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Elf Atochem North America Calvert City, Kentucky

Elf Atochem North America Calvert City, Kentucky. Learning from the Past Operating in the Present Preparing for the Future. PI Provides Exceptional ROI Even with Simple Applications. Elf Atochem North America. Diversified Chemicals Manufacturer Intermediate, Fine and Performance Chemicals

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Elf Atochem North America Calvert City, Kentucky

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  1. Elf Atochem North America Calvert City, Kentucky PI Users Conference 2000

  2. Learning from the PastOperating in the PresentPreparing for the Future PI Provides Exceptional ROI Even with Simple Applications

  3. Elf Atochem North America • Diversified Chemicals Manufacturer • Intermediate, Fine and Performance Chemicals • Performance Polymers • $2.2 Billion 1998 Sales • 4900 Employees • Manufacturing Sites • 24 US, 2 Canada, 4 Mexico, 16 Other World Wide PI Users Conference 2000

  4. Affiliate of TotalFinaElf • Fourth Largest Oil Company Worldwide • Oil Exploration, Production, Refining • Petrochemicals • Chemicals • World Wide Operations • Headquarters Paris, France PI Users Conference 2000

  5. Calvert City, Kentucky • Refrigerants • HFC • HCFC • Kynar (PVDF) • HCl • Continuous • Batch PI Users Conference 2000

  6. Why OSI PI? • World Wide Operations • Many Different DCS Systems • Desired Common Tool for Access to Process Data • Share Process Technology and Operational Support • Share Custom Applications PI Users Conference 2000

  7. Why OSI PI? • Best Archive Technology • Best Set of Client Tools • Included Microsoft Technology for Custom Work • VB, VBA • ODBC • Joint Decision with all parties including IT PI Users Conference 2000

  8. Elf PI Systems 48 Servers >300,000 Points >225 Clients Shanghai PI Users Conference 2000

  9. PI at Calvert City • Installed September 1997 • 10,000 DCS Points • 1,000 Lab Points Interfaced to LIMS • 15 Pro-Packs PI Users Conference 2000

  10. My Third User’s Conference • 1998 - Awed by all of the great things that could be done with PI • 1999 - Discouraged that I had not accomplished “great” things • 2000 - Realizing that PI is providing great ROI even without major “killer” application PI Users Conference 2000

  11. Typical PI Administrator PI Users Conference 2000

  12. Sharing Information at Calvert City Lab Operations Logistics Maintenance Engineering Shift Super Process Technology Environmental Purchasing PI Users Conference 2000

  13. Sharing Information and Expertise Worldwide • Process Technology @ Calvert City Supporting Downsized Wichita • Central Engineering/R&D at KOP studying processes remotely • Sharing operating data with sister plant in France France KOP, PA Five Other Plants Wichita PI Users Conference 2000

  14. How Does PI Produce ROI? • Increased Revenue • Increase production and/or quality • Displaced Costs • Eliminate or reduce existing cost • Avoided Costs • Eliminate future cost • Redirected Costs • Free resources for other purposes • Intangible Returns • Benefits not easily quantified PI Users Conference 2000

  15. Increased Revenue • Sharing of Information Worldwide & in Plant • Experts only a few clicks away from your problem • Process Studies for Process Optimization & Debottlenecking • PI easily provides data to Aspen & other data hungry applications PI Users Conference 2000

  16. On-Line Material Balance &Composition Predictor • Built with DataLink • Developed remotely at KOP R&D • One week trial looked good • Enhancements being added • Advises operator on correct feed flows to reactor • Stabilize reaction section of process • Reduced upsets & reduction in impurities PI Users Conference 2000

  17. Improve QualityIncreased Revenue • Could not produce product with tight spec • Poor temperature control • Used Atochem ProcessBook “extra” to detect valve problem PI Users Conference 2000

  18. Improve QualityIncreased Revenue • New valve installed • Continued improvement using PI-Profile to determine best control point on column • No missed shipment, customer satisfaction PI Users Conference 2000

  19. Displaced Costs • Remote Access to Data and Technical Support • KOP, PA R&D, Central Engineering • Atochem S.A. • Greatly reduced travel costs • Data available on their remote desktop PI Users Conference 2000

  20. Displaced Costs • One of our plants has experienced extreme technical downsizing • PI system installed to provide remote technical support from Calvert City • Timely assistance • Reduced travel costs PI Users Conference 2000

  21. Application for Displaced Cost • Virtual On-Line Analyzer • 5 Minute data instead of 12 Hour lab data • Improved process control • Increased Safety • Reduced Lab Costs • Reduced Maintenance PI Users Conference 2000

  22. Supplier RelationsDisplaced Costs • Slurry delivered by pipeline appeared to be highly variable in composition • Could analyze properly only in lab • Cost based on nominal composition - not actual composition • PI data from various locations in plant used to show supplier our problem PI Users Conference 2000

  23. Supplier RelationsDisplaced Costs • Supplier now understood our problems • Now working in cooperation to improve composition control • Could possibly result in innovative control that will solve years old problem and reduce future costs for slurry • Supplier adjusted charges by $50,000 • Projected $100,000/year recurring savings • Now working on another supplier problem • Potential savings of $100,000 annually PI Users Conference 2000

  24. Reduce Pump MaintenanceDisplaced Costs • PumpGard - Inexpensive & Continuous • DataLink Monitor Application • 117 Pumps checked every 10 minutes • High current, Low current, “Scratching” • Indication that pump is in trouble - cavitation, dry run, dead head, clogged strainer, etc. • Numeric page generated alerting rotating engineer PI Users Conference 2000

