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Oil & Gas Operational Excellence

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Presentation on theme: "Oil & Gas Operational Excellence"— Presentation transcript:

1 Oil & Gas Operational Excellence
Not an official UNCTAD record Oil & Gas Operational Excellence 8th Africa Oil & Gas Conference Morocco 2004 Phil Millette Oil & Gas Industry Consultant Honeywell Process Solutions

2 Agenda Introduction Oil & Gas industry drivers / challenges
What is Operational Excellence? Solution components & Customer Examples

3 Company Overview 108,000 employees in nearly 100 countries
A Fortune 100 company – $23 billion sales in year 2003 One of 30 select companies represented by the Dow Jones Industrial Average On Money magazine’s list of 75 Best Benefits companies for the third consecutive year – December 2003 Winner of the Technology and Business Vision Award from Start magazine and Microsoft®, and the Control Engineering Editors’ 2003 Choice Award, for Honeywell’s Experion PKS™ system, an integrated solution that boosts manufacturing capacity and cost effectiveness.

4 Honeywell’s Business Segments
2003 Sales $8.8B $3.7B $7.5B $3.2B Aerospace Specialty Materials Automation and Control Solutions Transportation Systems Total = $23B Broad and Diverse Businesses, Technologies and Products

5 Automation and Control Solutions
Businesses: Honeywell Fire Solutions Honeywell Sensing & Control Now also including Honeywell Sensotec Honeywell Environmental Combustion & Control Honeywell Building Solutions Honeywell Process Solutions Products: Controls for heating, cooling, ventilation, air conditioning, humidification, industrial process automation, video surveillance, people and asset tracking and access control equipment; Security/fire alarm and industrial safety systems, home automation systems; Advanced software applications for home/building control and industrial optimization; Sensors, switches, control systems and instruments for measuring pressure, air flow, temperature, electrical current and more Drinking water solutions Combustion control solutions Commitment to service Global Presence: 40,000+ employees in 100 countries Headquarters: Minneapolis, Minnesota Sales --- $7.5 billion in 2003

6 Evolution of Honeywell Automation Technology
TDC 2000 (1974) TDC 3000 (1983) TDC 3000x (1992) TPS (1996) PCDM (1988) SCAN 3000 (1993) Plant Scape (2002) FSC Safety Manager PKS @ssetMax Asset Manager PKS Consistent Evolution for Customer Investment Protection

7 Experion PKS Process Knowledge System
Honeywell’s Process Knowledge System™ expands the role of an automation platform to address all of a company’s critical business objectives. Experion PKS combines best-in-class technologies of existing Honeywell systems and emerging new technologies to provide customers with an enterprise-wide automation solution.

8 Solutions for the whole Oil & Gas Supply Chain
Exploration Production Upstream Processing Transportation Storage Markets Customers Onshore Oil Offshore Oil & Gas Gas Processing LNG Liquefaction Drilling Gas Pipelines LNG Regasification and Storage Power Generation Gas Plants Natural Gas Distribution Gas Terminals Gas Pipelines LNG Carriers Chemicals Offshore Production Platforms Oil & Gas Pipelines Petrochemicals Oil & Gas Plants Oil Terminals FPSO Refining Deep Water Oil Tankers Offshore Gas Oil and Gas Pipelines Oil and Gas Separation Treatment / Processing Drilling Oil and Gas Separation / Processing / Storage 5 6 6 4 2 5

