PI Users Conference 2000 1
Elf Atochem North AmericaCalvert City, Kentucky
Learning from the PastOperating in the PresentPreparing for the Future
Learning from the PastOperating in the PresentPreparing for the Future
PI Provides Exceptional
ROI Even with Simple
Applications
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Elf Atochem North AmericaElf Atochem North AmericaElf Atochem North AmericaElf Atochem North America
• Diversified Chemicals Manufacturer– Intermediate, Fine and Performance Chemicals– Performance Polymers
• $2.2 Billion 1998 Sales
• 4900 Employees
• Manufacturing Sites– 24 US, 2 Canada, 4 Mexico, 16 Other World
Wide
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Affiliate of TotalFinaElf
• Fourth Largest Oil Company Worldwide
• Oil Exploration, Production, Refining
• Petrochemicals
• Chemicals
• World Wide Operations
• Headquarters Paris, France
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Calvert City, Kentucky
• Refrigerants– HFC
– HCFC
• Kynar (PVDF)• HCl• Continuous• Batch
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Why OSI PI?
• World Wide Operations– Many Different DCS Systems– Desired Common Tool for Access to Process
Data– Share Process Technology and Operational
Support– Share Custom Applications
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Why OSI PI?
• Best Archive Technology
• Best Set of Client Tools
• Included Microsoft Technology for Custom Work– VB, VBA– ODBC
• Joint Decision with all parties including IT
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Elf PI Systems
Shanghai
48 Servers>300,000 Points>225 Clients
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PI at Calvert City
• Installed September 1997
• 10,000 DCS Points
• 1,000 Lab Points Interfaced to LIMS
• 15 Pro-Packs
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My Third User’s Conference
• 1998 - Awed by all of the great things that could be done with PI
• 1999 - Discouraged that I had not accomplished “great” things
• 2000 - Realizing that PI is providing great ROI even without major “killer” application
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Typical PI Administrator
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Sharing Information at Calvert City
Operations
Engineering
Purchasing
Maintenance
Logistics Lab
Shift Super
Process TechnologyEnvironmental
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Sharing Information and Expertise Worldwide
• Process Technology @ Calvert City Supporting Downsized Wichita
• Central Engineering/R&D at KOP studying processes remotely
• Sharing operating data with sister plant in France
Five OtherPlants
Wichita
KOP, PAFrance
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How Does PI Produce ROI?
• Increased Revenue– Increase production and/or quality
• Displaced Costs– Eliminate or reduce existing cost
• Avoided Costs– Eliminate future cost
• Redirected Costs– Free resources for other purposes
• Intangible Returns– Benefits not easily quantified
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Increased Revenue
• Sharing of Information Worldwide & in Plant– Experts only a few clicks away from your
problem
• Process Studies for Process Optimization & Debottlenecking– PI easily provides data to Aspen & other data
hungry applications
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On-Line Material Balance &Composition Predictor
• Built with DataLink• Developed remotely at KOP R&D• One week trial looked good• Enhancements being added• Advises operator on correct feed flows to
reactor• Stabilize reaction section of process• Reduced upsets & reduction in impurities
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Improve QualityIncreased Revenue
• Could not produce product with tight spec
• Poor temperature control
• Used Atochem ProcessBook “extra” to detect valve problem
Steam Flow vs Valve Position
2450
2500
2550
2600
2650
2700
39.5 40 40.5 41
Valve Position
Ste
am
Flo
w L
B/H
R
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Improve QualityIncreased Revenue
• New valve installed• Continued
improvement using PI-Profile to determine best control point on column
• No missed shipment, customer satisfaction
New Valve Steam Flow vs Valve Position
2720
2740
2760
2780
2800
2820
2840
2860
60.2 60.4 60.6 60.8 61 61.2 61.4
Vavle Position
Ste
am
Flo
w
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Displaced Costs
• Remote Access to Data and Technical Support– KOP, PA R&D, Central Engineering– Atochem S.A.– Greatly reduced travel costs– Data available on their remote desktop
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Displaced Costs
• One of our plants has experienced extreme technical downsizing
• PI system installed to provide remote technical support from Calvert City
• Timely assistance
• Reduced travel costs
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Application for Displaced Cost
• Virtual On-Line Analyzer– 5 Minute data instead
of 12 Hour lab data
– Improved process control
– Increased Safety
– Reduced Lab Costs
– Reduced Maintenance
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Supplier RelationsDisplaced Costs
• Slurry delivered by pipeline appeared to be highly variable in composition
• Could analyze properly only in lab
• Cost based on nominal composition - not actual composition
• PI data from various locations in plant used to show supplier our problem
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Supplier RelationsDisplaced Costs
• Supplier now understood our problems• Now working in cooperation to improve
composition control• Could possibly result in innovative control
that will solve years old problem and reduce future costs for slurry
• Supplier adjusted charges by $50,000– Projected $100,000/year recurring savings
• Now working on another supplier problem– Potential savings of $100,000 annually
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Reduce Pump MaintenanceDisplaced Costs
• PumpGard - Inexpensive & Continuous
• DataLink Monitor Application– 117 Pumps checked every 10 minutes– High current, Low current, “Scratching”– Indication that pump is in trouble - cavitation,
dry run, dead head, clogged strainer, etc.– Numeric page generated alerting rotating
engineer
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Reduce Pump MaintenanceDisplaced Costs
• Pump crash repair can run from $1k to $50K
• Positive progression:– Why did this pump
fail?
