ditc commb energy 0188
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Technical PaperTRANSCRIPT
Oil & Gas Operational Excellence
8th Africa Oil & Gas ConferenceMorocco 2004
Phil MilletteOil & Gas Industry ConsultantHoneywell Process Solutions
Not an official UNCTAD record
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
AgendaAgendaAgendaAgenda
• Introduction• Oil & Gas industry drivers / challenges• What is Operational Excellence?• Solution components & Customer Examples
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Company OverviewCompany OverviewCompany OverviewCompany 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.
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Honeywell’s Business SegmentsHoneywell’s Business SegmentsHoneywell’s Business SegmentsHoneywell’s Business Segments
Broad and Diverse Businesses, Technologies and Products Broad and Diverse Businesses, Technologies and Products
2003 Sales
$8.8B$8.8B
$3.7B$3.7B
$7.5B
$3.2BAerospaceSpecialty
Materials
Automationand Control Solutions
Transportation Systems Total = $23B
Content Owner: Phil MilletteLast 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 SolutionsAutomation and Control SolutionsAutomation and Control SolutionsAutomation and Control Solutions
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
AGIPAmerada HessAramcoAshlandBritish Gas
Dakota GasificationDiamond ShamrockDome PetroleumELFEl Paso Natural Gas
Examples - Honeywell Oil & Gas ExperienceExamples - Honeywell Oil & Gas Experience
Northwest PipelineOccidentalPetronasPhillipsShell
British PetroleumBritoilBotasChevronCorpoven
EnronEnterpriseExxon/EssoKuwait OilMobilMarathon
StatoilSunTexacoTotalTransokWoodside
customerGas Plant
AmocoTexacoExxonConocoGas Plants
CorpovenGas Fractionation /Marine Terminal Sonatrach
LNG Plant
WoodsidePetroleumLNG/Platforms
EPMI/PetronasPlatforms
PetronasGas Plants
AramcoProductionProjects
Over 15 MajorNorth Sea Platforms
TuhaOil Field
TarimOil Field
DukhanOil Field
AGLPipeline
PemexGas Fractionation
Atlanta Gas LightLNG Plant
ChevronOil Field
Amoco TrinidadOffshore PlatformLNG Plant
India OilPipelineBP
Gas MeteringShellPipeline
KazakhstanWell Field / Fractionation
British PetroleumWell Field
British PetroleumMarine Terminal
Chevron Escravos
Sasol
Content Owner: Phil MilletteLast 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 FPSReferences:-Hydro Troll Olje / Norway- Semisub.-Texaco Captain / UK FPSO-Woodside Laminaria / Australia FPSO-Esso Jotun / Norway FPSO
Oil &Gas - Offshore production ReferencesOil &Gas - Offshore production ReferencesOil &Gas - Offshore production ReferencesOil &Gas - Offshore production References
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operational Excellence Solutions
ProductionOFF-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 SolutionsHoneywell Integrated Oil & Gas Solutions
Processing
PRODUCTION TERMINAL
GAS PLANTBusiness metrics
Bestpractices
ImprovedPerformanceLower OPEX
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Oil & Gas Operational ExcellenceOil & Gas Operational ExcellenceOil & Gas Operational ExcellenceOil & 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
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operating Excellence: Achieving Optimal asset Operating Excellence: Achieving Optimal asset performanceperformanceOperating Excellence: Achieving Optimal asset Operating Excellence: Achieving Optimal asset performanceperformance
DCS/ESDRegulatory
Control
APC
Optimization
Operator
CMMS
AssetDiagnostics
Maintenance
Approach:Decision Support
Diagnosticfor Integrated Teams
Remote expertdiagnostic fromsupport center
The Future?In use now!