9 Examples - Honeywell Oil & Gas Experience
Amoco Trinidad Offshore Platform LNG Plant British Petroleum Well Field Kazakhstan Well Field / Fractionation Over 15 Major North Sea Platforms Atlanta Gas Light LNG Plant Tarim Oil Field British Petroleum Marine Terminal Tuha Oil Field customer Gas Plant Petronas Gas Plants Amoco Texaco Exxon Conoco Gas Plants EPMI/Petronas Platforms Chevron Oil Field Pemex Gas Fractionation Woodside Petroleum LNG/Platforms Corpoven Gas Fractionation / Marine Terminal Sonatrach LNG Plant India Oil Pipeline AGL Pipeline BP Gas Metering Chevron Escravos Aramco Production Projects Shell Pipeline Sasol Dukhan Oil Field AGIP Amerada Hess Aramco Ashland British Gas British Petroleum Britoil Botas Chevron Corpoven Dakota Gasification Diamond Shamrock Dome Petroleum ELF El Paso Natural Gas Enron Enterprise Exxon/Esso Kuwait Oil Mobil Marathon Northwest Pipeline Occidental Petronas Phillips Shell Statoil Sun Texaco Total Transok Woodside

10 Oil &Gas - Offshore production References
Honeywell controls offshore platforms and FPS in all worldwide regions North Sea (UK and Norway) Middle East Australia Southwest Asia Selected FPS References: -Hydro Troll Olje / Norway- Semisub. -Texaco Captain / UK FPSO -Woodside Laminaria / Australia FPSO -Esso Jotun / Norway FPSO West Africa Gulf of Mexico Caribbean Recent EMEA Offshore Projects Shell Shearwater, North Sea Mobil Galahad, North Sea Amerada Hess Scott, North Sea Shell Brent, North Sea Chevron Escravos, Nigeria Chevron Robertkiri, Nigeria Statoil Kvitebjorn, Norway Esso Ringhorne, Norway Veba Hanze 2, The Netherlands ExxonMobil Skene/UK BP Clair UK / FEED Dong Naturgas Torup, Denmark

11 Honeywell Oil & Gas Installations
#1 Offshore w/ 100+ Platform and FPSO Projects Norsk-Hydro Troll, Texaco Captain, Chevron Alba, Esso Jotun, ConocoPhillips Bacton, BP GOM, Shell Expro, ConocoPhillips #1 Onshore w/ 77 Projects Tazhong IV, Chevron Kutubu, Amoco Pine Creek, BP Badami, Tengiz Chevroil, Karachaganak, Exxon Chad, Aramco #1 in Gas Processing w/ 94 Gas Plants / LNG Jobs Shell Brunei, ARAMCO Safaniya, Adco, ConocoPhillips Bacton, Phoenix Park, Exxon King Ranch #1 in Transportation w/ 65 Pipeline, 75 Terminal Projects ConocoPhillips Blue Ridge, Duke Energy - gas transmission BP Forties, CNPC - crude oil, Shell / Petronas - refined products Sonatrach LNG Export terminal, Aramco Crude Oil Terminal, Petronas Melaka truck terminal

12 Honeywell Integrated Oil & Gas Solutions
Operational Excellence Solutions Asset Management & Security Solutions Oil & Gas Process & Production Management Solutions Transportation PRODUCTION TERMINAL ONSHORE GAS/OIL FIELDS Business metrics Best practices Improved Performance Lower OPEX GAS PLANT Processing OFF-SHORE PLATFORMS Production SCADA / DCS & Safety, Security Systems Field Instrumentation

13 Oil & Gas Operational Excellence
Performing at best-possible state People Assets Process Business With the equipment, assets, production configuration we have today From minute-to-minute, hour-to-hour, day-to-day For improved management of Safety, Reliability, Security, Process & production performance optimisation, Production management

14 Industry Drivers – Operational Performance
Looking to produce reliably, consistently, optimally But managing support costs And lowering engineering costs Using more consistent approaches across assets, supportive tools But wanting increased visibility of processing facilities/ asset capability, reliability More data collection, interpretation and communication More rigorous analysis and follow up, ‘optimise’ the operations Looking to replicate use of best practices Accumulate and manage knowledge on new operations Maximizing production given short term equipment capability Lowering lifting costs Developing and bringing online additional similar facilities based on the knowledge gained Safety Security

