Presentation is loading. Please wait.

Presentation is loading. Please wait.

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

Similar presentations


Presentation on theme: "Process, Power & Marine SmartPlant Process Safety Ray Howarth 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam."— Presentation transcript:

1 Process, Power & Marine SmartPlant Process Safety Ray Howarth August 2008 Hilton Opera Hotel Hanoi, Vietnam

2 Process, Power & Marine January 21, 2014– 2 – Operating the Plant Integrate ALL Information... DESIGN & PROCESS Create the SMART PLANT of the Future … Making Plants Smarter, Safer & More Profitable By Design

3 Process, Power & Marine January 21, 2014– 3 – The process always tells on itself. BASF Sr. Staff Engineer. Cuts through information overload WHATWHEN Its not WHAT you know, its WHEN you know it! FALCONEER Listens … Making Plants Smarter, Safer & More Profitable By Design

4 Process, Power & Marine January 21, 2014– 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 FALCONEERIV 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

5 Process, Power & Marine 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 SMART PLANT PERFECT PLANT INTELLIGENT PLANT of the FUTURE

6 Process, Power & Marine January 21, 2014– 6 – Operation at Design Operation at Capacity Instrumentation Calibration Safety Systems ISO Systems Environmental Systems Design Validation & Operational Risk Making Plants Smarter, Safer & More Profitable By Design

7 Process, Power & Marine 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 Process, Power & Marine January 21, 2014– 8 – CONTROL SYSTEM Flow Temperature Pressure Level SHOULD WORK IS WORKING ADVICE OK OR PROBLEMS Process Design and Operation Information THE MFG PROCESS System Auditing Point Auditing DIGITAL DASHBOARD KPI CHARTS REPORTS S How Does FALCONEER IV Work? Making Plants Smarter, Safer & More Profitable By Design

9 Process, Power & Marine January 21, 2014– 9 – WHAT HAPPENED SINCE YESTERDAY? CHECK OPERATIONS CONTROL ROOM SPREADSHEETS DCS TOOLS PROBLEMS? IMMEDIATE ACTION ADDITIONAL RESOURCES REQUIRED LONGER TERM PLAN FORM TEAM GATHER INFO ANALYZE INFO ID CAUSE DEVELOP SOLUTIONS CREATE PROJECT DOCUMENT PSM ISO MOC OPERATION NORMAL PROJECT WORK REPORTS MEETINGS INTERRUPTIONS PROCESS PROBLEMS PROCESS OPPORTUNITIES IMPLEMENT SOLUTION FORM TEAM DEVELOP PLAN INVESTIGATE GATHER INFO ANALYZE INFO IDENTIFY CAUSE DEVELOP SOLUTIONS PREPARE FOR TOMORROW at Improved Daily Workflow & Information Management Making Plants Smarter, Safer & More Profitable By Design

10 Process, Power & Marine 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 The real value of right information at the right time! Making Plants Smarter, Safer & More Profitable By Design 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 Process, Power & Marine 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 Savings per Cost of Production Low (cents / $) High (cents / $) Operating Costs Reduction Maintenance Costs Reduction Improved Efficiencies Addl Product Sales Reduced Energy Usage OVERALL ANNUAL COST SAVINGS POTENTIAL % UNIT COST Improvement 1.6%6.0% + IMPROVED SAFETY The real value of right information at the right time! Making Plants Smarter, Safer & More Profitable By Design

12 Process, Power & Marine

13 January 21, 2014– 13 – 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

14 Process, Power & Marine January 21, 2014– 14 – Design to Operations Business Cases Add Monitoring System for Compliance Automating HAZOP Process Correcting Equipment Performance Correcting Equipment Performance Support Systems PID Equipment Spec Instrument Specs Predictive / Preventive Maintenance Simulations Excel Pilot Study Reports SOPS Making Plants Smarter, Safer & More Profitable By Design

15 Process, Power & Marine January 21, 2014– 15 – Intelligent P&IDs Existing P&IDs Implement Project Develop Solution 1) Design Modification 2) Process Change DCS Historian Data Consolidation Specifications Controls Piping Other Correcting Performance Equipment or Process Unit Underperforming DCS Historian ID Problem & Root Cause Validate Solution Engineering Models Spreadsheets, Simulations Maintain & Optimize Improved or Design Performance Real-Time Performance Monitoring & Auditing Safety check Making Plants Smarter, Safer & More Profitable By Design