  25. Reduce Pump MaintenanceDisplaced Costs • Pump crash repair can run from $1k to $50K • Positive progression: • Why did this pump fail? • Why is this pump in trouble? • How do we keep pump out of trouble? PI Users Conference 2000

  26. Avoided Costs • Make Informed Decisions Based on Factual Information • Spend Wisely, Eliminate - • Knee Jerk • Gut Feel • Design in Ignorance • 80/20% Rule on Data Gathering/Analysis changed to 5/95% PI Users Conference 2000

  27. Separator ProblemsAvoided Costs • First Guess • Instrument Doesn’t Work, Separator Does • PI Proves Instrument • Second Guess • Instrument Works, Separator Doesn’t • Separator Not Large Enough PI Users Conference 2000

  28. Separator ProblemAvoided Costs • PI Data + Intelligent Engineer • If operating parameters correct: • Instrument Works • Separator Works • No need to spend $250k on separator fix PI Users Conference 2000

  29. Capacity IncreaseAvoided Costs • Refrigeration Bottleneck • PI Data Used to Investigate 25% Refrig Increase • Upset data helpful • 4 Refrig users have opportunities for reduced demand • Refrig machine operating parameter change • Looks like new Refrig machine not necessary - $1.2 million cost avoided PI Users Conference 2000

  30. Redirected Costs • A number of routine reports have been automated • Allows people freed from reporting tasks to use their talents more productively • Reduces labor cost that can be used for other purposes • Provides information that would be almost impossible if done manually PI Users Conference 2000

  31. Redirected Costs • Shift Superintendent Report • 1/2 hour per shift now spent on running plant • $18,200/year • Daily production report eliminated 1/2 time clerk at one unit • $26,000/year • Unit monthly quality report PI Users Conference 2000

  32. Redirected Costs • Automatic batch reports • Reports now done daily • Timely information to improve quality • Supervision/Clerk savings $18,000/year • Purchasing accesses raw material inventories • Eliminates telephone tag PI Users Conference 2000

  33. Redirected Costs • Incinerator trip report • Permit renewal requires human health risk assessment • Dependent on “Upset Time” with default value of 20% • DataLink used to document trips and upset time • Even with ProcessBook this task very labor intensive • Report showing upset time significantly < 1% PI Users Conference 2000

  34. Intangible Returns • Probably one of major ways PI provides ROI. • Access to process information at your desktop • If information is readily accessible it will be used for informed decisions • DCS console equipment expensive and rigid while PI clients are affordable and flexible PI Users Conference 2000

  35. Intangible Returns • View operations and Supply Chain Management anywhere • Logistics • Plant wide responsibilities • Can keep track of boiler operation and tank levels • Loaders • Had no DCS console • Now can view some loading operations from office • Home • Provide consultation after hours PI Users Conference 2000

  36. Intangible Returns • Opens closed systems • Ties together information from many sources • DCS • LIMS • Oracle and other relational databases • Aspen, Honeywell & other Advanced Process Control Applications • And many more PI Users Conference 2000

  37. Unfortunately, Incidents Do Happen. It’s critical that you learn from them. PI Users Conference 2000

  38. Incident InvestigationIntangible Returns • PI provides accurate information on incident events • Facts lead to determining root cause of incident • Facts lead to corrective actions to avoid future incidents • PI has proven to be very useful in the investigation process PI Users Conference 2000

  39. Incident InvestigationIntangible Returns • PI is now used routinely • Its use has lead to the discovery of potential problems that may have been missed • Results in improved safety, environmental compliance, and process reliability • I was even asked “Can you get the switch engine on PI?” PI Users Conference 2000

  40. Intangible Returns • What are these intangible benefits worth? • Preventing a unit shutdown occasionally • Preventing a future safety or environmental incident • Approval of an important environmental permit • Customer satisfaction PI Users Conference 2000

  41. ROI Summary Increased Revenue Not yet quantified Displaced Costs Not all quantified Supplier relations $50,000 to date Possible $200k in 2000 Reduced travel Not quantified Reduced pump maintenance possible $100k in 2000 Improved on-line analyzer performance Results to be seen in 2000 Performance equations Providing process feedback not otherwise possible Not quantified PI Users Conference 2000

  42. ROI Summary Avoided Cost Separator $250K Refrig $1.2M Flow meter problems $50K Redirected Cost Shift Report $18.2K/year Batch Report $18K/year Production Report $26K/year Utility Metering & Cost Distribution $14.4K/year PI Users Conference 2000

  43. ROI Summary • One time savings • $1. 5M • Recurring savings • $126.6K/year documented • $300K/year projected additional in 2000 • Unreported/Not Quantified and intangible • $? but probably more than total of above PI Users Conference 2000

  44. How to Maximize ROI • Site champion(s) • User training • Share information between site/corporate users • Tips • Tricks • Applications • Learn VB/VBA! PI Users Conference 2000

  45. One User’s Comments “Simplifies and Distributes access to DCS information five fold. Conceptually simple tasks are actually simple compared to DCS, such as creating a new trend display or doing some calculations on data available within the DCS. This can take days for the DCS depending on the availability of the DCS engineer. It can be done in minutes in PI.” PI Users Conference 2000

  46. One User’s Comments “Because of the simplicity, organizing seemingly unrelated data into trends and spreadsheets makes troubleshooting quick and effective. Relationships not known before are discovered that aid in improving process operation.” PI Users Conference 2000

  47. One User’s Comments “Before PI, when I got a call at home on a process problem, the only way to solve it was to get in the car and drive an hour to the plant. I now have access to PI from home and have access to all of the data that is available in the control room. I can usually provide guidance to the operator needing help. This not only saves me lost sleep and long drives, but the problem gets solved an hour earlier. This can mean avoiding lost production.” PI Users Conference 2000

  48. Questions

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