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Oil & Gas Operational Excellence 8 th Africa Oil & Gas Conference Morocco 2004 Phil Millette Oil & Gas Industry Consultant Honeywell Process Solutions.

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Presentation on theme: "Oil & Gas Operational Excellence 8 th Africa Oil & Gas Conference Morocco 2004 Phil Millette Oil & Gas Industry Consultant Honeywell Process Solutions."— Presentation transcript:

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

2 Content Owner: Phil Millette Last Modified: Apr, 2004 Process SolutionsAgendaAgenda Introduction Oil & Gas industry drivers / challenges What is Operational Excellence? Solution components & Customer Examples

3 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Honeywell’s Business Segments Broad and Diverse Businesses, Technologies and Products 2003 Sales $8.8B $3.7B $7.5B $3.2B Aerospace Specialty Materials Automation and Control Solutions Transportation Systems Total = $23B

5 Content Owner: Phil Millette Last Modified: Apr, 2004 Process 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 Automation and Control Solutions

6 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Consistent Evolution for Customer Investment Protection TDC 2000 (1974) TDC 3000 (1983) TDC 3000x (1992) TPS (1996) PCDM (1988) SCAN 3000 (1993) Plant Scape (1996) (2002) Evolution of Honeywell Automation Technology FSC Safety Manager Asset Manager PKS

7 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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. Experion PKS Process Knowledge System

8 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Exploration Upstream Processing Production Onshore Oil Offshore Oil & Gas Gas PipelinesDrilling Transportation Deep Water Oil Tankers Power Generation Storage FPSO Gas Pipelines Gas Processing LNG Liquefaction LNG Regasification and Storage Offshore Gas Oil and Gas Pipelines Drilling Oil and Gas Separation Treatment / Processing Oil and Gas Separation / Processing / Storage Oil & Gas Pipelines Oil & Gas Plants Oil Terminals Gas Terminals Gas Plants LNG Carriers Natural Gas Distribution Petrochemicals Chemicals Refining Markets Customers Offshore Production Platforms Solutions for the whole Oil & Gas Supply Chain

9 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions AGIP Amerada Hess Aramco Ashland British Gas Dakota Gasification Diamond Shamrock Dome Petroleum ELF El Paso Natural Gas Examples - Honeywell Oil & Gas Experience Northwest Pipeline Occidental Petronas Phillips Shell British Petroleum Britoil Botas Chevron Corpoven Enron Enterprise Exxon/Esso Kuwait Oil Mobil Marathon Statoil Sun Texaco Total Transok Woodside customer Gas Plant Amoco Texaco Exxon Conoco Gas Plants Corpoven Gas Fractionation / Marine Terminal Sonatrach LNG Plant Woodside Petroleum LNG/Platforms EPMI/Petronas Platforms Petronas Gas Plants Aramco Production Projects Over 15 Major North Sea Platforms Tuha Oil Field Tarim Oil Field Dukhan Oil Field AGL Pipeline Pemex Gas Fractionation Atlanta Gas Light LNG Plant Chevron Oil Field Amoco Trinidad Offshore Platform LNG Plant India Oil Pipeline BP Gas Metering Shell Pipeline Kazakhstan Well Field / Fractionation British Petroleum Well Field British Petroleum Marine Terminal Chevron Escravos Sasol

10 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Honeywell controls offshore platforms and FPS in all worldwide regions North Sea (UK and Norway) Middle East Australia Southwest Asia 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 Selected FPS References: -Hydro Troll Olje / Norway- Semisub. -Texaco Captain / UK FPSO -Woodside Laminaria / Australia FPSO -Esso Jotun / Norway FPSO Oil &Gas - Offshore production References

11 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Operational Excellence Solutions Production OFF-SHORE PLATFORMS ONSHORE GAS/OIL FIELDS Transportation Field Instrumentation SCADA / DCS & Safety, Security Systems Oil & Gas Process & Production Management Solutions Asset Management & Security Solutions Honeywell Integrated Oil & Gas Solutions Processing PRODUCTION TERMINAL GAS PLANT Business metrics Best practices Improved Performance Lower OPEX

13 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Operating Excellence: Achieving Optimal asset performance DCS/ESD Regulatory Control APC Optimization Operator CMMS Asset Diagnostics Maintenance Approach: Decision Support Diagnostic for Integrated Teams Remote expert diagnostic from support center The Future? In use now! onshore & offshore production Process Sensors Process & Asset Sensors Advanced Analysis tools Security Business Management Flexible real-time technology must support the operational business processes

