Visual MESA Production Accounting (VM-PA)

VM-PA software provides a complete state-of-theart solution for production/yield accounting and data reconciliation for the hydrocarbon and chemical process industry. It can model both the process side as well as the utility side.

Click here to learn about Visual MESA Production Accounting (VM-PA)


Key areas for Operational Excellence Transformation

Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services. We provide comprehensive solutions for business automation in all four areas using consulting and digital technology.

 

Supply Chain Optimization 

Supply Chain Management deals with satisfying customer demands by selecting the most appropriate feedstocks the plant can process efficiently, and delivering the products to the customers with maximum efficiency. Today, most of the industry SCM solutions are executed manually and/or separately. In most cases, specialized planning and software packages that have been implemented previously are not connected to other systems, such as sales and distribution and real-time production systems. As a result, the benefits of SCM are not fully realized.
 
Yokogawa's strategy to improve supply chain management starts with defining the corporate long-term strategy and aligning it with operations, maintenance and all other functions involved in the entire value chain. It includes:

Key Operational Competencies in Supply Chain Optimization

  • Term Contract Planning: Commercial and economic evaluation of long-term contract obligations
  • Supply Chain Planning: Economic optimization of the hydrocarbon supply chain for short-term, mid-term, long-term and strategic time horizons
  • Price Deck Formulation: Generate price forecasts based on optimization boundaries and time horizons for feedstock and products
  • Supply Chain Scheduling: Schedule optimized operations (process inventory and blending) over time, taking logistical constraints into account
  • Commercial Contracting: Develop and negotiate favorable and competitive contract terms for feedstocks and products
  • Inventory Management: Measure and reconcile the amount of each product made and raw materials consumed to produce an accurate material balance through production accounting and oil loss measurement

 
Yokogawa's approach to supply chain management involves digitalizing operations from supply to distribution. We then adopt the identified end-to-end optimization strategy to discover and manage all hidden costs (wastes) in the long chain. Our main objective is to find the Global Optimum to enable Just-in-Time in manufacturing and delivery for suppliers and customers, using minimum inventory and movement. 
 
By applying digital technologies onto the end-to-end process of the supply chain (manufacturing raw materials to final products and managing purchase orders to good receipts), we may be able to improve the following:

  • Customer & Supplier Experience: Deliver personalized engagement with an improved understanding of the product value directly to customers and suppliers
  • End-to-End optimization: Extend the optimization horizon using real-time information on supplier delivery and customer demand across organizations and companies involved in the long supply chain
  • Information Mobility: Enable optimal delivery and visibility by tracking personal location and activities with mobile technology
  • Predictive Insights: Anticipate demand, supply and asset requirements with better insights
  • Digital Business: Improve overall business agility and borderless collaborations by eliminating internal information silos

By combining Yokogawa’s product portfolio and KBC’s consulting services, we provide our customers best practices and domain knowledge that empower them to improve their operations, as well as a digital platform that supports such activities and initiatives. Our Operational Risk Management scope does not only cover partial improvements in the organization but also optimizations in plant operations to achieve continuously improving safety, reliability and operability.

 

·Asset Operations and Optimization
- Optimize the potential of physical assets, by pushing throughput and maximizing the production of the highest value products, whilst minimizing variable costs such as energy.
- Deliver small and large capex projects, on time and on budget, to deliver growth and meet environmental requirements.
·Operational Risk Management 
- Reliably control safety, health and environmental risk at a personal and process level. This assures the robustness required to avoid catastrophic losses.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities. 


Visual MESA Production Accounting

PA

In any plant or facility, numerous variables are regularly measured and recorded for process control and optimization. As massive volumes of data are collected from disparate devices and systems, the risk of extracting inaccurate data and making poor quality decisions increases, ultimately affecting the plant’s and company’s operational and financial performance negatively. 

A plant-wide production accounting system is the first step towards any loss control and optimization initiative. Visual Mesa Production Accounting (VM-PA) software provides a complete state-of-the-art solution for production accounting and data reconciliation, promising actionable results for both operators in the plant and decision-makers in the headquarters.

Support for data loss control initiatives in complex industrial environments

Sitewide mass balance is the basis of any loss control initiative. In one single system, VM-PA captures information from all available sources of data to provide the foundation for analysis and decision-making.

It fulfills the following loss control initiative requirements:

  • Daily sitewide water-free, mass balance collection
  • Sufficient redundancy of measurements and flows between tanks, process units, and shipment points
  • Integration of plants and processes with tank farms to eliminate mismatches
  • Tracking of material transfers and inventory reclassifications in any point of the analysis period

Detecting errors in early stages: Global Mass Balance and Components Reconciliation

VM-PA enables the users to compare the monthly LP (linear program) plan to the actual performance data for any type of plan by mass, component and energy. Data from multiple sources can be automatically reconciled and verified in one single system to enhance accuracy and reliability.

  • Powerful gross error detection algorithm: Choose between the embedded methods to minimize statistical errors for mass balance reconciliation -- traditional gross error identification method and the SEI&SC method (successive error identification and simultaneous compensation)
  • Graphical analysis: Visually alert users of errors and calculation status using color coding. Represent entities using nodes and connections
  • Scripting: Extend scope of data through scripting

Accuracy in Viewing Operations: Material Movements and Inventories

VM-PA enables the user to track various business rules, in an advanced dynamic graphical environment, from the feedstock reception to the finished products. 

VM-PA also calculates stocks, movements and meters compensation using international standards, such as API and ISO.

  • Composition Tracking: Calculate composition of a group of nodes, tanks and the transfers between them
  • Multi-product Pipeline Tracking: Using FIFO (first-in, first-out) approach, monitor the correct composition calculation in multi-product pipelines for material reception or shipments, and location of batches in a pipeline across thousands of kilometers
     

Minimize product revenue loss

Typical instruments have an accuracy limit of±2%. With VM-PA’s daily sitewide mass balance collection capability, measurement redundancies can be used to identify costly mass balance errors.

  • Improve maintenance program: Systematically analyze plant measurement errors and custody transfer points to improve operating procedures 
  • Infer tank inventory from level and strapping table
  • Balance monetization: Express the balance results in economic terms (price per mass unit)
     

Access Complete and Validated Information: Integrate with ERP and Planning Systems

VM-PA integrates with the Plant Information Management Systems (PIMS) and Enterprise Resource Planning Systems seamlessly through standard protocols and files. Inventories, movements and other related data can be collected, distributed and stored for the entire enterprise.

Production Accounting System

With an integrated web environment, users can process, store and connect massive volumes of data anytime, from anywhere in a secure manner.

  • Permissions: Assign access rights for VM-PA and for models on a model and period status basis
  • Audit manager: Track the complete lifecycle of balance data and model configuration in an auditable environment
  • Report Library: Generate standard reports based on best practices, and design customized reports based on user’s unique needs. Access all reports via web browser.
     

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