy to (centrally) Manage      NO Disruptions/Failures
Expertise is different ...
           Understand Computers       Understand The Plant
Role is different ...
                Enable the Business   Create the Wealth
   Service Oriented Architecture ...

 reusable services
tightly aligned with
business processes




  data wrappers
   around API’s
                                       (courtesy of Chevron)
Back in the 1970’s ...




                         (courtesy of Chevron)
Integrated ... YET Separate ...
                                                        Enterprise Network

                                 WAN                                         Enterprise
                                 Router


                                                  Site Business Network      Site Business Planning
                                FW
    Production     Optimizing                   Process
     Control        Control
                                 DMZ            Historian
                                                                 Process     Site Manufacturing Operations
                                                          Control Network
                                  FW
   Supervisory                            Supervisory
     Control                                Control
                            Operator                    Operator             Area Supervisory Control
                            Interface                   Interface



    Batch        Discrete                   Continuous        Process
    Control      Control                     Control         Monitoring      Basic Process Control



                                                                             Field Instrumentation
The Process



                               Protective
                                System                                       Safety – Critical


                                                                                             (courtesy of Chevron)
How to Integrate Plant/Machinery to ERP?

                   Enterprise Business Systems
                Enterprise Resource Planning (ERP)



                       BIG

                                                     Maintenance
   Operations




                        ??
                       GAP
                      Physical Asset Control
                       Real-time Systems
A Direct Interface Approach to Data Exchange
within the Enterprise .....
                     Production Management                    Enterprise Management
                     Historian System                  Data                    Financial
                                                                       Data     System
                      Reconciliation System            Data            Data   HR System

                      Maintenance System               Data                   Production
                                                                       Data    System
                      Engineering CAD/CAE Systems      Data
                                                                              Documents
                                                                       Data    System
                      Document Management              Data
                                                                              Procedures
                                                                       Data     System
                       Lab Information Management      Data
                                                                               Planning
                                                                       Data    System
                      Process Modeling Systems         Data

                       Planning and Dispatch Systems Data              Data EHS System

                                                                              Maintenance
                     Environmental Monitoring System   Data            Data     System
            –   System Stability And Reliability Issues
                                                                       Data Supply System
            –   No Single Version Of The Truth
            –   System Maintenance Issues
            –   Difficult Access To Multiple Systems/Applications

      Don’t want to do this anymore….!!!
                                                                     (courtesy of Emerson Process Management)
A Data Warehouse Approach to Data Exchange
within the Enterprise
                                                             Enterprise Management
                                                                                   Financial
                 Production Management                                     Data     System

                                                                           Data   HR System
                  Historian System                 Data
                                                                                  Production
                  Reconciliation System            Data                    Data    System
                  Maintenance System               Data                           Documents
                                                                           Data    System
                   Engineering CAD/CAE Systems     Data
                                                            Data                  Procedures
                  Document Management              Data   Warehouse        Data     System

                   Lab Information Management      Data                            Planning
                                                                           Data    System
                  Process Modeling Systems         Data
                                                                           Data EHS System
                   Planning and Dispatch Systems Data
                                                                                  Maintenance
                                                                           Data     System
                 Environmental Monitoring System   Data


         – No Single Version Of The Truth                                  Data Supply System

         – Single Point Of Failure
         – Difficult Access To Multiple Systems

   – Don’t want to do this either…..
                                                                      (courtesy of Emerson Process Management)
A Coordinated Approach to Full Integration
within the Enterprise

                                                                                                     Integration Platform




                                                                                                                                               Admin Advanced
      Historian System                                             Data
                                                                                                   Process-modeling & optimization

      Reconciliation System                                        Data                                        Workflow
                                                                                                  Pre-packaged Adaptors/ Connectors

      Maintenance System                                           Data




                                                                              Message Transport
                                                                                                      Encryption, Audit, Security
                                                                                                       Adapter Development Kit
      Engineering CAD/CAE Systems                                  Data                               Integration Administration
                                                                                                    Message Routing & Brokering
      Document Management                                          Data