onshore & offshore production
ProcessSensors
Process & AssetSensors
AdvancedAnalysis
tools
Security
Business Management
Flexible real-time technology must support the operational business processes
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operating Excellence ChallengesOperating Excellence ChallengesOperating Excellence ChallengesOperating Excellence ChallengesProduction 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 safetyFocus on more production, more reliability, more safety
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Honeywell’s approachHoneywell’s approachHoneywell’s approachHoneywell’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
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Figure from POSC SmartFields meetings: Figure from POSC SmartFields meetings: Loop Characteristics (Shell)Loop Characteristics (Shell)Figure from POSC SmartFields meetings: Figure from POSC SmartFields meetings: Loop Characteristics (Shell)Loop Characteristics (Shell)
subjectivityuncertaintycomplexity
organizational scale
production optimization
production operations
Reservoir Surveillance
cycle time
Physical Asset
Models
Pla
ns &
Decis
ion
s
Data
Physical Asset
Models
Pla
ns
&D
ecis
ion
s
Data
generate and
evaluate options
inte
rpre
t
and m
odel
exec
ute
acquire data
Physical Asset
Models
Pla
ns
&D
ecis
ion
s
Data
generate and
evaluate options
inte
rpre
t
and m
odel
exec
ute
acquire data
Physical Asset
Models
Pla
ns
&D
ecis
ion
s
Data
Field Development
Focus on short term improvement opportunities, with
given assetEnable Ease of information exchange to
reservoir surveillance function
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Experion, PlantscapeTPS
Operations
EnterpriseReservoir
Management
Reservoir Management
ERPERP
Oil & Gas Operations Excellence: Solution Oil & Gas Operations Excellence: Solution Map Map Oil & Gas Operations Excellence: Solution Oil & Gas Operations Excellence: Solution Map Map
Field
SecuritySecurity
Regulatory Reporting
Regulatory Reporting
Enterprise IntegrationEnterprise Integration
Integrated FieldIntegrated Field
APC & OptimizationAPC & OptimizationAsset ManagementAsset Management
Production Management
Production Management
Decision SupportDecision Support
Operator Effectiveness
Operator Effectiveness
Production ReportProduction Report
Intelligent Choke CntrlIntelligent Choke CntrlPipeline Leak Detection*Pipeline Leak Detection*
Well Test ManagerWell Test Manager
Production Event Analyst& Shift Report
Production Event Analyst& Shift Report
Metering ReportMetering Report
Production SummaryProduction Summary
Shut Down AnalyzerShut Down Analyzer
Safety StateSafety State
PCC Rich Client &Thin Client
PCC Rich Client &Thin Client
Safety Valve ScoutSafety Valve Scout
KPI ManagerKPI ManagerOperations Management
Operations Management
All the components to achieve Operations ExcellenceAll the components to achieve Operations Excellence
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operational Excellence Solutions: People, Operational Excellence Solutions: People, BusinessBusinessOperational Excellence Solutions: People, Operational Excellence Solutions: People, BusinessBusiness• 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 shiftSafe and Efficient operations: It's like having the best operator on every shift
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operational Excellence Solutions: People, Operational Excellence Solutions: People, BusinessBusinessOperational Excellence Solutions: People, Operational Excellence Solutions: People, BusinessBusiness
• 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
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
A Typical Control Room ScreenA Typical Control Room ScreenA Typical Control Room ScreenA Typical Control Room Screen
Proprietary and Confidential
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Experion, PlantscapeTPS
Operations
EnterpriseReservoir
Management
Reservoir Management
ERPERP
Oil & Gas Operations Excellence: Solution Oil & Gas Operations Excellence: Solution Map Map Oil & Gas Operations Excellence: Solution Oil & Gas Operations Excellence: Solution Map Map
Field
SecuritySecurity
Regulatory Reporting
Regulatory Reporting
Enterprise IntegrationEnterprise Integration
Integrated FieldIntegrated Field
APC & OptimizationAPC & OptimizationAsset ManagementAsset Management
Production Management
Production Management
Decision SupportDecision Support
Operator Effectiveness
Operator Effectiveness
Production ReportProduction Report
Intelligent Choke CntrlIntelligent Choke CntrlPipeline Leak Detection*Pipeline Leak Detection*
Well Test ManagerWell Test Manager
Production Event Analyst& Shift Report
Production Event Analyst& Shift Report
Metering ReportMetering Report
Production SummaryProduction Summary
Shut Down AnalyzerShut Down Analyzer
Safety StateSafety State
PCC Rich Client &Thin Client
PCC Rich Client &Thin Client
Safety Valve ScoutSafety Valve Scout
KPI ManagerKPI ManagerOperations Management
Operations Management
All the components to achieve Operations ExcellenceAll the components to achieve Operations Excellence
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operational Excellence Solutions: AssetsOperational Excellence Solutions: AssetsOperational Excellence Solutions: AssetsOperational 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 performanceTransmitters, valves, process equipment, exchangers, vessels,
pumps etcAll 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 safetyReliable means more production, lower cost, more safety
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operational Excellence Solutions: AssetsOperational Excellence Solutions: AssetsOperational Excellence Solutions: AssetsOperational 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 safetyReliable means more production, lower cost, more safety
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Solution ComponentsSolution ComponentsSolution ComponentsSolution 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
Content Owner: Phil MilletteLast 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 email...
