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Achieving Operational Excellence. March, 2006. The World Has Gone DIGITAL!. Law Of Accelerating Returns. Analysis shows that Technological change is exponential. My old PC. Disposable printers?. Storage is ‘free’: $65. Greenfield. 34%. Expansion /. Modernization. 66%.

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law of accelerating returns
Law Of Accelerating Returns

Analysis shows that Technological change is exponential

slide4

My old PC

Disposable printers?

Storage is ‘free’: $65

shell our vision
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
The Technology Universe

W-bluetooth

Parallel computing

Energy Scavenging

.NET

GPRS

AVALON

DSP’s

Smart Objects

Artificial

Intelligence

Security S99

Motes

Scaleable

Graphics - Avalon

Ultrasonic

AES

Predictive Algorithms

MEMS

Model Base

Programming

.NET

Vista

SOA

GPS

RSS

Enhanced EDDL

FoundationFieldbus

UML

Advanced Signal Processing

OPC UA

802.15.4

PAT

FireFox

Process Diagnostics

MP3

Moore’s Law

XML

Security

HART

Fuel Cells

Bit Torrent

802.11 (beyond G)

OPML

Skype

operational excellence

 Higher sustained production with minimize costs

 Longer duration to scheduled outage

 Faster time-to profit

 Shorter scheduled outage

 Fewer unscheduled outages

 Safer operation

Operational Excellence

Profit

$

time

Cost

slide9

Tire icon indicates low pressure

Smart cars monitor tire pressure

Car advises driver of abnormal situation made possible via disruptive technologies

slide10

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

slide11

Two requirements:

- Sensing technology

- Presentation to user at the right time

sequence of events

Early

warning

Sequence Of Events

Change Oil Light

Oil Pressure Alarm

Major Performance Impact

Car Performance

Safety incident

time

slide13

We Help Our Customers

Deploy Smart Digital Plants

smart plant architecture

SMART

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

Smart Plant Architecture
today s smart field devices predict abnormal situations
Today’s 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

Intelligent Devices Report Health

Device alert

Device failure

Process Impact

Plant Performance

Safety Incident

time

smart plant architecture1

SMART

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

Smart Plant Architecture
smart predictive alerts valve example
Smart Predictive AlertsValve Example

Valve is performing sub-optimally

smart predictive alerts valve example1
Smart Predictive AlertsValve Example

Valve needs maintenance

10 year old plants do not have predictive capabilities
10 Year Old Plants Do Not Have Predictive Capabilities

Process view clear

Process view is fuzzy

a real case of not seeing what is happening
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

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

Should All These Alarms Go To The Operator?

?

alarms to operator example shown no

Time For Action > 6 months

Early alarm to MAINTENANCE only as there is a long time before process impact.

Alarms To Operator?Example shown: NO

Device Performance

Impellor Imbalance

Motor Overheating

Process Impact

time

alarms to operator example shown no long time before failure

Time For Action > 1 year

Early alarm to MAINTENANCE only as there is long time before process impact

Alarms To Operator?Example shown: NO (long time before failure)

Valve frozen open in utilities plant

Device Performance

Process impact

time

failure of a critical valve column impacts the process immediately

Time For Action < 30 minutes

Early alarm to MAINTENANCE and OPERATOR as action is required immediately to prevent process problems

Failure of a Critical Valve Column Impacts The Process Immediately

Valve frozen open in distillation column

Device Performance

Process impact

time

plants must have an alarm message map

High Priority

Medium Priority

Medium Priority

Low Priority

Plants Must Have An Alarm Message Map

Alarm Destination Map

  • Operator
  • Maintenance
  • Safety Personnel
  • Maintenance
  • Optimization Personnel
  • Safety Personnel

Cost of

Ignoring

Alarm

  • Operator
  • Maintenance
  • Optimization Personnel
  • History Collection

Time To Avoid Process/Safety Impact

the importance of alarm handling
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

SMART

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

Alarm Messaging Map

Asset Health

Degraded Safety Alarms

Predictive Abnormal Situation Alarms

all critical alarms to operator regardless of whether a device or controller created them

SMART

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

All Critical Alarms – To Operator(Regardless of whether a device or controller created them)

OPERATOR INTERFACE

slide33

Operator Interface

Alert The Operator Before Process Impact

PT-101

all asset alarms to maintenance

SMART

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

All Asset Alarms To Maintenance

ASSET INTERFACE

all safety alarms to safety personnel

SMART

DIGITAL CONTROL

SAFETY

SMART

ASSET OPTIMIZATION

SMART

MEASUREMENT

SMART

ANALYTICAL

SMART

SAFETY

SMART

FINAL CONTROL

SMART

FINAL CONTROL

SMART

MEASUREMENT

SMART

SAFETY

SMART

ANALYTICAL

SMART

MACHINERY HEALTH

MANAGEMENT

All Safety Alarms To Safety Personnel

Degraded Safety Alarms

safety personnel are roaming
Safety Personnel Are Roaming

Cell phone, pager, email…

Detailed Summary

best practices for operator alarms eemua 191 benchmarks
Best Practices For Operator Alarms EEMUA 191 Benchmarks

Milford Haven was 25x the recommended maximum

slide39

Exceed EEMUA guidelines

Alarm Analysis Dashboard

in a smart plant does the number of alarms to the operator increase
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
expect poor performance in plants with poor asset health
Expect Poor Performance In Plants With Poor Asset Health

Disconnected

Damper Drive

Leaking Valve

Body

Mercury Filled

Transmitters & Switches

Poor Equipment Results in Poor Performance and Unsafe Plants

expect poor performance in plants with poor asset health1
Expect Poor Performance In Plants With Poor Asset Health

Advanced Control Dashboard

Poorly performing control is identified

expect poor performance in plants with poor asset health2

SchedulingOnline Optimization

Advanced Process Control (APC)

Soft Sensors, Model Based Supervision

PIMS, PIMS interfaces

DCS, Basic Automation

Field Level, Instrumentation

Expect Poor Performance In Plants With Poor Asset Health

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
some smart plant builders
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

our vision shell deer park

Shell Deer Park Refining Company

Deer Park Refining Limited Partnership

“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
control room

Shell Deer Park Refining Company

Deer Park Refining Limited Partnership

Control Room

BEFORE

AFTER

cabinet

Shell Deer Park Refining Company

Deer Park Refining Limited Partnership

Cabinet

BEFORE

AFTER

field junction

Shell Deer Park Refining Company

Deer Park Refining Limited Partnership

Field Junction

BEFORE

AFTER

control valve diagnostics
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
Results Delivered
  • Operational Excellence
    • Safety: No OSHA’s
    • 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
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
Satellite Service Providers Know Tire Pressure…

What use is there for the old-fashioned tire gauge?

change or be changed
“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
  • Similarly, there are also two kinds of people
    • Those who are changing
    • Those who are setting themselves up to be victims of change

Jim Clemmer

http://www.clemmer.net

slide56

Cannot Be Done Without Technology

Cannot Be Done With Technology Alone