                                                                                                                                               Basic
                                                                                                    Data Mapping & Transformation
                                                                                                       Message Transportation
      Lab Information Management                                   Data

      Process Modeling Systems                                     Data                                                      Data Index
                                                                                                                             Financial
                                                                                                                             HR
      Planning and Dispatch Systems                                Data                              Analysis Tools          Production
                                                                                                                             Documents
                                                                                                                             Procedures
                                                                                                     Spreadsheets            Planning
      Environmental Monitoring System                               Data                                                     EHS
                                                                                                                             Maintenance
                                                                                                        “Portals”            Supply
• “Adapters” are listeners that integrate a given system to the integration
   platform making it “visible” to the enterprise.                                                  (courtesy of Emerson Process Management)
BP’s eRTIS Project – Application Integration



 User Access



                                                           Portal
 Environment                   Applications       Functions         Process         Data Web
 & Applications                                                     Graphics        Services


 Data Mgmt                                    Open O&M Data Model
                                                                                                             Ideally
 Data Interfaces        Web Service               Web Service   Web Service    Web Service   Web Service   application
                                                                                                            provides
                                                                                                           Open O&M
 Legacy Systems        LIMS           Historian     SAP           EAM            etc…           RDMS       compatible
                                                                                                              Web
                                                                                                            Service
 Controls                               DCS                                   PLC

                                                                                                            (courtesy of BP)
 Equipment & Devices
                                          Valves, Equipment, Analysers, …
      bp data model map
              Plant Lifecycle
                Engineering              Procurement         Construction                   Operation                      Capability

                                        Piping Specs.                                                                   Spare Parts Lists
Materials         Material                                                                Crude Assays
                                        Material Master      Tool Catalog                                               Stores Inventory
Model           Specifications                                                               MSDS
                                           Catalog                                                                       Reliability Data



                                                                                                                    Maintenance Procedures
Equipment                                                                            Operations Procedures
                                                              As-installed                                                  Job plans
Model          Vendor Catalogs           Bill of Material                        Equipment & Alarm Configuration
                                                            Equipment Data                                           As maintained eqpt. data
                                                                                      Operating Envelopes
                                                                                                                    As operated reliability data



Personnel         Vendor &
Model                                                          Contracted                                             Trade skills register
                 Engineering           Service Contracts    Services Contracts        Operator Unit knowledge       Root Cause Analysis Data
                  Contracts



                                                                                                                          Work requests
                                                                                            Shift roster                    TAR plans
                   Design                                    Construction                   Daily plans                    PM program
Plant Model                            Purchase Requests                                                               Inspection schedule
                Requirements                                  Schedule                  Stock progressions
                                                                                            Price sets                 Maintenance roster
                                                                                                                        Equipt. Calibration
                                                                                                                    Equipt. Capability Forecast



                                                                                 Tag Monitoring Locations Process
                                                                                                Data                       TAR reports
                                                                                        Tank inventories             Fault data w Op Params
Actuals          Calculations           Purchase Orders     As-built P&ID’s                 Lab results                Component tracking
Model           Project P&ID’s              Invoices        HAZOP minutes                  Bill of Lading               Inspection records
                                                                                                                       Work Order History
                                                                                        Transfer Advices
                                                                                                                           Work Permits
                                                                                          Operator Logs




    PISTEP
                               ISA95                 OPC            MIMOSA               ISO14224
     PIDX
                                                                                                                             (courtesy of BP)
      bp data model map
               Engineering        Procurement         Construction                  Operation                       Capability


                                 Piping Specs.                                                                   Spare Parts Lists
Materials        Material                                                          Crude Assays
                                 Material Master      Tool Catalog                                               Stores Inventory
Model          Specifications                                                         MSDS
                                    Catalog                                                                       Reliability Data



