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Achieving Operational Excellence

Achieving Operational Excellence. March, 2006. The World Has Gone DIGITAL!. Law Of Accelerating Returns. Analysis shows that Technological change is exponential. My old PC. Disposable printers?. Storage is ‘free’: $65. Greenfield. 34%. Expansion /. Modernization. 66%.

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Achieving Operational Excellence

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  1. Achieving Operational Excellence March, 2006

  2. The World Has Gone DIGITAL!

  3. Law Of Accelerating Returns Analysis shows that Technological change is exponential

  4. My old PC Disposable printers? Storage is ‘free’: $65

  5. Greenfield 34% Expansion/ Modernization 66% We Have To Serve Both Greenfield and Brownfield Customers

  6. Shell - “Our Vision” • Use the newest technology to create the “Plant of the Future” • Concentrate on safety and environmental concerns – System must be robust • Focus on cost – Low life cycle cost • Manpower training – Must be easy to operate and maintain • Obsolesce resistance – must be based on industry standard software norms

  7. The Technology Universe W-bluetooth Parallel computing Energy Scavenging .NET GPRS AVALON DSP’s Smart Objects Artificial Intelligence Security S99 Motes Scaleable Graphics - Avalon Ultrasonic AES Predictive Algorithms MEMS Model Base Programming .NET Vista SOA GPS RSS Enhanced EDDL FoundationFieldbus UML Advanced Signal Processing OPC UA 802.15.4 PAT FireFox Process Diagnostics MP3 Moore’s Law XML Security HART Fuel Cells Bit Torrent 802.11 (beyond G) OPML Skype

  8.  Higher sustained production with minimize costs  Longer duration to scheduled outage  Faster time-to profit  Shorter scheduled outage  Fewer unscheduled outages  Safer operation Operational Excellence Profit $ time Cost

  9. Tire icon indicates low pressure Smart cars monitor tire pressure Car advises driver of abnormal situation made possible via disruptive technologies

  10. Smart Car Messages  Seat belt  Cargo door open  Passenger door open  Wiper fluid low  Turn signal on  Right rear tire pressure low  Change engine oil  Fuel low Messages I do not get   Check engine  Big red oil light

  11. Two requirements: - Sensing technology - Presentation to user at the right time

  12. Early warning Sequence Of Events Change Oil Light Oil Pressure Alarm Major Performance Impact Car Performance Safety incident time

  13. We Help Our Customers Deploy Smart Digital Plants

  14. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT Smart Plant Architecture

  15. Today’s Smart Field Devices Predict Abnormal Situations • On-board computing power enables step changes in functionality • Often have more than one process variable for a single pipe intrusion • Full with diagnostics • health of device is known • health of the application is monitored • health of the process is monitored “At 12:45 tomorrow, this valve will fail”

  16. Early warning Intelligent Devices Report Health Device alert Device failure Process Impact Plant Performance Safety Incident time

  17. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT Smart Plant Architecture

  18. Smart Predictive AlertsPressure Transmitter Example Sensor failure

  19. Smart Predictive AlertsPressure Transmitter Example Process problem

  20. Smart Predictive AlertsValve Example Valve is performing sub-optimally

  21. Smart Predictive AlertsValve Example Valve needs maintenance

  22. Smart Predictive AlertsCompressor Protection Example Compressor needs maintenance

  23. 10 Year Old Plants Do Not Have Predictive Capabilities Process view clear Process view is fuzzy

  24. A Real Case Of Not Seeing What Is Happening The explosion was caused by flammable hydrocarbon liquid continuously being pumped into a process vessel that, due to a valve malfunction, had its outlet closed. A control valve being shut when the control system indicated it was open.

  25. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT Should All These Alarms Go To The Operator? ?

  26. Time For Action > 6 months Early alarm to MAINTENANCE only as there is a long time before process impact. Alarms To Operator?Example shown: NO Device Performance Impellor Imbalance Motor Overheating  Process Impact time

  27. Time For Action > 1 year Early alarm to MAINTENANCE only as there is long time before process impact Alarms To Operator?Example shown: NO (long time before failure) Valve frozen open in utilities plant Device Performance  Process impact time

  28. Time For Action < 30 minutes Early alarm to MAINTENANCE and OPERATOR as action is required immediately to prevent process problems Failure of a Critical Valve Column Impacts The Process Immediately Valve frozen open in distillation column Device Performance  Process impact time

  29. High Priority Medium Priority Medium Priority Low Priority Plants Must Have An Alarm Message Map Alarm Destination Map • Operator • Maintenance • Safety Personnel • Maintenance • Optimization Personnel • Safety Personnel Cost of Ignoring Alarm • Operator • Maintenance • Optimization Personnel • History Collection  Time To Avoid Process/Safety Impact

