Production Unit Downtime

The Challenge
This refinery faced three interlinked problems:
Costly demurrage charges from shipment timing errors.
Frequent downtime during product turnovers.
Rigid, outdated planning tools limiting proactive decision-making
The Work
1. Demurrage Savings via Smarter Yield Forecasting
Introduced improved scheduling software for better yield prediction
Enabled more accurate export planning and reduced standby delays
2. Downtime Reduction on VDU
Streamlined changeover process with real-time lab alignment and crude routing
Eliminated inefficiencies causing frequent turnover delays
3. Simulation Software Implementation
Deployed scenario-based tools for dynamic planning
Allowed crude/product simulations to be run in advance, improving confidence and responsiveness
The Results
$2 million/year saved in export penalties
8 hours/week recovered in operational uptime
Planners transitioned from reactive reporting to proactive optimisation
Why It Matters
By combining technology, process change, and coordination, the site unlocked major value — and set itself up for long-term resilience.