The client site encompasses both a refinery and a chemical plant. The refinery is a major site in the Southern USA with approximately 340 MBPD. The site utilizes pipeline, railcar, and marine transportation methods to receive and ship hydrocarbons. Trindent was asked to evaluate the Hydrocarbon Loss Control Program and identify sources for hydrocarbon mass gain and volatility.
29%
REDUCTION IN MASS BALANCE FLUCTUATION
$18,400,000
ANNUALIZED SAVINGS
490%
RETURN ON INVESTMENT
HOW WE MADE IT HAPPEN
Meter Measurements
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Installed a robust meter measurement program which tracks leading and lagging indicators through Meter Factor Control Charts (MFCC), prioritizes witnessing schedule based on errors and stream value, and escalates meter errors utilizing a three-layer process including field corrections, regression analysis, and contract related adjustments.
Marine Variance
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Increased witnessing of marine observation by 700% without any additional FTE, improving the marine variance to 0.14% — a 5x improvement from baseline — while bringing the witnessing program at Deer Park in line with competitors.
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Provided marine movement dashboards to track KPI at each dock and inspection company by refinery and chemical plant, providing not only awareness of the marine performance, but also a process to reduce, and if necessary, escalate variances.
Inventory Measurement
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Increased the accuracy of the coke inventory calculation by changing the sampling location while improving the turnaround time required to meet end of month closing, directly impacting the hydrocarbon mass balance volatility.
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Increased inventory mass accuracy through the development of tools and process changes to calculate more accurate API gravities, reducing errors in the hydrocarbon mass balance.
S&W Accuracy
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Introduced Karl Fischer testing on pipeline crude, saving $735k in COGS through unaccounted water, impacting both mass balance and bottom line.