Or run a program …
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Asset Manager as the key real-time notification Asset Manager as the key real-time notification and work flow platformand work flow platformAsset Manager as the key real-time notification Asset Manager as the key real-time notification and work flow platformand work flow platform
OPC
APCScout
APCApps
Asset Manager
PKS
Safety Valve Scout
Asset ManagementCollaborative Control Center
Scouts
SafetyValves
AllLoops
Loop Scout
TurboSuite
Rotating
ProfitSensor
Data Scout
HART & FF
ShutdownAnalyzer
Valves..All
ExperionPKS
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
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Experion, PlantscapeTPS
Operations
EnterpriseReservoir
Management
Reservoir Management
ERPERP
Oil & Gas Operations Excellence: Solution Oil & Gas Operations Excellence: Solution Map Map Oil & Gas Operations Excellence: Solution Oil & Gas Operations Excellence: Solution Map Map
Field
SecuritySecurity
Regulatory Reporting
Regulatory Reporting
Enterprise IntegrationEnterprise Integration
Integrated FieldIntegrated Field
APC & OptimizationAPC & OptimizationAsset ManagementAsset Management
Production Management
Production Management
Decision SupportDecision Support
Operator Effectiveness
Operator Effectiveness
Production ReportProduction Report
Intelligent Choke CntrlIntelligent Choke CntrlPipeline Leak Detection*Pipeline Leak Detection*
Well Test ManagerWell Test Manager
Production Event Analyst& Shift Report
Production Event Analyst& Shift Report
Metering ReportMetering Report
Production SummaryProduction Summary
Shut Down AnalyzerShut Down Analyzer
Safety StateSafety State
PCC Rich Client &Thin Client
PCC Rich Client &Thin Client
Safety Valve ScoutSafety Valve Scout
KPI ManagerKPI ManagerOperations Management
Operations Management
All the components to achieve Operations ExcellenceAll the components to achieve Operations Excellence
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Operational Excellence Solutions: ProcessOperational Excellence Solutions: ProcessOperational Excellence Solutions: ProcessOperational 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!APC provides proven value in oil & gas!
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Field Optimization NetworkField Optimization Network
iDOWell, Pipe Network, Facilities
iDOWell, Pipe Network, Facilities
Profit OptimizerProfit Optimizer
Profit ControllersProfit Controllers
SCADASCADA
UNIFORMANCEUNIFORMANCE
Facilities
Manifold
Well Choke Valve
Field Pump
Oil
Gas
Gathering Compressor
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
SEPARATOR 1MV CONTROL
PVO OBJECTIVE FUNCTION{PRODUCT VALUES, ENERGY COSTS}
Profit Optimizer – MV Control coord
Wells, Separators
Profit Bridge
Production Planning
SEPARATOR 2MV CONTROL
GAS LOOPMV CONTROL
MULTIPLECHOKES
MV CONTROL
i-DOi-DO Server
i-DO Client
Targets
LAN/WAN/Internet/Intranet
Review,Approval
EngineerPCs
Well PerfCurvesNetwork
Model and
OptimizerPres, kh,Skin
TransientPressure Analysis
Pres,GOR, BS&W
ReservoirModels
ProductionTests
WellModels
Production Data
Management
EconomicParameters
GAIN
AIM
i-DO SUSTAIN
Profit Controllers(RMPCT)
Integrated Field-Wide optimisation:
Closing the loop with Multivariable Control
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Additional areas covered by HoneywellAdditional areas covered by HoneywellAdditional areas covered by HoneywellAdditional 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
Content Owner: Phil MilletteLast Modified: Apr, 2004
Process Solutions
Oil & Gas Operational Excellence: Oil & Gas Operational Excellence: conclusionsconclusionsOil & Gas Operational Excellence: Oil & Gas Operational Excellence: conclusionsconclusions
• 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