  30. The Importance Of Alarm Handling In the last 11 minutes before explosion, the operators had to recognize, acknowledge and act on 276 alarms Milford Haven was 25x the recommended maximum

  31. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT Alarm Messaging Map Asset Health Degraded Safety Alarms Predictive Abnormal Situation Alarms

  32. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT All Critical Alarms – To Operator(Regardless of whether a device or controller created them) OPERATOR INTERFACE

  33. Operator Interface Alert The Operator Before Process Impact PT-101

  34. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT All Asset Alarms To Maintenance ASSET INTERFACE

  35. Maintenance / Reliability Dashboard

  36. SMART DIGITAL CONTROL SAFETY SMART ASSET OPTIMIZATION SMART MEASUREMENT SMART ANALYTICAL SMART SAFETY SMART FINAL CONTROL SMART FINAL CONTROL SMART MEASUREMENT SMART SAFETY SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT All Safety Alarms To Safety Personnel Degraded Safety Alarms

  37. Safety Personnel Are Roaming Cell phone, pager, email… Detailed Summary 

  38. Best Practices For Operator Alarms EEMUA 191 Benchmarks Milford Haven was 25x the recommended maximum

  39. Exceed EEMUA guidelines Alarm Analysis Dashboard

  40. In A Smart Plant, Does The Number Of Alarms To the Operator Increase? • No • Best practices are established in the design of the alarm system • EEMUA • Alarm Map • Early warning alarms properly acted on may actually decrease the incoming alarms as process alarms may be avoided

  41. Poor Health Delivers Unsatisfactory Results At 200 kph !!!

  42. Expect Poor Performance In Plants With Poor Asset Health Disconnected Damper Drive Leaking Valve Body Mercury Filled Transmitters & Switches Poor Equipment Results in Poor Performance and Unsafe Plants

  43. Expect Poor Performance In Plants With Poor Asset Health Advanced Control Dashboard Poorly performing control is identified

  44. SchedulingOnline Optimization Advanced Process Control (APC) Soft Sensors, Model Based Supervision PIMS, PIMS interfaces DCS, Basic Automation Field Level, Instrumentation Expect Poor Performance In Plants With Poor Asset Health Enterprise Integration: • Validated Data (Inventory, Loss, etc) Is transmitted to SAP • Asset alerts are transmitted to SAP for scheduling • Integrating Transactions is Easy • Reversing them (on bad data) is very difficult

  45. Some Smart Plant Builders Shell- Deer Park,Tx** $32M*(vs. HW)- FCCU, Hydrocracker Petrobras Brazil(3)** $17M(displaced Bailey)- Coker, Blending, Crude Pemex- Tula $3M(displaced HW)- Alkylation Unit Shell Motiva Norco $17M*(displaced HW)- Reformers(2), DHT, NHT, SMR, HC Pdvsa, Curacao** $5M*(displaced Foxboro)- SRU(4), H2 Plant, Hydrocracker MOL PLC, Hungary $10M*(vs. YEW, HW)- Diesel Hydrotreater, Sulfur Plant Rompetrol(Romania) $20M(Modernization)- Entire Refinery BP SECCO $30M(vs. YEW)- Ethylene Complex Cenex, Montana $1.5M(vs. Moore)- Desulfurization Scanraff, Lysekil $1M(vs HW)- Merox, Propylene, FCCU*** Yukos, Odessa $2M(vs HW, YEW)- Isomerization, Reformer *-MAC Scope of supply **- Facility in operation ***- Portion of FCCU -64 Refineries with PlantWeb last 30 months, over 500 PlantWeb installations in Refining -Process units: FCCU, Hydrotreaters(Diesel and Naphtha), SRU, H2 Plant, SMR, Alkylation Units, Crude Unit, Vacuum Unit, Asphalt unit, Delayed Coker, Hydrocracker, Reformer

  46. Shell Deer Park Revamp 2003

  47. Shell Deer Park Refining Company Deer Park Refining Limited Partnership “Our Vision” – Shell Deer Park • Use the newest technology to create the “Refinery of the Future” • Concentrate on safety and environmental concerns – System must be robust • Focus on cost – Low life cycle cost • Manpower training – Must be easy to operate and maintain • Obsolesce resistance – must be based on industry standard software norms

  48. Shell Deer Park Refining Company Deer Park Refining Limited Partnership Control Room BEFORE AFTER

  49. Shell Deer Park Refining Company Deer Park Refining Limited Partnership Cabinet BEFORE AFTER

  50. Shell Deer Park Refining Company Deer Park Refining Limited Partnership Field Junction BEFORE AFTER

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