16 Process, Power & Marine January 21, 2014– 16 – 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 TaskTodaySmart Plant Problem Analysis & ID16$1,6002$200 As-built40$2,40010$600 Safety Check100$6,00040$2,400 Process Validation125$7,50035$2,100 Update design80$4,80040$2,400 Commissioning24$1,44012$720 Update documentation25$1,50010$600 Savings$25,240$9,020 *based on estimates Savings$16,220 Workflow cases per year7$113,540 ROI – Correcting Performance Making Plants Smarter, Safer & More Profitable By Design

17 Process, Power & Marine January 21, 2014– 17 – 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

18 Process, Power & Marine January 21, 2014– 18 – 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 1 st 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

19 Process, Power & Marine January 21, 2014– 19 – 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. Chemical\Petrochemical Solid Oxidizer Plant EO Plant Polymerization Plants Incinerators Pipelines (Oil & Gas) Salt Plant Water & Waste Water Utilities Chemicals Energy Power Generation Co-Generation Boiler Systems Pulp & Paper Pulp Mill Making Plants Smarter, Safer & More Profitable By Design

20 Process, Power & Marine CUSTOMER WANTS… 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 USER $$$ Making Plants Smarter, Safer & More Profitable By Design SAP SmartPlant Enterprise

21 Process, Power & Marine January 21, 2014– 21 – 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

22 Process, Power & Marine January 21, 2014– 22 – INTERGRAPH 2008 Presenter: Dr. Doug Lenz Q & A Making Plants Smarter, Safer & More Profitable By Design

23 Process, Power & Marine January 21, 2014– 23 – 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

24 Process, Power & Marine January 21, 2014– 24 – Method Of Minimal Evidence Example Secondary Model (Eliminates Flow 1 ) SM 1 = 0 = Flow 2 * cp * (Temp 2 – Temp 1 ) – Flow 3 * cp * (Temp 3 – Temp 1 ) Primary Models (Mass and Energy Balances) PM 1 = 0 = Flow 1 + Flow 2 – Flow 3 – Leaks PM 2 = 0 = Flow 1 * cp * Temperature 1 + Flow 2 * cp * Temperature 2 – Flow 3 * cp * Temperature 3 – Leaks * cp * Temperatures Making Plants Smarter, Safer & More Profitable By Design

25 Process, Power & Marine January 21, 2014– 25 – Virtual Statistical Process Control (V-SPC) Controlled Process Variable Virtual EWMA Chart Flow meter Controlled Process Variable Flow Meter Failure - 12 Hours before TDC Alarm Indication Making Plants Smarter, Safer & More Profitable By Design

26 Process, Power & Marine January 21, 2014– 26 – Why Cant 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

27 Process, Power & Marine January 21, 2014– 27 – A Powerful Union The Power of Information Captured in SmartPlant P&ID The Goldmine of Information & Wisdom Provided by FALCONEER Process Performance Auditing Making Plants Smarter, Safer & More Profitable By Design

28 Process, Power & Marine January 21, 2014– 28 – ROI – Automating HAZOP & Beyond Cost savings Cost of the solution for 3 users $95k (incl. training and few days of consultancy) ROI with the first year of projects $168,000 - $95,000=$73,000 TaskTodaySmart Plant Safety Study500$30,000230$13,800 Design updates100$6,00040$2,400 Process Validation200$12,00075$4,500 Update documentation75$4,50020$1,200 Isometric updates75$4,50025$1,500 Commissioning Savings$57,000$23,400 *based on estimates Savings$33,600 Workflow cases per year5$168,000 Making Plants Smarter, Safer & More Profitable By Design

29 Process, Power & Marine January 21, 2014– 29 – Business Case Automating HAZOP Process & Beyond Benefits Increase the plant safety Reduce risk of production interruption Execute safety study faster and with consistent approach Consistent and auditable study MOC Making resource available for operational tasks Making Plants Smarter, Safer & More Profitable By Design

30 Process, Power & Marine January 21, 2014– 30 – Engineering & Process Data Working Together MeasuredCalculatedReal-time CostDaily CostMonthly CostYearly Cost Real-Time PV305 SCFH300 SCFH$45 / hr$1,080$32,400 $394 K Design PV325 SCFH Deviation+ 5 SCFH- 20 SCFH TOTAL Cost$45 / hr$180 / hr$225 / hr$5,400$162,000 $1.97 M Calibration Error Cost $394 K, Underperforming Asset $1.97 M Incinerator Performance – Environmental Liability, Gas Consumption Making Plants Smarter, Safer & More Profitable By Design

31 Process, Power & Marine SmartPlant Process Safety Ray Howarth August 2008 Hilton Opera Hotel Hanoi, Vietnam


Download ppt "Process, Power & Marine SmartPlant Process Safety Ray Howarth 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam."

Similar presentations


Ads by Google