16 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Improve People Effectiveness –Work Practices improvement –Learn from Operations –Safety Management Detect Problems, Mitigate Impact –Safety Management –Reliability, Uptime! : need to track health and performance of all plant and automation assets –Environmental Monitoring / compliance 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Figure from POSC SmartFields meetings: Loop Characteristics (Shell) subjectivity uncertainty complexity organizational scale production optimization production operations Reservoir Surveillance cycle time Field Development Focus on short term improvement opportunities, with given asset Enable Ease of information exchange to reservoir surveillance function

19 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Experion, Plantscape TPS Operations Enterprise Reservoir Management Reservoir Management ERP Oil & Gas Operations Excellence: Solution Map Field Security Regulatory Reporting Regulatory Reporting Enterprise Integration Integrated Field APC & Optimization Asset Management Production Management Production Management Decision Support Operator Effectiveness Operator Effectiveness Production Report Intelligent Choke Cntrl Pipeline Leak Detection* Well Test Manager Production Event Analyst & Shift Report Production Event Analyst & Shift Report Metering Report Production Summary Shut Down Analyzer Safety State PCC Rich Client & Thin Client PCC Rich Client & Thin Client Safety Valve Scout KPI Manager Operations Management Operations Management All the components to achieve Operations Excellence

20 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions A Typical Control Room Screen Proprietary and Confidential

23 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Experion, Plantscape TPS Operations Enterprise Reservoir Management Reservoir Management ERP Oil & Gas Operations Excellence: Solution Map Field Security Regulatory Reporting Regulatory Reporting Enterprise Integration Integrated Field APC & Optimization Asset Management Production Management Production Management Decision Support Operator Effectiveness Operator Effectiveness Production Report Intelligent Choke Cntrl Pipeline Leak Detection* Well Test Manager Production Event Analyst & Shift Report Production Event Analyst & Shift Report Metering Report Production Summary Shut Down Analyzer Safety State PCC Rich Client & Thin Client PCC Rich Client & Thin Client Safety Valve Scout KPI Manager Operations Management Operations Management All the components to achieve Operations Excellence

24 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Solution Components Asset Effectiveness – Early, rich diagnostics per type of equipment  Including partnerships with 3 rd 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions The Asset Manager PKS – responding to faults Fill out a work order … Clicking on the advised action can trigger an action--in this case a work order An action has many different possibilities Send a page... Or an ... Or run a program …

28 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Asset Manager as the key real-time notification and work flow platform OPC APC Scout APC Apps Asset Manager PKS Safety Valve Scout Asset Management Collaborative Control Center Scouts Safety Valves All Loops Loop Scout Turbo Suite Rotating Profit Sensor Data Scout HART & FF Shutdown Analyzer Valves.. All Experion PKS Virtual Notification via all methods, including Experion Alarm interface Collaboration and Impact Assessment Documentation, Information IntelaTrac PKS Field Entry, View The plant is more than the sum of the instruments Usable on any facility, whatever the automation platform

29 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Well Test Manager - Sample Displays Well Testing - test and flow details, flow/pressure curve, test times

33 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Experion, Plantscape TPS Operations Enterprise Reservoir Management Reservoir Management ERP Oil & Gas Operations Excellence: Solution Map Field Security Regulatory Reporting Regulatory Reporting Enterprise Integration Integrated Field APC & Optimization Asset Management Production Management Production Management Decision Support Operator Effectiveness Operator Effectiveness Production Report Intelligent Choke Cntrl Pipeline Leak Detection* Well Test Manager Production Event Analyst & Shift Report Production Event Analyst & Shift Report Metering Report Production Summary Shut Down Analyzer Safety State PCC Rich Client & Thin Client PCC Rich Client & Thin Client Safety Valve Scout KPI Manager Operations Management Operations Management All the components to achieve Operations Excellence

34 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions Field Optimization Network iDO Well, Pipe Network, Facilities iDO Well, Pipe Network, Facilities Profit Optimizer Profit Controllers SCADA UNIFORMANCE Facilities Manifold Well Choke Valve Field Pump Oil Gas Gathering Compressor

36 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions SEPARATOR 1 MV CONTROL PVO OBJECTIVE FUNCTION {PRODUCT VALUES, ENERGY COSTS} Profit Optimizer – MV Control coord Wells, Separators Profit Bridge Production Planning SEPARATOR 2 MV CONTROL GAS LOOP MV CONTROL MULTIPLE CHOKES MV CONTROL i -DO i -DO Server i -DO Client Targets LAN/WAN/Internet/Int ranet 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 Managemen t Economic Parameters GAIN AIM i -DO SUSTAIN Profit Controllers (RMPCT) Integrated Field-Wide optimisation: Closing the loop with Multivariable Control

37 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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 3 rd 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 Content Owner: Phil Millette Last Modified: Apr, 2004 Process Solutions 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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