                                                                                                             Maintenance Procedures
Equipment                                                                     Operations Procedures
                                                       As-installed                                                  Job plans
Model         Vendor Catalogs     Bill of Material                        Equipment & Alarm Configuration
                                                     Equipment Data                                           As maintained eqpt. data
                                                                               Operating Envelopes
                                                                                                             As operated reliability data



Personnel        Vendor &
Model                                                   Contracted                                             Trade skills register
                Engineering     Service Contracts    Services Contracts        Operator Unit knowledge       Root Cause Analysis Data
                 Contracts



                                                                                                                   Work requests
                                                                                     Shift roster                    TAR plans
                  Design                               Construction                  Daily plans                    PM program
Plant Model                     Purchase Requests                                                               Inspection schedule
               Requirements                             Schedule                 Stock progressions
                                                                                     Price sets                 Maintenance roster
                                                                                                                 Equipt. Calibration
                                                                                                             Equipt. Capability Forecast



                                                                          Tag Monitoring Locations Process
                                                                                         Data                       TAR reports
                                                                                 Tank inventories             Fault data w Op Params
Actuals         Calculations     Purchase Orders     As-built P&ID’s                 Lab results                Component tracking
Model          Project P&ID’s        Invoices        HAZOP minutes                  Bill of Lading               Inspection records
                                                                                 Transfer Advices               Work Order History
                                                                                   Operator Logs                    Work Permits




                                           OpenO&M Standards
                                (based on MIMOSA, OPC, ISA95, etc.
                                                                                                                       (courtesy of BP)
Standards Based InterOperability ...

                   Enterprise Business Systems
                Enterprise Resource Planning (ERP)




                                                     Maintenance
   Operations




                      OpenO&M™
                              Collaboration

                     FOUNDATION



                      Physical Asset Control
                       Real-time Systems
Organizationally ...
Gartner              Business Drivers                                     Technology Response
“… the skill set of the IT department will have to change.
Technical systems generally are event-driven, or they deal
         1. Attract and retain customers
with non-textual content and operate at a real-time interval,
         2. Improve the sub-second level. Five or six "nine's"
often measured atworkforce effectiveness
         3. or greater) availability is considered the norm, and
(99.999%Build an agile and innovative organization
         4. Improve critical processes and workflows
reflects the fact that returning to functionality can have
         5. Manage tens of thousands of compliance
implications in the governance, risk and dollars per hour,
         6. the CIO to change his or her skill mix to
requiring Maximize performance, profitability and one that has     IT
            competitiveness
engineering-centric characteristics balanced with traditional IT   • Corporate Applications: ERP etc
skills.”
                                                                   • Information: Data warehouse
                                                                   • Integration: Network Infrastructure, ETL
                            Board of
                            Directors                              Automation IT
                                                                   • Operational Applications: alarm
                                                                     management, condition monitoring,
                                                                     production accounting, scheduling,
           COO                                 CIO
                                                                     performance monitoring
                                                                   • Information: events, diagnoses, material
                                                                     movements, shutdowns, logistics schedule
                                                                   • Integration: Connectivity between real-time
   Operations/Engineering                      ???                   and corporate applications; aggregation of
                                                                     data.
                                                                   Automation
                              Automation/
                            Process Control/                       • Engineering Applications: LIMS, etc
                            Instrumentation                        • Information: Measurements, real-time DB
                                                                   • Integration: OPC, Measurement Highway

                                                                              (courtesy of Matrikon)
So..., What’s Needed Now?