15 Operating Excellence: Achieving Optimal asset performance
Flexible real-time technology must support the operational business processes Business Management Advanced Analysis tools Optimization CMMS Approach: Decision Support Diagnostic for Integrated Teams APC Operator Maintenance Asset Diagnostics DCS/ESD Regulatory Control The Future? In use now! Remote expert diagnostic from support center Security Process Sensors Process & Asset Sensors onshore & offshore production

16 Operating Excellence Challenges
Production Cost reduction / control Reliability, Uptime! Personnel Work Practices improvement Increased top line revenue Reliability, Uptime! Maximize production from existing facilities Push constraints Optimize process Detect Problems, Mitigate Impact Safety Management Reliability, Uptime! : need to track health and performance of all plant and automation assets Environmental Monitoring / compliance Improve People Effectiveness Work Practices improvement Learn from Operations Safety Management Lifecycle Costs Plan and Manage Version-up & obsolescence to capture operational improvements Integrated Management of automation asset WITH the plant asset Focus on more production, more reliability, more safety

17 Honeywell’s approach Honeywell looks at all Oil & Gas operational Business Processes Provide solutions that are focused on enabling the day-to-day, hour-by-hour decisions Including closed loop response capability where appropriate and possible Minute-by-minute events & activities Not focused on the drilling business processes Not focused on detailed reservoir/petrophysic part of oil & gas asset management Knowledge of Automation & safety Process Advanced Control Asset Management Production Management Security IT / Integration Expertise

18 Figure from POSC SmartFields meetings: Loop Characteristics (Shell)
cycle time Field Development production optimization Focus on short term improvement opportunities, with given asset production operations Reservoir Surveillance subjectivity uncertainty complexity Enable Ease of information exchange to reservoir surveillance function organizational scale

19 Oil & Gas Operations Excellence: Solution Map
Reservoir Management Decision Support ERP Enterprise Production Summary Enterprise Integration Operations PCC Rich Client & Thin Client Production Management Well Test Manager KPI Manager Production Report Operations Management Regulatory Reporting Production Event Analyst & Shift Report Asset Management APC & Optimization Operator Effectiveness Experion, Plantscape TPS Pipeline Leak Detection* Intelligent Choke Cntrl Metering Report Security Integrated Field Safety Valve Scout Safety State Field Shut Down Analyzer All the components to achieve Operations Excellence

20 Operational Excellence Solutions: People, Business
Production Control Center (PCC) enables improved decision making & Improved visibility of facilities Installations on Statoil Kvitebjorn, Norsk Hydro Troll B, BP Ula, BP Valhall, ChevronTexaco Alba, Talisman Gyda Consistent management & work practices Helps operators, managers focus on the real issues: find / focus on bottlenecks to improve production and manage important safety issues Single environment to manage all operations work related tasks Assign causes for production deferments Includes safety valve scout, shutdown analyzer, production event analyzer, Well test Manager Integrates production, process, safety, asset and work flow information together Designed for Collaborative work, improving work practices, such as reducing routine work load Matches the vision of major oil companies Is the overall framework enabling new value to be captured from even existing historians Use from any web page Safe and Efficient operations: It's like having the best operator on every shift

21 Operational Excellence Solutions: People, Business
Available functions / applications/ reports with PCC: Production Overview – advanced form of report and display Production Reporting Well Test Manager Production Balance Production Allocation Metering Reports Lab, chemicals, Emissions tracking Operations Monitoring & KPI - Manager Flexible Shift Reporting system Production Event Analyst Weather Information Load Stabilisation With a partner Pipeline Management, including multiphase With Fantoft as pipeline management partner

