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Master Planning & Margin Improvement

Find and capture integrated margin across the whole complex, and plan configuration, crude flexibility and investment in phases.

Direct value

  • Margin Improvement Programme: 20–80 cents/bbl, or US$15–60M a year for a 10 MMTPA complex. The first 20 cents comes at near-zero investment, the next 20–40 cents at low to very modest capex, and the next 20–40 cents from affordable, less complex de-bottlenecks
  • Configuration studies, baselined on the outcomes of the Margin Improvement Programme, then deliver a further 50 cents to US$2/bbl, depending on the extent of a revamp or the addition of new units under the Investment Masterplan
  • Payback typically 0.5–2 years for the programme; 2–6 years for master-plan projects
  • GRM uplift of 5–20% from master plans, depending on capex deployed

Indirect benefits

  • Sharper crude, throughput and product-slate decisions
  • Transparent, phased capex roadmap that investors and boards can follow
  • Strategic clarity on diversification into petrochemicals

Collateral benefits

  • Lower corrosion-related failures through Sulphur and TAN control
  • Energy-efficiency and emissions gains alongside margin
  • Resilience to crude-price and regulatory shifts

DetailsRequest a Proposal

Business Planning & LP Model

Make the planning model reflect reality, so crude, throughput and product decisions are made on numbers you can trust.

Direct value

  • Margin gain of 20–40 cents/bbl, mostly with no capex
  • US$15–30M a year for a 10 MMTPA complex; payback under 1 year
  • 50–75% improvement in model accuracy from current levels

Indirect benefits

  • Crude basket 20–30% more flexible
  • Better scheduling and plan adherence
  • Intermediate feedstocks routed to the best use

Collateral benefits

  • Less product-quality give-away and fewer reblends
  • Planning, operations and finance working from one set of numbers
  • Faster, better-informed buying decisions

DetailsRequest a Proposal

Troubleshooting & Operations (i-TOP / i-TROM / i-MORE)

Hands-on problem solving for furnaces, fouling, corrosion, hot spots, reactor excursions and catalyst life on CDU/VDU, hydrocracker and FCC units, through our i-TOP, i-TROM and i-MORE assessments.

Direct value

  • Margin gain of 5–40 cents/bbl; US$4–30M a year
  • Payback typically 0.5–1 year
  • Desalter outlet targets of BS&W under 0.1% and salt under 5 ppm

Indirect benefits

  • Constraint management that unlocks capacity
  • Better product quality and yield
  • Operators trained on root causes, not symptoms

Collateral benefits

  • Lower unplanned downtime and safer operation
  • Longer catalyst and equipment life
  • Lower energy use through tuned operation

DetailsRequest a Proposal

Safety, Integrity & Reliability

Protect people, assets and production with structured safety reviews and a reliability programme built on evidence.

Direct value

  • Benefit of 20–40 cents/bbl from safer, more reliable and better-protected operation
  • Plant availability improved by 3–7%
  • Unplanned downtime down 10–20%
  • Reliability improved by 5–20%; payback 0.5–1 year, US$4–15M a year

Indirect benefits

  • Safer start-up, shutdown and emergency transitions (about 90% of incidents occur in transient modes)
  • Higher unit utilisation with fewer constraints
  • Corrective-maintenance spend reduced

Collateral benefits

  • Regulatory compliance with OSHA, API, IEC standards
  • Stronger safety culture and operating discipline
  • Confidence for board, insurers and regulators

DetailsRequest a Proposal

Digital Transformation (RWDT²)

A staged route from IT–OT integration to a refinery-wide real-time digital twin, with agentic AI models that monitor, reason and recommend within your guardrails, led by process domain expertise.

