SmartPlant Process Safety

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SmartPlant Process Safety Ray Howarth
21-22 August 2008 Hilton Opera Hotel Hanoi,
Vietnam
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Operating the Plant

• Integrate ALL Information ...
• DESIGN PROCESS
• Create the SMART PLANT of the Future

November 11, 2020
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• FALCONEER Listens

• Cuts through information overload
• Its not WHAT you know, its WHEN you know it!

• The process always tells on itself.
•     BASF Sr. Staff Engineer.
•  

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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

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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

SMART PLANT PERFECT PLANT INTELLIGENT PLANT of
the FUTURE
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Design Validation Operational Risk

• Operation at Design
• Operation at Capacity
• Instrumentation Calibration
• Safety Systems
• ISO Systems
• Environmental Systems

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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

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How Does FALCONEER IV Work?

• DIGITAL DASHBOARD
• KPI
• CHARTS
• REPORTS
• EMAILS

IS WORKING

• CONTROL SYSTEM
• Flow
• Temperature
• Pressure
• Level

• ADVICE

OK OR PROBLEMS
THE MFG PROCESS

• System Auditing

• Point Auditing

SHOULD WORK
Process Design and Operation Information
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Improved Daily Workflow Information Management

• at

• CHECK OPERATIONS
• CONTROL ROOM
• SPREADSHEETS
• DCS TOOLS

• OPERATION NORMAL
• PROJECT WORK
• REPORTS
• MEETINGS

• INTERRUPTIONS
• PROCESS PROBLEMS
• PROCESS OPPORTUNITIES

• PROBLEMS?
• IMMEDIATE ACTION
• ADDITIONAL RESOURCES REQUIRED

• WHAT HAPPENED SINCE YESTERDAY?

• LONGER TERM PLAN
• FORM TEAM
• GATHER INFO
• ANALYZE INFO
• ID CAUSE
• DEVELOP SOLUTIONS
• CREATE PROJECT

• INVESTIGATE
• GATHER INFO
• ANALYZE INFO
• IDENTIFY CAUSE
• DEVELOP SOLUTIONS

• IMPLEMENT SOLUTION
• FORM TEAM
• DEVELOP PLAN

• DOCUMENT
• PSM
• ISO
• MOC

• PREPARE FOR TOMORROW

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REAL BENEFITS!!
The real value of right information at the right
time!
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.

• Global Industry Benchmarks
• (BASF, FMC, PPG, Taiwan, India)
• Prevented unscheduled shutdown saving gt200,000
  per day
• Improved Power Generation Revenue gt200,000 per
  year
• 30,000 Savings with One Alert on Steam System
• Steam Reconciliation Savings of 50,000 in 6
  months
• Raw Material Savings of gt40,000 per Quarter
• Energy Savings Opportunities
• gt 70,000 per Month w/ Natural Gas
• gt 100,000 per year Pumps Blowers

Compared to other approaches, FALCONEER is more
fundamental with easily configurable and
understandable equations and logic, according to
FMC
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REAL BENEFITS!!
The real value of right information at the right
time!
Savings per Cost of Production Low (cents / ) High (cents / )
Operating Costs Reduction 0.1 2.0
Maintenance Costs Reduction 0.1 0.5
Improved Efficiencies 0.3 1.0
Addl Product Sales 1.0 2.0
Reduced Energy Usage 0.1 0.5
OVERALL ANNUAL COST SAVINGS POTENTIAL 1.6 6.0
UNIT COST Improvement 1.6 6.0

• Global Industry Benchmarks
• (BASF, FMC, PPG, Taiwan, India)
• Prevented unscheduled shutdown saving gt200,000
  per day
• Improved Power Generation Revenue gt200,000 per
  year
• 30,000 Savings with One Alert on Steam System
• Steam Reconciliation Savings of 50,000 in 6
  months
• Raw Material Savings of gt40,000 per Quarter
• Energy Savings Opportunities
• gt 70,000 per Month w/ Natural Gas
• gt 100,000 per year Pumps Blowers

IMPROVED SAFETY
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OO Bundle Solution Components

• Engineering tasks that made up the solution
• SmartPlant PID
• Rule and asset based intelligent PID 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

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Design to Operations Business Cases

• Add Monitoring System for Compliance
• Automating HAZOP Process
• Correcting Equipment Performance

• Support Systems
• PID
• Equipment Spec
• Instrument Specs
• Predictive / Preventive Maintenance
• Simulations
• Excel
• Pilot Study Reports
• SOPS

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Correcting Performance
Equipment or Process Unit Underperforming

• Data Consolidation
• Specifications
• Controls
• Piping
• Other

• DCS
• Historian

ID Problem Root Cause
Intelligent PIDs
Develop Solution 1) Design Modification 2)
Process Change

• Engineering Models
• Spreadsheets,
• Simulations

Existing PIDs
Validate Solution

• Safety
• check

Real-Time Performance Monitoring Auditing
Implement Project
Maintain Optimize Improved or Design Performance

• DCS
• Historian

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ROI Correcting Performance
Task Today Today Smart Plant Smart Plant
Problem Analysis ID 16 1,600 2 200
As-built 40 2,400 10 600
Safety Check 100 6,000 40 2,400
Process Validation 125 7,500 35 2,100
Update design 80 4,800 40 2,400
Commissioning 24 1,440 12 720
Update documentation 25 1,500 10 600
Savings 25,240 9,020
based on estimates
Savings 16,220
Workflow cases per year 7 113,540

• 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

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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 PID updates
• Safety checks on the modifications
• Ensure PID, process data, Isometrics and safety
  are all consistent and verified.

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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 1st 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

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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.

• Water Waste Water
• Utilities
• Chemicals
• Energy

• Chemical\Petrochemical
• Solid Oxidizer Plant
• EO Plant
• Polymerization Plants
• Incinerators
• Pipelines (Oil Gas)
• Salt Plant

• Power Generation
• Co-Generation
• Boiler Systems

• Pulp Paper
• Pulp Mill

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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

SAP
USER
SmartPlant Enterprise
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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!

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INTERGRAPH 2008
Q A
Presenter Dr. Doug Lenz
www.falconeertech.com
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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

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Method Of Minimal Evidence Example
Primary Models (Mass and Energy Balances) PM1 0
Flow1 Flow2 Flow3 Leaks PM2 0 Flow1
cp Temperature1 Flow2 cp Temperature2
Flow3 cp Temperature3 Leaks cp
Temperatures
Secondary Model (Eliminates Flow1) SM1 0
Flow2 cp (Temp2 Temp1) Flow3 cp
(Temp3 Temp1)
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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

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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

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A Powerful Union

• The Power of Information Captured in SmartPlant
  PID

The Goldmine of Information Wisdom
Provided by FALCONEER Process Performance
Auditing
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ROI Automating HAZOP Beyond
Task Today Today Smart Plant Smart Plant
Safety Study 500 30,000 230 13,800
Design updates 100 6,000 40 2,400
Process Validation 200 12,000 75 4,500
Update documentation 75 4,500 20 1,200
Isometric updates 75 4,500 25 1,500
Commissioning
Savings 57,000 23,400
based on estimates
Savings 33,600
Workflow cases per year 5 168,000

• 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 - 95,00073,000

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Business CaseAutomating 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

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Engineering Process Data Working Together
Measured Calculated Real-time Cost Daily Cost Monthly Cost Yearly Cost
Real-Time PV 305 SCFH 300 SCFH 45 / hr 1,080 32,400 394 K
Design PV 325 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

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