Emerson Eng

Achieving Operational Excellence
March, 2006
The World Has Gone DIGITAL!
Copyright Emerson Process Management, March 2006, Slide 2
Law Of Accelerating Returns

Analysis shows that Technological change is exponential
Storage is free: $65 My old PC
Disposable printers?
We Have To Serve Both Greenfield and Brownfield Customers

World Area O&G Refining Pharma Chemical Power W&W
NA LA W Europe E Europe ME Africa AP
Greenfield 34%
Expansion / Modernization 66%

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
The Technology Universe

.NET
AVALON Smart Objects
W-bluetooth Energy Scavenging DSPs Security S99 GPRS
Artificial Intelligence Ultrasonic AES
Motes Predictive Algorithms MEMS
Scaleable Graphics - Avalon
.NET
GPS Foundation Fieldbus PAT
Parallel computing Vista UML RSS OPC UA
Model Base Programming
Enhanced EDDL
Advanced Signal Processing FireFox
SOA
802.15.4 MP3
Process Diagnostics HART
XML
Moores Law
Fuel Cells Security
Bit Torrent OPML

802.11 (beyond G) Skype
Operational Excellence
Higher sustained production with minimize costs Faster time-to profit Longer duration to scheduled outage
Profit
time
Cost
Fewer unscheduled outages Safer operation

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

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

Sequence Of Events
Early warning
Change Oil Light
Car Performance
Oil Pressure Alarm
Major Performance Impact
Safety incident
time
We Help Our Customers Deploy Smart Digital Plants
Smart Plant Architecture

SAFETY
SMART ASSET OPTIMIZATION SMART DIGITAL CONTROL
SMART ANALYTICAL
SMART MACHINERY HEALTH MANAGEMENT
SMART SAFETY
SMART MEASUREMENT
SMART FINAL CONTROL
Todays 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
Intelligent Devices Report Health

Early warning
Plant Performance
Device alert Device failure Process Impact
Safety Incident
time
Smart Plant Architecture

SAFETY SMART ASSET OPTIMIZATION SMART DIGITAL CONTROL
SMART ANALYTICAL
SMART SAFETY
SMART MEASUREMENT
SMART FINAL CONTROL
Smart Predictive Alerts

Pressure Transmitter Example
Sensor failure

Pressure Transmitter Example
Process problem

Valve Example
Valve is performing sub-optimally

Valve Example
Valve needs maintenance

Compressor Protection Example
Compressor needs maintenance
10 Year Old Plants Do Not Have Predictive Capabilities
Process view is fuzzy
Process view clear
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.
Should All These Alarms Go To The Operator?

?
SMART ANALYTICAL SMART MACHINERY HEALTH MANAGEMENT SMART SAFETY
SMART MEASUREMENT
SMART FINAL CONTROL
Alarms To Operator?
Example shown: NO
Time For Action > 6 months
Device Performance
Early alarm to MAINTENANCE only as there is a long time before process impact.
Impellor Imbalance Motor Overheating
Process Impact
time
Alarms To Operator?
Example shown: NO (long time before failure)
Device Performance
Valve frozen open in utilities plant
Time For Action > 1 year Early alarm to MAINTENANCE only as there is long time before process impact
Process impact
time
Failure of a Critical Valve Column Impacts The Process Immediately
Device Performance
Valve frozen open in distillation column

Time For Action < 30 minutes
Early alarm to MAINTENANCE and OPERATOR as action is required immediately to prevent process problems
Process impact
time
Plants Must Have An Alarm Message Map Alarm Destination Map

Operator Maintenance Safety Personnel
Cost of Ignoring Alarm
Maintenance Optimization Personnel Safety Personnel
High Priority Operator
Medium Priority Maintenance Optimization Personnel History Collection Low Priority
Medium Priority
Time To Avoid Process/Safety Impact

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
Alarm Messaging Map

Asset Health
Degraded Safety SMART Alarms

ANALYTICAL
SMART Predictive Abnormal SAFETY Situation Alarms
SMART MEASUREMENT
SMART FINAL CONTROL
All Critical Alarms To Operator

(Regardless of whether a device or controller created them)
OPERATOR INTERFACE
SMART ANALYTICAL
SMART SAFETY
SMART MEASUREMENT
SMART FINAL CONTROL
Operator Interface
Alert The Operator Before Process Impact

PT-101
All Asset Alarms To Maintenance

ASSET INTERFACE
SMART ANALYTICAL
SMART SAFETY
SMART MEASUREMENT
SMART FINAL CONTROL
Maintenance / Reliability Dashboard
All Safety Alarms To Safety Personnel

Degraded Safety SMART Alarms

ANALYTICAL
SMART SAFETY
SMART MEASUREMENT
SMART FINAL CONTROL
Safety Personnel Are Roaming

Cell phone, pager, email Detailed Summary
Best Practices For Operator Alarms EEMUA 191 Benchmarks

Plant Alarms
Average Alarm rate (over 10 minutes) Alarms after plant upset (over 10 minutes) Average number of standing alarms Average number of shelved alarms
#
1 10 10 30
Configured Alarm Priority Mix