22 A Typical Control Room Screen
Proprietary and Confidential

23 Oil & Gas Operations Excellence: Solution Map
Reservoir Management Decision Support ERP Enterprise Production Summary Enterprise Integration Operations PCC Rich Client & Thin Client Production Management Well Test Manager KPI Manager Production Report Operations Management Regulatory Reporting Production Event Analyst & Shift Report Asset Management APC & Optimization Operator Effectiveness Experion, Plantscape TPS Pipeline Leak Detection* Intelligent Choke Cntrl Metering Report Security Integrated Field Safety Valve Scout Safety State Field Shut Down Analyzer All the components to achieve Operations Excellence

24 Operational Excellence Solutions: Assets
Asset Management Solutions enables path to Best Practice AND lowest cost reliable Oil & Gas Operations Overall Improvements due to 3-5% increase in production reliability & increase in throughput In some markets, savings in cost $1M-$2M due to staff effectiveness & reduction in maintenance cost Large installation on Pemex Cantarell Lower deferred production from fewer trips and unplanned shutdowns Lower maintenance cost through better real time follow up of equipment performance Transmitters, valves, process equipment, exchangers, vessels, pumps etc All plant assets can be tracked by Asset Manager Catch Abnormal Situations early! Alarm Configuration management, Early Even Detection Reliable means more production, lower cost, more safety

25 Operational Excellence Solutions: Assets
(2) Asset Management Solutions enables path to Best Practice AND lowest cost reliable Oil & Gas Operations Through TurboSuite: Better follow-up of turbo-machinery performance due to advanced real-time performance tracking Lower cost of work order generation – automatic links to ERP systems Safety Valve Scout & Shutdown Analyzer: Lower cost of safety system tests – obtain business value from analyzing actual shutdown / safety system performance. Opportunity to foster joint work teams – maintenance and operations Alert Manager: Better engineering and management response due to quicker notification of alerts: issues and potential problems, using automatic , SMS etc messaging. Reliable means more production, lower cost, more safety

26 Solution Components Asset Effectiveness Safety Management Reporting
Early, rich diagnostics per type of equipment Including partnerships with 3rd party equipment suppliers Diagnostic knowledge with the equipment itself Automate work processes Wireless field work support Calibration support Compressor / rotating equipment monitoring Control Loop monitoring Links to CMMS, documentation Safety Management Reporting Checking Shutdown systems Safety Valve monitoring Safe management of the Alarm system Remote Management Example Solutions Web-framework for oil & gas operations and production management

27 The Asset Manager PKS – responding to faults
Fill out a work order … An action has many different possibilities Send a page ... Clicking on the advised action can trigger an action--in this case a work order Or an ... Or run a program …

28 Asset Manager as the key real-time notification and work flow platform
Usable on any facility, whatever the automation platform Notification via all Collaboration methods, including Documentation, and Impact Experion Alarm Information Assessment interface Asset Manager Field Entry, View Asset Management Collaborative Control Center IntelaTrac PKS PKS Scouts Safety APC Scout Loop Turbo Profit Data HART Shutdown Valve Scout Suite Sensor Scout & FF Analyzer Scout APC Apps Safety All Experion OPC Rotating Virtual All Valves Loops PKS Valves.. The plant is more than the sum of the instruments

29 Automating “Safety Management Reporting”
For offshore installations safety is crucial Safety Equipment like Safety Valves must be monitored Safety Systems like ESD / PSD, Fire protection systems etc. have to be regularly controlled The Regulatory Agencies (government) requires regularly reports Safety Management Reporting is time consuming for offshore personnel Integrated with Asset Manager PKS, open software-enabled Safety Management can: Standardized Work-processes Continuously Monitored Real-time Remotely Managed Enables More Effectiveness of Offshore Staff

30 Shut Down Analyzer Analyze events after a ESD / PSD
Compare the events with the Cause & Effects Matrix Report the result of the comparison Web based HMI Benefits: Early detection of ESD / PSD failure Simplify safety reporting

31 Safety Valve Scout Analyze all events related to safety valves
Reports for all valves not been operated failed during operation long travel time Connection to Alert Manager is planned Output from Valve verification becomes a symptom for each valve in Alert Manager Alert Manager fills inn notification / work order

