Implementation of Digital Tools - Imperative for Increased Operational Excellence

Oil and Gas operators are slowly transitioning not just into processing companies but expanding into companies providing energy and energy services. Meaning a better understanding and connection between all types of assets is now more important than ever. Currently these companies are in the middle, between the legacy control systems established in the near past and the contemporary and new IIoT architectures. This journey is commonly referred to as Digital Transformation. Each company sets its own pace in these developments, however it is noticeable that the scale of digitalisation in refineries is getting bigger. Every day we can clearly see that a little more is done than previously and this is what defines the true transition from the 3^rd industrial revolution to the 4^th.

When we speak about refinery digitalisation, we have in mind the implementation of Information and Communication Technologies (ITC) and Operational Technologies (OT) architectures within the classic refinery operations and automation systems.

The implementation of such new technologies, especially during these unpredictable times is proving to be a greater challenge than what most operators would have foreseen. There are some key steps that can be performed to help, these include:

• Understanding & evaluating the current maturity of your digital assets before doing any major steps
• Laying down foundations that will cover the entire picture, at least in mid-term
• For any planned steps towards refinery digitalisation implementations or upgrades, it is highly recommended to perform a digital audit of current units and systems, as well as to define a strong digital transformation strategy, set the initial boundaries and evaluate what are the current needs, before jumping into further decisions

Turning our attention to some of the tools and solutions, which are available to producers to help improve operation in terms of production and supply chain. These include:

• Digital Twins
• Real-Time Communication Tools
• Planning Tools
• Augmented & Virtual Reality Tools
• Smart Metering & Data Validation
• Remote Inspection & Maintenance Tools
• Building Digital Culture & Cyber Security Awareness

Digital Twins

The shortest description of a digital twin can be summarised as virtual representation/clone of the physical plant’s processes, synchronised at a specified frequency and fidelity in a real-time virtual environment. The description speaks by itself, building such refinery clone requires a lot of resources as well as cross-understanding of both engineering and digital matters. However, once implemented, the digital twin system can help to optimise (and/or transform) the refinery production regimes by adapting holistic approaches and unlocking the optimal conditions to help decision-making.

In other words, the process engineers can experiment over the digital twin and provide different production scenarios in real-time, allowing better understanding of the refinery flexibility potentials. The idea behind the digital twin systems is also to record the refinery data and present it as a comparison between past and current indicators and to simulate the available production scenarios.

Real-time Communication Tools

There are two major groups of tools or services that can be identified – those that are already publicly available, and people are familiar with (e.g. Teams) and advanced tailored solutions for the specific refinery needs. The advanced solutions often come as a bundle of specially engineered software and hardware designed to work together and provide the refinery staff exactly what is needed onsite. This includes a multi-platform compatibility between computers and mobile devices. Such mobile devices have an expanded features such as end to end encrypted safety data protocols for great cyber security, increased battery capacities, rugged and hazard-proof designs, precise touch screen panels which are able to recognise tactile touch through protective glove or stylus-pens. We can mention the advanced best-case scenario, when the mobile devices can act as a barcode, QR or other industry standard code readers, allowing the production people onsite to achieve better data gathering, reporting and planning.

Planning Tools

To be efficient all modern planning tools must be well integrated within the daily refinery processes and set to provide a full and clear overview of the current refinery status and progress. The need for increased integration between the existing and new architectures is coming from the big responsibility that these systems have to manage, such as feedstock and supply chain optimisation, and production plans. Аnother compulsory feature is the ability to make future predictions based on current results and trajectories.

Reducing uncertainty and managing any refining business risks tends to be one of the major aspects to take into consideration. For example, evaluating such concerns accurately and quickly can allow better selection of optimal feedstocks and allow the refiner more time for preparation in case of potential operational changes - which in the end gives the refiner the ability to plan with more confidence.