– Why is this pump in trouble?
– How do we keep pump out of trouble?
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Avoided Costs
• Make Informed Decisions Based on Factual Information
• Spend Wisely, Eliminate -– Knee Jerk– Gut Feel– Design in Ignorance
• 80/20% Rule on Data Gathering/Analysis changed to 5/95%
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Separator ProblemsAvoided Costs
• First Guess– Instrument Doesn’t Work, Separator Does– PI Proves Instrument
• Second Guess– Instrument Works, Separator Doesn’t– Separator Not Large Enough
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Separator ProblemAvoided Costs
• PI Data + Intelligent Engineer– If operating parameters
correct:
– Instrument Works
– Separator Works
– No need to spend $250k on separator fix
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Capacity IncreaseAvoided Costs
• Refrigeration Bottleneck• PI Data Used to Investigate 25% Refrig
Increase– Upset data helpful– 4 Refrig users have opportunities for reduced
demand– Refrig machine operating parameter change
• Looks like new Refrig machine not necessary - $1.2 million cost avoided
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Redirected Costs
• A number of routine reports have been automated
• Allows people freed from reporting tasks to use their talents more productively
• Reduces labor cost that can be used for other purposes
• Provides information that would be almost impossible if done manually
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Redirected Costs
• Shift Superintendent Report– 1/2 hour per shift now spent on running plant– $18,200/year
• Daily production report eliminated 1/2 time clerk at one unit– $26,000/year
• Unit monthly quality report
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Redirected Costs
• Automatic batch reports– Reports now done daily– Timely information to improve quality– Supervision/Clerk savings $18,000/year
• Purchasing accesses raw material inventories– Eliminates telephone tag
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Redirected Costs
• Incinerator trip report– Permit renewal requires human health risk
assessment– Dependent on “Upset Time” with default value
of 20%– DataLink used to document trips and upset time– Even with ProcessBook this task very labor
intensive– Report showing upset time significantly < 1%
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Intangible Returns
• Probably one of major ways PI provides ROI.• Access to process information at your
desktop• If information is readily accessible it will be
used for informed decisions• DCS console equipment expensive and rigid
while PI clients are affordable and flexible
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Intangible Returns
• View operations and Supply Chain Management anywhere– Logistics
• Plant wide responsibilities• Can keep track of boiler operation and tank levels
– Loaders• Had no DCS console• Now can view some loading operations from office
– Home• Provide consultation after hours
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Intangible Returns
• Opens closed systems• Ties together information from many
sources– DCS– LIMS– Oracle and other relational databases– Aspen, Honeywell & other Advanced Process
Control Applications– And many more
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Unfortunately,Incidents Do Happen.It’s critical that you learn from them.
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Incident InvestigationIntangible Returns
• PI provides accurate information on incident events
• Facts lead to determining root cause of incident
• Facts lead to corrective actions to avoid future incidents
• PI has proven to be very useful in the investigation process
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Incident InvestigationIntangible Returns
• PI is now used routinely • Its use has lead to the discovery of potential
problems that may have been missed • Results in improved safety, environmental
compliance, and process reliability• I was even asked “Can you get the switch
engine on PI?”
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Intangible Returns
• What are these intangible benefits worth?– Preventing a unit shutdown occasionally– Preventing a future safety or environmental
incident– Approval of an important environmental permit– Customer satisfaction
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ROI Summary
• Increased Revenue– Not yet quantified
• Displaced Costs– Not all quantified
– Supplier relations• $50,000 to date
• Possible $200k in 2000
– Reduced travel• Not quantified
– Reduced pump maintenance
• possible $100k in 2000
– Improved on-line analyzer performance
• Results to be seen in 2000
– Performance equations• Providing process
feedback not otherwise possible
• Not quantified
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ROI Summary
• Avoided Cost– Separator
• $250K
– Refrig • $1.2M
– Flow meter problems• $50K
• Redirected Cost– Shift Report
• $18.2K/year
– Batch Report• $18K/year
– Production Report• $26K/year
– Utility Metering & Cost Distribution
• $14.4K/year
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ROI Summary
• One time savings– $1. 5M
• Recurring savings– $126.6K/year documented– $300K/year projected additional in 2000
• Unreported/Not Quantified and intangible– $? but probably more than total of above
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How to Maximize ROI
• Site champion(s)• User training• Share information between site/corporate
users– Tips– Tricks– Applications
• Learn VB/VBA!
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One User’s Comments
“Simplifies and Distributes access to DCS information five fold.
Conceptually simple tasks are actually simple compared to DCS, such as creating a new trend display or doing some calculations on data available within the DCS. This can take days for the DCS depending on the availability of the DCS engineer. It can be done in minutes in PI.”
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One User’s Comments
“Because of the simplicity, organizing seemingly unrelated data into trends and spreadsheets makes troubleshooting quick and effective. Relationships not known before are discovered that aid in improving process operation.”
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One User’s Comments
“Before PI, when I got a call at home on a process problem, the only way to solve it was to get in the car and drive an hour to the plant. I now have access to PI from home and have access to all of the data that is available in the control room. I can usually provide guidance to the operator needing help. This not only saves me lost sleep and long drives, but the problem gets solved an hour earlier. This can mean avoiding lost production.”
Questions