Introduction of S-OIL

Transcription

1 Introduction of S-OIL

2 Ⅱ. 온산공장소개 1. Location S-OIL is located at On-San national Industrial area in Ulsan, Korea. S-OIL Refinery in Ulsan, Korea Seoul (Ulsan 669 MB/D) KPIC Inchon Daesan KNOC (Inchon) Ulsan (Ulsan) ISU Poongsan M etal LS Nikko Yeosu (Yeosu) Storage Tanks (Shinwon Area) SPM (Daesan) 2

3 Ⅱ. 온산공장소개 2. View of S-OIL Area : 2.74 mil. m2 - SPM : DWT x 2ea - 9 Shipping Berths : 5,000 ~ 120,000 DWT #1/2 Jetty SPM 1 & 2 #3 Jetty #2 Aro. Complex KPIC #3 CDU #5 Facility #2 CDU LS Nikko #2 RHDS #1 Aromizer Lube #1 CDU HYC #1 Facility RFCC #1 RHDS #1 PX #2 Facility #4 Facility #3 Facility 3

4 History of S-OIL 76 Korea Iran Petroleum Co., Ltd. 80 SSangyong Oil Refining Co., Ltd., 80 #1 CDU(90MBD) Lube base oil plant 81 #2 CDU(240MBD) #1 Aro m izer(btx) 91 J/V(Saudi Aramco) #3 CDU(250MBD) S-O IL. Lt d. 11 #2 Aromatics Complex 96 BCC(Hydrocracker / #1 RHDS) 97 BCC(RFCC / VGO HDS) 97 #1 PX plant 02 BCC(#2 RHDS) 580MB/ D 669MB/ D 330MB/ D 252MB/ D 181MB/ D 1,600KTA 2,430KTA 60MB/ D 90MB/ D 790KTA 97MB/ D 900KTA 1,550KTA 28MB/ D 40MB/ D 43MB/ D 6 MB/ D 14MB/ D (Un it : b il. KRW ) (Un it : m il. USD) ,309 7,698 11,650 19,552 33,070 (As of 2012, $1 = 1,050 KRW) 3,474 8,083 12,232 20,530 34,723 4

5 Ⅱ. 온산공장소개 3. Production Process The main production process step Lube Base Oil Complex #1/2 Aromatics Complex Crude #1 /2 /3 CDU CFU LPG Naphtha Kero DSL Atmospheric Residue #1 VDU M DO HDO DAO Asphalt #2 VDU SDA Lube Plant VGO Vac. Residue Lube Base Oil / Wax VGO HDS #2RHDS #1RHDS Vacuum Gas Oil Hydrotreated Heavy Oil #2 ARO #1 ARO Naphtha ULSD Naphtha DSL RFCC Bunker-C Cracking Center Aromizate Benzene Toluene M -Xylene Heavy Aro. Hydrocracker M TBE Alkylation #2 PX #1 PX Benzene Para Xylene Benzene Para Xylene Naphtha LPG Kerosene ULSD Lube Base Oil Propylene M TBE / Alkylate LPG Gasoline Diesel LS B-C 5

6 The most competitive refining and marketing company in Asia Pacific region Sustainable profitable growth through new investment Laying the foundation for growth with strategic investment in upgrading facilities Stable growth with contribution to the local community, advanced management of safety and the environment and operational excellence 6

7 S-OIL Customized OTS Introduction

8 Background Progress Challenges and Solutions Background Increase of new employees Retirement of experienced operators Expansion of the Refinery Less opportunities for S/U & S/D Extended turnaround interval Decrease of process troubles due to enhanced reliability of facilities Increase of process complexity Increase of integration between processes for more efficient operation Training simulator is the most effective method to secure skillful workforce

9 Background Progress Challenges and Solutions Advantages of training simulator Most effective training method ( National Training Laboratories, The Learning Pyramid ) Fastest and most effective way for system familiarization Training simulator provides realistic, hands-on training of operation without any operation risk Operators can obtain various experience in a short time Training Simulator Standardized knowledge transfer Standardized knowledge transfer with systematic training programs Standardized and effective responds to various operation cases (Normal, S/U, S/D, Emergency Case)

10 Background Progress Challenges and Solutions Expected benefit Decrease number of unplanned S/D per year & Saving Loss Unplanned S/D, C/D would be reduced Efficient and Safe turn-around Profit improvement through operational excellence - According to World Oil report (2012), decrease the number of unplanned S/D is 3 times a year which result in saving loss from unplanned S/D : 2.6 mil.$ - Typical loss from operational error in the Refinery about 1.2 mil.$ <1M$ 1~3M$ 3~10M$ 10~20M$ 20~30M$ > 30M$ Global company trend Global leading companies such as ExxonMobil, Shell, Total increase application of training simulator Other domestic refineries(gsc,hdo) also introduced training simulator and increase its application Training simulator is key solution to achieve Best-in-class operational excellency

11 Background Progress Challenges and Solutions Completion of training simulator introduction Eight(8) Major Processes : #2 CDU, #2 VDU, #2 RHDS, HYC, RFCC, #3 HMP, #1 ARO, #1 PX Kick off FAT (Factory Acceptance Test) ~ Completion of Introduction ( ) Simulation Training MAT (Model Acceptance Test) ~ SAT (Site Acceptance Test) ~ ~ Operation training center Training center named as S-OIL Operation Training Center located in Welfare and Education BLDG Training center have 8 rooms and 15 trainees can be trained at a time. ( 복지교육관 )

12 Background Progress Challenges and Solutions Challenges Most Challenging and Aggressive Delivery It was very tight to deliver 8 process units within a year. Most of the 8 process units were complex ones, including Aromatics, PX, RFCC, RHDS, HYC Designed heat and material balance was not applicable due to plant expansion/modifications, so reconciled heat and material balance needed to be created Resource Arrangement Challenges For some process units, T/A schedule was overlapped with OTS project schedule, so it was very difficult to fix resource arrangement and testing schedule for S-Oil. The S-Oil project team members had to be away from plant operation for MAT/FAT activities, which were 2 weeks for each MAT and FAT of each process unit, so there was challenge for operation team in the normal operation.

13 Background Progress Challenges and Solutions Solutions Management Commitment Steering Committee from both S-Oil and Schneider Software delivery was formed in the very beginning of project execution and guided the project execution at management level Dedicated Project Manager and Project Coordinator at Project execution level Best and Consistent Resource Arrangement from S-Oil S-Oil arranged the same best resource (operators & managers) throughout the project execution, so the tests were highly effective and efficient, and both technical and project management issues were addressed timely Closely Work with Schneider Project Team Reconciled heat and material balance was firstly created in Pro/II based on actual operation data by Schneider Project Team and then validated by S-Oil before they were implemented in OTS Highly professional OTS delivery team together with excellent Korean local project management and technical support

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