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SmartPlant Process Safety Ray Howarth

SmartPlant Process Safety Ray Howarth. 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam. Operating the Plant. Integrate ALL Information ... DESIGN & PROCESS Create the SMART PLANT of the Future …. Making Plants Smarter, Safer & More Profitable By Design. October 23, 2014. – 2 –.

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SmartPlant Process Safety Ray Howarth

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  1. SmartPlant Process Safety Ray Howarth 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam

  2. Operating the Plant Integrate ALL Information ... DESIGN & PROCESS Create the SMART PLANT of the Future … Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 2 –

  3. “The process always tells on itself.”     BASF Sr. Staff Engineer. Making Plants Smarter, Safer & More Profitable By Design • FALCONEER Listens … Cuts through information overload “It’s not WHAT you know, it’s WHEN you know it!” October 23, 2014 – 3 –

  4. Smart Plant of the Future - NOW The Virtual Engineer in the Smart Process The Right Information Automatically Provided at the Right Time Cost Savings, Increased Production Improved Daily Workflow Better, More Timely Decision-Making Enhanced Safety BENEFITS & ROI FALCONEER™ IV - SPPID FALCONEER™IV Process Performance Solution - Making Plants Smarter, Safer & More Profitable by Design SmartPlant Enterprise Bundle for O/O SmartPlant Enterprise (SPO) for O/O Smart Link from Control Systems to SAP Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 4 –

  5. The Drivers/Challenges Support of Plant Strategy Production, quality, safety, resource utilization Reduce Operational Risks such as: Production interruption Regulatory compliance Safety Incidents Knowledgeable Workforce Reduce Engineering Costs such as: Turnaround/Outage Planning & Execution Preventative Maintenance Planning & Execution Inspections Reduce operational overhead cost (contractors / own staff) How to retain knowledge How to regain knowledge Making Plants Smarter, Safer & More Profitable By Design SMART PLANT PERFECT PLANT INTELLIGENT PLANT of the FUTURE

  6. Operation at Design Operation at Capacity Instrumentation Calibration Safety Systems ISO Systems Environmental Systems Making Plants Smarter, Safer & More Profitable By Design Design Validation & Operational Risk October 23, 2014 – 6 –

  7. What is FALCONEER™ THE VIRTUAL ENGINEER The Right Information Automatically Provided at the Right Time! Process Performance Auditing & Advising Software Real-time Process Information Management Fundamental Engineering Models-based Patented-Pending Making Plants Smarter, Safer & More Profitable By Design

  8. How Does FALCONEER™ IV Work? Making Plants Smarter, Safer & More Profitable By Design DIGITAL DASHBOARD • KPI • CHARTS • REPORTS • EMAILS IS WORKING CONTROL SYSTEM • Flow • Temperature • Pressure • Level • ADVICE OK OR PROBLEMS THE MFG PROCESS • System Auditing • Point Auditing SHOULD WORK Process Design and Operation Information October 23, 2014 – 8 –

  9. Improved Daily Workflow & Information Management Making Plants Smarter, Safer & More Profitable By Design • at • CHECK OPERATIONS • CONTROL ROOM • SPREADSHEETS • DCS TOOLS • OPERATION NORMAL • PROJECT WORK • REPORTS • MEETINGS • INTERRUPTIONS • PROCESS PROBLEMS • PROCESS OPPORTUNITIES • PROBLEMS? • IMMEDIATE ACTION • ADDITIONAL RESOURCES REQUIRED • WHAT HAPPENED SINCE YESTERDAY? • LONGER TERM PLAN • FORM TEAM • GATHER INFO • ANALYZE INFO • ID CAUSE • DEVELOP SOLUTIONS • CREATE PROJECT • INVESTIGATE • GATHER INFO • ANALYZE INFO • IDENTIFY CAUSE • DEVELOP SOLUTIONS • IMPLEMENT SOLUTION • FORM TEAM • DEVELOP PLAN • DOCUMENT • PSM • ISO • MOC • PREPARE FOR TOMORROW October 23, 2014 – 9 –