The nine AI-modules

  1. Process Calibration & Real-Time Scenario Simulation
  2. Crude Blend Optimisation & Product Quality Prediction
  3. Integrated Operations Optimisation, Constraints & Throughput
  4. Integrated Energy, Furnace & Utilities Optimisation
  5. Catalyst Monitoring & Management of Change (MOC)
  6. Integrated Reliability, Asset Health & Turnaround Planning
  7. Process Plant Safety & Operating-Envelope Management
  8. Integrated Margin & Network Optimisation
  9. Automation of Daily Processes & Decisions

Direct value

  • Margin gain from 20 cents/bbl to US$1/bbl and more, as the nine AI-modules mature
  • US$15–75M+ a year for a 10 MMTPA complex
  • Payback typically 0.5–2 years

Indirect benefits

  • Decisions made faster, from one trusted real-time view
  • Repetitive daily tasks automated
  • Benefits tracked automatically against KPIs

Collateral benefits

  • Reliability and asset health improved through condition monitoring
  • Energy and emissions tracked in real time
  • Operator knowledge captured in the models

DetailsDigital Transformation pageRequest a Proposal

Project Front-End Development Management (FEDM)

Owner’s-Consultant leadership from feasibility to final investment decision: choose the right project, and develop it rightly.

Direct value

  • Capex reduction of 5–10% and opex reduction of 5–10%
  • IRR improvement of 2–5 points; schedule savings of about 10%
  • GRM uplift of $0.2–1 per barrel

Indirect benefits

  • Stronger design basis and fewer changes in detailed engineering
  • Clear stage-gate decisions backed by TRL and risk matrices
  • Competitive licensor and contractor bids

Collateral benefits

  • Wrong projects stopped before capital is committed
  • Safer, more operable plants through design and 3D model reviews
  • Board and investor confidence

DetailsRequest a Proposal

Technical Services Agreements (TSA)

On-call access to senior process specialists under a fixed annual agreement: secure Global Expert advice that solves your reliability or troubleshooting problems at a fraction of the cost of consulting licensors, and can save you millions of dollars in productivity or by averting an outage through higher plant reliability and availability.

Direct value

  • Global Expert advice at a fraction of the cost of consulting licensors, with potential savings of millions of dollars in productivity or from averting an outage
  • Typical queries answered in 0–5 hours
  • Investigations of 5–40 hours within the agreement
  • Fixed 12-month renewable term with no added headcount

Indirect benefits

  • Faster, better troubleshooting decisions
  • Unit monitoring and trending with operating-envelope guidance
  • Best-practice documentation for operators

Collateral benefits

  • Improved reliability and availability
  • Higher production with lower risk
  • Knowledge transfer to your own team

DetailsRequest a Proposal

Energy Efficiency, Offsites & Logistics

Cut fuel, losses and emissions together, from quick operating wins to moderate-capex projects.

Direct value

  • Margin benefit of 20–40 cents/bbl from energy efficiency, offsites and logistics
  • Energy-intensity improvement of 5–10 points; fuel savings of 3–5%
  • US$7.5–22.5M a year for energy; US$4–9M a year for oil loss
  • Oil loss brought from typical 0.3–0.7% toward below 0.3% of throughput

Indirect benefits

  • Furnace efficiency up through O₂ trim and hot-spot control
  • Better steam, power and hydrogen balance
  • Flare and fuel-gas losses reduced

Collateral benefits

  • CO₂ reduced by 5–10%
  • Lower emissions-compliance risk
  • Better tankage, jetty and pipeline utilisation

DetailsRequest a Proposal

Bio-Fuels & Low-Carbon Solutions (LCS)

Evaluate how SAF, renewable feedstocks, 2G ethanol, E2J (ethanol-to-jet) technologies, co-processing and carbon management can fit existing refining and petrochemical assets, with a decarbonisation strategy for deep brownfield plants.

Direct value

  • Technology evaluations for SAF (sustainable aviation fuel), bio-fuels, 2G ethanol and E2J technologies
  • Strategy for decarbonisation in deep brownfield plants, with net-zero master plans
  • Carbon capture feasibility inside a phased plan

Indirect benefits

  • Reuse of existing units where possible
  • Policy and certification considerations in the business case
  • Phased investment pathways

Collateral benefits

  • Lower carbon intensity of products
  • ESG alignment that improves financing options
  • Optionality as regulation evolves

DetailsRequest a Proposal

Full A2Z of servicesService CatalogueAll service details

Note. Benefits are indicative for a 10 MMTPA (210 kbpsd) complex and are not guaranteed. See Legal Disclaimers.

Disclaimer. General information only. Nothing on this website is legal, financial, tax or engineering advice or an offer capable of acceptance. Binding terms arise only under a signed written agreement. See our Legal Disclaimers, NDA & Confidentiality.