32 Well Test Manager - Sample Displays
Well Testing - test and flow details, flow/pressure curve, test times

33 Oil & Gas Operations Excellence: Solution Map
Reservoir Management Decision Support ERP Enterprise Production Summary Enterprise Integration Operations PCC Rich Client & Thin Client Production Management Well Test Manager KPI Manager Production Report Operations Management Regulatory Reporting Production Event Analyst & Shift Report Asset Management APC & Optimization Operator Effectiveness Experion, Plantscape TPS Pipeline Leak Detection* Intelligent Choke Cntrl Metering Report Security Integrated Field Safety Valve Scout Safety State Field Shut Down Analyzer All the components to achieve Operations Excellence

34 Operational Excellence Solutions: Process
APC (Advanced Process Control) and Optimization technologies boost Production, providing a direct Revenue Increase Honeywell’s APC and Optimization have repeatedly been used to increase Production and Reduce Cash Costs. Can increase production by 2% to 10% depending on current conditions Intelligent Choke controller Flexible control able to smooth impact of slugs by manipulating choke valves. Reduces trips due to smoother resulting level control in high pressure separator. Documented cases on Shell platforms Multivariable control – Profit Controller Mature technology Proven in oil & gas, onshore and offshore applications In one recent case, increase was 6000 bbl/d. Also documented cases on BP Ula platform, Woodside Optimisation – Gas Lift and field wide Coordinating multiple controllers for optimal performance Enhanced optimisation by modeling from sand face to surface, through gathering network and gas lift. – with partner EPS. APC provides proven value in oil & gas!

35 Well, Pipe Network, Facilities
Field Optimization Network Manifold iDO Well, Pipe Network, Facilities Well Choke Valve Field Pump Profit Optimizer Gathering Compressor Profit Controllers UNIFORMANCE SCADA Oil Gas Facilities

36 Network Model and Optimizer Transient Pressure Analysis
Integrated Field-Wide optimisation: Closing the loop with Multivariable Control GAIN AIM i-DO SUSTAIN i-DO i-DO Server i-DO Client Targets LAN/WAN/Internet/Intranet Review, Approval Engineer PCs Well Perf Curves Network Model and Optimizer Pres, kh, Skin Transient Pressure Analysis Pres, GOR, BS&W Reservoir Models Production Tests Well Models Production Data Management Economic Parameters Production Planning PVO OBJECTIVE FUNCTION {PRODUCT VALUES, ENERGY COSTS} Profit Bridge Profit Optimizer – MV Control coord Profit Controllers (RMPCT) SEPARATOR 1 MV CONTROL SEPARATOR 2 MV CONTROL GAS LOOP MV CONTROL MULTIPLE CHOKES MV CONTROL Wells, Separators

37 Additional areas covered by Honeywell
Operator Training simulators High fidelity Platforms, gas plants etc, as well as LNG Shell, BP as major customers Business integration Large project capability Experience at Nodco, Statoil, others Integration to SAP via Business Hiway Implementation of SAP via partner Experience at Sasol Implementation of Maximo Maintenance system Improved Production Site, Plant & platform security Honeywell security solutions include perimeter protection, Honeywell cctv cameras, Access control, Personnel on Board Implement and link in 3rd party marine or other harsh service cameras Central Management capability – country wide DVM: Digital Video Manager TemaLine Access Control Integrated, unique real-time monitoring platform – EBI. Including Caspian Pipeline consortium, Shell, Spanish nuclear plants, Dubai airport, Sydney Olympics

38 Oil & Gas Operational Excellence: conclusions
It’s achievable now Technologies exist to support integration of safety, reliability, process and business management as well as security of facilities Benefits are real: in increased production, reduced lifting costs, improved reliability and safety Does not require a capital project to get started Is not dependent on the underlying automation platform


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