  10. REAL BENEFITS!! Global Industry Benchmarks (BASF, FMC, PPG, Taiwan, India) Prevented unscheduled shutdown saving >$200,000 per day Improved Power Generation Revenue >$200,000 per year $30,000 Savings with One Alert on Steam System Steam Reconciliation Savings of $50,000 in 6 months Raw Material Savings of >$40,000 per Quarter Energy Savings Opportunities > $70,000 per Month w/ Natural Gas > $100,000 per year Pumps & Blowers Making Plants Smarter, Safer & More Profitable By Design The real value of right information at the right time! A former Foxboro manager appreciates our approach as: “being rigorous enough to identify the problems without being too complex or expensive, combined with being easy enough to configure and maintain.” “Compared to other approaches, FALCONEER is more fundamental with easily configurable and understandable equations and logic”, according to FMC

  11. REAL BENEFITS!! Global Industry Benchmarks (BASF, FMC, PPG, Taiwan, India) Prevented unscheduled shutdown saving >$200,000 per day Improved Power Generation Revenue >$200,000 per year $30,000 Savings with One Alert on Steam System Steam Reconciliation Savings of $50,000 in 6 months Raw Material Savings of >$40,000 per Quarter Energy Savings Opportunities > $70,000 per Month w/ Natural Gas > $100,000 per year Pumps & Blowers Making Plants Smarter, Safer & More Profitable By Design The real value of right information at the right time! + IMPROVED SAFETY

  12. OO Bundle Solution Components Engineering tasks that made up the solution: SmartPlant P&ID Rule and asset based intelligent P&ID solution SmartPlant Process Safety Knowledgebase HAZOP analysis solution SmartPlant Isometrics (formerly I-Sketch) Specification driven Isometric solution FALCONEER Process Performance Validation, Abnormal Condition Detection & Optimization Functionality Out-of-the-Box capabilities Flexibility to be configured to meet specific user demands Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 13 –

  13. Design to Operations Business Cases Add Monitoring System for Compliance Automating HAZOP Process Correcting Equipment Performance Making Plants Smarter, Safer & More Profitable By Design • Support Systems • PID • Equipment Spec • Instrument Specs • Predictive / Preventive Maintenance • Simulations • Excel • Pilot Study Reports • SOPS October 23, 2014 – 14 –

  14. Correcting Performance Making Plants Smarter, Safer & More Profitable By Design Equipment or Process Unit Underperforming Data Consolidation • Specifications • Controls • Piping • Other • DCS • Historian ID Problem & Root Cause Intelligent P&ID’s Develop Solution 1) Design Modification 2) Process Change • Engineering Models • Spreadsheets, • Simulations Existing P&ID’s Validate Solution • Safety • check Real-Time Performance Monitoring & Auditing Implement Project Maintain & Optimize Improved or Design Performance • DCS • Historian October 23, 2014 – 15 –

  15. Cost savings Cost of the solution for 3 users $95k (incl. training and few days of consultancy) ROI with the first year of projects $113,540 - $95,000= $18,540 plus Cost Avoidance or Opportunity Cost Savings ranging in the hundreds to thousands of dollars per hour that problem persists unrecognized ROI – Correcting Performance Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 16 –

  16. Business Case – Correcting Performance Benefits Virtual Engineer - Analyze process performance Maintain Safe Conditions Operational Risk Management Abnormal Condition Detection & Reporting Fault & Failure Detection & Reporting Validation of Safety Critical Instrumentation Provide recommendations to improve output Ensure design consistency Provide consistent P&ID updates Safety checks on the modifications Ensure P&ID, process data, Isometrics and safety are all consistent and verified. Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 17 –

  17. ROI Recap on 3 Business Cases Automating HAZOP Process 168,000 Add Monitoring System for Compliance $139,500 Correcting Equipment Performance 113,540 Total ROI $421,040 Less Cost 95,000 Total ROI 1st Year of Projects $326,040 Plus Cost Avoidance or Opportunity Cost Savings ranging in the hundreds to thousands of dollars per hour that problems persist unrecognized Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 18 –