Critical alarms High Alarms Medium Alarms Low Alarms
Milford Haven was 25x the recommended maximum
#
< 1% 5% 15% 80%
Exceed EEMUA guidelines
Alarm Analysis Dashboard
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
Poor Health Delivers Unsatisfactory Results At 200 kph !!!
Expect Poor Performance In Plants With Poor Asset Health

Mercury Filled Transmitters & Switches Disconnected Damper Drive Leaking Valve Body
Poor Equipment Results in Poor Performance and Unsafe Plants


Advanced Control Dashboard
Poorly performing control is identified

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
Scheduling Online Optimization Advanced Process Control (APC) Soft Sensors, Model Based Supervision PIMS, PIMS interfaces DCS, Basic Automation Field Level, Instrumentation
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
Shell Deer Park Revamp 2003
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
Shell Deer Park Refining Company Deer Park Refining Limited Partnership
Control Room
BEFORE
AFTER
Cabinet
BEFORE
AFTER
Field Junction
BEFORE
AFTER
Control Valve Diagnostics

ValveLink diagnostics prior to cutover found a hidden problem. This valve has not been in automatic for years!
Roger Erfurdt, Deer Park Control Systems manager, has stated that getting this loop to run in automatic has paid for the entire investment in diagnostics.
Results Delivered
Operational Excellence
Safety: No OSHAs Environmental: No Incidents State of the art operating interfaces
Financial
1% maintenance cost reduction achieved (3%+ is believed possible) Overall 1-3% utilization improvement Improved unit reliability Greatly improved maintenance effectiveness Huge project savings by reutilizing previous engineering
BARRIERS To Operational Excellence
Overly aggressive focus on CAPEX
The technology change is the easiest

In plant visionaries are necessary and hard to find Management support is critical The human resistance to change is greater than you think
Satellite Service Providers Know Tire Pressure
What use is there for the oldfashioned tire gauge?

Change Or Be Changed
There are two kinds of organizations in today's world:

those that are changing those that are going out of business
Jim Clemmer http://www.clemmer.net
Similarly, there are also two kinds of people

Those who are changing Those who are setting themselves up to be victims of change
Cannot Be Done Without Technology Cannot Be Done With Technology Alone

Technology And Experience Deliver Performance


Emerson Eng

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Emerson Eng

Uploaded by

Copyright:

Available Formats

Achieving Operational Excellence

The World Has Gone DIGITAL!

Copyright Emerson Process Management, March 2006, Slide 2

Law Of Accelerating Returns

Copyright Emerson Process Management, March 2006, Slide 3

Storage is free: $65 My old PC

We Have To Serve Both Greenfield and Brownfield Customers

NA LA W Europe E Europe ME Africa AP

Expansion / Modernization 66%

Shell - Our Vision

Focus on cost Low life cycle cost

Obsolesce resistance must be based on industry standard software norms

Copyright Emerson Process Management, March 2006, Slide 6

The Technology Universe

W-bluetooth Energy Scavenging DSPs Security S99 GPRS

Artificial Intelligence Ultrasonic AES

Motes Predictive Algorithms MEMS

Scaleable Graphics - Avalon

Parallel computing Vista UML RSS OPC UA

Model Base Programming

Process Diagnostics HART

Bit Torrent OPML

802.11 (beyond G) Skype

Fewer unscheduled outages Safer operation

Shorter scheduled outage

Tire icon indicates low pressure

Smart cars monitor tire pressure

Messages I do not get Check engine Big red oil light

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

Change Oil Light

Oil Pressure Alarm

Major Performance Impact

We Help Our Customers Deploy Smart Digital Plants

Copyright Emerson Process Management, March 2006, Slide 13

Smart Plant Architecture

SMART MACHINERY HEALTH MANAGEMENT

SMART FINAL CONTROL

Copyright Emerson Process Management, March 2006, Slide 14

Todays Smart Field Devices Predict Abnormal Situations

On-board computing power enables step changes in functionality

At 12:45 tomorrow, this valve will fail

Copyright Emerson Process Management, March 2006, Slide 15

Intelligent Devices Report Health

Device alert Device failure Process Impact

Smart Plant Architecture

SMART MACHINERY HEALTH MANAGEMENT

SMART FINAL CONTROL

Copyright Emerson Process Management, March 2006, Slide 17

Smart Predictive Alerts

Copyright Emerson Process Management, March 2006, Slide 18

Smart Predictive Alerts

Copyright Emerson Process Management, March 2006, Slide 19

Smart Predictive Alerts

Valve is performing sub-optimally

Copyright Emerson Process Management, March 2006, Slide 20

Smart Predictive Alerts

Valve needs maintenance

Copyright Emerson Process Management, March 2006, Slide 21

Smart Predictive Alerts

Compressor needs maintenance

Copyright Emerson Process Management, March 2006, Slide 22

10 Year Old Plants Do Not Have Predictive Capabilities

Process view is fuzzy

Process view clear