Augmented and Virtual Reality

The Augmented (AR) and Virtual (VR) Reality environments and tools are gaining momentum, but currently, the main application of such technologies remain as a training tools. A note to make is that, the advanced digital twins can be designed in 3D models to adapt the AR and VR technologies, allowing next level of interactivity during trainings and refinery simulations.

Remote Inspection and Maintenance Tools

With the current data transfer advancements, mobile networks and the introduction of 5G, the remote inspection tools are now able to develop their full potential. We can explore three types of tools:

• Handheld Non-Destructive Testing (NDT) Method Tools
  The NDT methods are a true game changer in refinery reliability and maintenance. They are mobile, smart, sensitive and precise, providing higher resolution and in-depth analysis of installed assets and highlighting any potential issues. For example, ultra-sonic devices can recognise vibrations in rotating equipment (invisible to the naked eye), in compressors and pumps, as well as identifying pressure loss points. Another example are UV thermal cameras, which can clearly help to identify any kind of thermal losses, including the pressure ones, especially if we talk about refinery heat and steam generation.
• Ground Surface Robots and Unmanned Aerial Vehicles (UAVs, Drones)
  When there is a risk of approaching a potentially problematic production unit, it is always advisable to stay within the borders of the approved HSE protocols. Today, maintenance engineers have an extended helping hand in the shape of remotely operated robots, which reduce considerably the need of sending field engineers equipped in hazard suites to do inspections onsite. If not integrated, remote operation tools are compatible to cope with the above-mentioned handheld tools through the variety of adapter mounts. For example, a high-resolution thermal aerial image scan of a refinery can clearly identify any major weak points causing energy loses. Real-time emission analyzers can also be hooked on drones to monitor air quality in and around the refinery area, providing instant information to the refinery staff. Another example is the potential for implementation of robotic fouling removal systems in various production bottoms that tend to be problematic.

Smart Metering and Data Validation

The core refinery parameters to monitor have always been temperature, pressure, air, flow control and catalyst dosing amongst others. Allowing refinery operators to receive real-time parameters is critical to ensure normal functioning of the production processes. As an example we can look to the main refinery heat source, the fired furnaces, where the equilibrium between crude oil, fuel and air supply needs to be constantly monitored in real-time and to be kept fine-tuned in order to run on optimal mode. There is a strong connection between accurate metering and further data evaluation, so it is very important that the variety of smart sensors to be compatible with each other as well as with the refinery control system.

Build Digital Culture and Cyber Security Awareness

Last but not least, when an energy company looks to embark on the digitalisation journey, it is important to start building a digital culture and cyber security awareness within the refinery teams – and this needs to be from the very beginning. The challenges of energy digitalisation have increased the requirements for cybersecurity in technologies such as advanced algorithms, blockchain architectures, cloud computing, IIoT (IT and OT), remote robotics, VR and AR can offer tangible benefits to oil and gas companies.

The very basic golden rules of cyber security can be listed as:

• Think before opening any links from unknown and/or unrecognised sources
• Use strong passwords on your accounts and locking methods on your mobile devices
• Turn on automatic lock of your devices when placed away
• Do not connect unknow devices, especially data sensitive medias such as USB flash drives, memory cards, portable storage drives & etc.
• Ensure you have set a regular backup of your data
• Trust your IT master and follow the golden cyber security safety rules

Due to the critical aspects of each segment, cybersecurity has become a key issue to consider and invest in all industry sectors. Oil and gas companies need to focus on increasing their cyber security levels and coverage, since the implementation of digital technologies creates new access points in the industrial networks, which are vulnerable to hacker attacks if not set properly. This is notably applicable for the vertically integrated companies, which operate within the upstream, midstream, downstream and retail sectors simultaneously. The interconnected nature of the cybersecurity value chain means that the oil and gas companies’ cybersecurity is only as robust as its most vulnerable element. One of the core elements exposed to such threads are the basic communication channels and tools between junior and senior engineers from planning and production departments.

Due to the lack of in-house skills, close collaborations between IT specialists and refinery staff have been put at the top of the agenda for the coming years.