• Open Architecture Solution to integrate process/operational,
  maintenance & business processes/systems
• NOW (initially, by 2007..!!)
• NOT more research
• Field Proven Solution (i.e. BP’s eRTIS) – IT WORKS!!
• All software vendors to write Adapters to talk OpenO&M
• Manufacturing Industry to demand compliance to OpenO&M
  standards
• Get Involved – Lead, Follow, Support!
    Summary


• Standard-of-Living depends on Energy & Manufacturing
• Manufacturing holds the keys to Wealth Generation
• IT’s Role is to Enable the Business, Not obstruct it!
• Keep the Manufacturing and IT domains separate
• Co-Exist: Foster a healthy Collaboration (& Tension)
  between Manufacturing & IT
• Collaborate & Integrate, rather than Converge
• Integrate the Business and Manufacturing through
  Standards Based InterOperability
Mending Wall – Robert L. Frost (1874-1963)

SOMETHING there is that doesn’t love a wall,       He is all pine and I am apple orchard.
That sends the frozen-ground-swell under it,       My apple trees will never get across
And spills the upper boulders in the sun;          And eat the cones under his pines, I tell him.
And makes gaps even two can pass abreast.          He only says,
The work of hunters is another thing:              “Good fences make good neighbours.”
I have come after them and made repair             Spring is the mischief in me, and I wonder
Where they have left not one stone on a stone,     If I could put a notion in his head:
But they would have the rabbit out of hiding,      “Why do they make good neighbours? Isn’t it
To please the yelping dogs. The gaps I mean,       Where there are cows? But here there are no
No one has seen them made or heard them            cows.
      made,                                        Before I built a wall I’d ask to know
But at spring mending-time we find them there.     What I was walling in or walling out,
I let my neighbour know beyond the hill;           And to whom I was like to give offence.
And on a day we meet to walk the line              Something there is that doesn’t love a wall,
And set the wall between us once again.            That wants it down.” I could say “Elves” to him,
We keep the wall between us as we go.              But it’s not elves exactly, and I’d rather
To each the boulders that have fallen to each.     He said it for himself. I see him there
And some are loaves and some so nearly balls       Bringing a stone grasped firmly by the top
We have to use a spell to make them balance:       In each hand, like an old-stone savage armed.
“Stay where you are until our backs are turned!”   He moves in darkness as it seems to me,
We wear our fingers rough with handling them.      Not of woods only and the shade of trees.
Oh, just another kind of out-door game,            He will not go behind his father’s saying,
One on a side. It comes to little more:            And he likes having thought of it so well
There where it is we do not need the wall:         He says again,
                                                   “Good fences make good neighbours.”
                         “Good Fences Make Good
                                  Neighbors”
                           (Mending Wall by Robert Frost)

                                Cliff Pedersen
                                       (just retired)
                                  Suncor Energy Inc.
Standards
Certification
Education & Training
Publishing                   Manufacturing IT Forum
Conferences & Exhibits
                                     Cleveland Ohio
                                     20-21 May 2008
For More Information ...

Websites
• www.openoandm.org
• www.mimosa.org

ISA Expo 2008 – Oct. 14-16, 2008 / Houston TX
    (Demo in the exhibit area)

IMC (International Maintenance Conference)
    Dec. 8-11, 2008 / Bonita Springs, FL


Oil Sands: Oil Sands Global Market Potential 2008, Market Research Reports
http://www.researchandmarkets.com/product/6cb54b/oil_sands_global_mar
    ket_potential_2008


                          Phone: (919) 549-8411
                   E-mail Address: info@isa.org
Thank You

 Cliff Pedersen


 CliffPedersen@sympatico.ca
         519-542-3021
Questions and Discussion ...
For More Information ...
     cliffpedersen@sympatico.ca (519-542-3021)

Websites
• www.openoandm.org
• www.mimosa.org

ISA Expo 2008 – Oct. 14-16, 2008 / Houston TX
    (Demo in the exhibit area)

IMC (International Maintenance Conference)
    Dec. 8-11, 2008 / Bonita Springs, FL



Oil Sands: Oil Sands Global Market Potential 2008, Market Research Reports
http://www.researchandmarkets.com/product/6cb54b/oil_sands_global_mar
    ket_potential_2008



                          Phone: (919) 549-8411
                   E-mail Address: info@isa.org

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:13
posted:5/19/2012
language:
pages:38