  18. FALCONEER Case Studies A former Foxboro manager appreciates our approach as “being rigorous enough to identify the problems without being too complex or expensive, combined with being easy enough to configure and maintain.” Making Plants Smarter, Safer & More Profitable By Design Water & Waste Water • Utilities • Chemicals • Energy Chemical\Petrochemical • Solid Oxidizer Plant • EO Plant • Polymerization Plants • Incinerators • Pipelines (Oil & Gas) • Salt Plant Power Generation • Co-Generation • Boiler Systems Pulp & Paper • Pulp Mill October 23, 2014 – 19 –

  19. CUSTOMER WANTS… Making Plants Smarter, Safer & More Profitable By Design • Process Information (Asset) Management • Real-Time Smart Link for Process Data to SAP to SP Enterprise to User • Automated Process Performance Auditing & Advising • Leveraging Design Information with Process Information $$$ SAP USER SmartPlant Enterprise

  20. Smart Plant of the Future - NOW FALCONEER Business Package Delivers Smart Link from Control System to SAP & Intergraph Enterprise Mass & Energy Balance Engine for optimizing energy utilization, costs, production Monitor, Report, Trend key performance indicators (KPI) and metrics in real time Energy & Raw Material Use & Cost Instrumentation & Equipment Condition Production Capacity & Utilization Receive proactive notifications of under-performing assets before they impact the bottom line Capture, retain & use aging workforce knowledge base REDUCED OPERATIONAL RISK ENSURING OPERATIONS PER DESIGN! Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 21 –

  21. Making Plants Smarter, Safer & More Profitable By Design INTERGRAPH 2008 Q & A Presenter: Dr. Doug Lenz www.falconeertech.com October 23, 2014 – 22 –

  22. FALCONEER Process Performance Solution Models Are the Key Material Balances Energy Balances Performance Equations Soft Sensor Models Six Sigma Transfer Functions Heuristics Empirical Equations / Correlations Multivariate Statistical Models PCA Models Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 23 –

  23. Method Of Minimal Evidence Example Making Plants Smarter, Safer & More Profitable By Design Primary Models(Mass and Energy Balances) PM1 = 0 = Flow1 + Flow2 – Flow3 – Leaks PM2 = 0 = Flow1 * cp * Temperature1 + Flow2 * cp * Temperature2 – Flow3 * cp * Temperature3 – Leaks * cp * Temperatures Secondary Model(Eliminates Flow1) SM1 = 0 = Flow2 * cp * (Temp2 – Temp1) – Flow3 * cp * (Temp3 – Temp1) October 23, 2014 – 24 –

  24. Virtual Statistical Process Control (V-SPC) Making Plants Smarter, Safer & More Profitable By Design • Controlled Process Variable • Virtual EWMA Chart • Flow meter • Controlled Process Variable • Flow Meter • Failure - 12 Hours before TDC Alarm Indication October 23, 2014 – 25 –

  25. Why Can’t our DCS / SCADA do this? DCS/SCADA monitors individual points only – FALCONEER monitors entire process and interactions between points as well Patent Pending Method and System Adds “wisdom” or intelligence to the raw information. Automatic model & rule generation for enhanced cross-checking High Level Auditing & Advising Accounts for ALL Information from Process More than just Individual High/Low Alarm Limits and Trending Statistical-based and Model-based Trending Real-time Continuous vs. Manual or Scheduled Proactive and Preemptive versus After-The-Fact WHAT & WHEN & WHY Certain Functions Possible (SPC, KPI, HART) Requires Significantly More Time, Effort, Long-Term Support to Configure & Maintain Older systems may not even be possible Making Plants Smarter, Safer & More Profitable By Design October 23, 2014 – 26 –

  26. SmartPlant Process Safety Ray Howarth 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam

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