Oil gas operational excellence
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Not an official UNCTAD record. Oil & Gas Operational Excellence. 8 th Africa Oil & Gas Conference Morocco 2004 Phil Millette Oil & Gas Industry Consultant Honeywell Process Solutions. Agenda. Introduction Oil & Gas industry drivers / challenges What is Operational Excellence?

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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


Agenda

Agenda

  • Introduction

  • Oil & Gas industry drivers / challenges

  • What is Operational Excellence?

  • Solution components & Customer Examples


Company overview

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.


Honeywell s business segments

Honeywell’s Business Segments

SpecialtyMaterials

Aerospace

$3.2B

$8.8B

$7.5B

$3.7B

Automation

and Control Solutions

Transportation Systems

2003 Sales

Total = $23B

Broad and Diverse Businesses, Technologies and Products


Automation and control solutions

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


Examples honeywell oil gas experience

Northwest Pipeline

Occidental

Petronas

Phillips

Shell

Examples - Honeywell Oil & Gas Experience

Amoco Trinidad

Offshore Platform

LNG Plant

Kazakhstan

Well Field / Fractionation

British Petroleum

Well Field

Over 15 Major

North Sea Platforms

Atlanta Gas Light

LNG Plant

Tarim

Oil Field

Tuha

Oil Field

British Petroleum

Marine Terminal

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

Aramco

Production

Projects

Chevron Escravos

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

Statoil

Sun

Texaco

Total

Transok

Woodside


Oil gas offshore production references

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


Honeywell integrated oil gas solutions

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

Improved

Performance

Lower OPEX

Business

metrics

Best

practices

GAS PLANT

Processing

OFF-SHORE PLATFORMS

Production

SCADA / DCS & Safety, Security Systems

Field Instrumentation


Oil gas operational excellence1

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


Operating excellence achieving optimal asset performance

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


Operating excellence challenges

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


Honeywell s approach

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


Figure from posc smartfields meetings loop characteristics shell

Figure from POSC SmartFields meetings: Loop Characteristics (Shell)

Focus on short term improvement opportunities, with given asset

cycle time

Field Development

production optimization

Reservoir Surveillance

production operations

subjectivityuncertaintycomplexity

Enable Ease of information exchange to reservoir surveillance function

organizational scale


Oil gas operations excellence solution map

Oil & Gas Operations Excellence: Solution Map

Reservoir

Management

ERP

Decision Support

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*

Metering Report

Intelligent Choke Cntrl

Security

Integrated Field

Safety Valve Scout

Safety State

Field

Shut Down Analyzer

All the components to achieve Operations Excellence


Operational excellence solutions people business

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


Operational excellence solutions people business1

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


A typical control room screen

A Typical Control Room Screen

Proprietary and Confidential


Oil gas operations excellence solution map1

Oil & Gas Operations Excellence: Solution Map

Reservoir

Management

ERP

Decision Support

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*

Metering Report

Intelligent Choke Cntrl

Security

Integrated Field

Safety Valve Scout

Safety State

Field

Shut Down Analyzer

All the components to achieve Operations Excellence


Operational excellence solutions assets

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


Operational excellence solutions assets1

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 email, SMS etc messaging.

Reliable means more production, lower cost, more safety


Solution components

Asset Effectiveness

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

Solution Components


Oil gas operational excellence

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 email...

Or run a program …


Asset manager as the key real time notification and work flow platform

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

Field Entry, View

Asset

Manager

Asset Management

Collaborative Control Center

IntelaTrac PKS

PKS

Scouts

Safety

Loop

Turbo

Profit

Data

HART

Shutdown

APC

Scout

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


Oil gas operations excellence solution map2

Oil & Gas Operations Excellence: Solution Map

Reservoir

Management

ERP

Decision Support

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*

Metering Report

Intelligent Choke Cntrl

Security

Integrated Field

Safety Valve Scout

Safety State

Field

Shut Down Analyzer

All the components to achieve Operations Excellence


Operational excellence solutions process

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!


Oil gas operational excellence

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


Integrated field wide optimisation closing the loop with multivariable control

Integrated Field-Wide optimisation:Closing the loop with Multivariable Control

AIM

i-DO

i-DO

GAIN

SUSTAIN

Production Data

Management

i-DO Server

Profit Bridge

Production Planning

Targets

Well PerfCurves

Network Model and Optimizer

ProductionTests

EconomicParameters

WellModels

Pres,GOR, BS&W

Pres, kh,Skin

Review,Approval

ReservoirModels

TransientPressure Analysis

i-DO Client

LAN/WAN/Internet/Intranet

EngineerPCs

PVO OBJECTIVE FUNCTION

{PRODUCT VALUES, ENERGY COSTS}

Profit Optimizer – MV Control coord

Profit Controllers

(RMPCT)

MULTIPLE

CHOKES

MV CONTROL

SEPARATOR 2

MV CONTROL

GAS LOOP

MV CONTROL

SEPARATOR 1

MV CONTROL

Wells, Separators


Additional areas covered by honeywell

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


Oil gas operational excellence conclusions

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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