Honeywell Technology Summit Kuwait

Ayman Mehdawe

October 3rd – 4th 2017Connected Performance Services

UOP 8013C-0 Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.

Introduction Meeting

Expectations

CPS Background &

Video

Discussion and

Next Steps

Agenda

1

UOP 8013C-1

Connected Performance Services (CPS)Knowledge Delivery as a Service

2

UOP 8013C-2

The Connected Plant Delivered with CPS

• Analyze plant performance to reveal full potential through a Cloud-

based service

- Around-the-clock monitoring of plant data and rigorous simulations

- Provides on-going, operational recommendations to close performance

gaps

- Leveraging UOP Process Models & longstanding experience in operational

support and troubleshooting

• Combining 100+ years of Oil & Gas processing experience with next-

generation software platforms

• Emission standards

• Energy reduction

• Sub-optimal operations

• Performance vs peers

• Knowledge gaps

• Operational excellence

Key Customer Challenges

Unplanned Downtime Human Capital Challenges

Underperforming Assets

• Process issues

• Equipment failures

Energy and Emissions

CPS PortfolioThe Connected Plant, Delivered:

3

UOP 8013C-3

Process Reliability Advisor• Pre-empt process issues with embedded root cause analysis

• Operate closer to constraints

• Drive best operating practices

Utilities Management*• Enhance heat recovery, fuel gas and H2 systems management

• Optimize supply and demand balance

Process Optimization Advisor• Maximize profitability through changing process

and economic conditions

• Evaluate new opportunities with “what-if” analysis

Predictive Maintenance*• Improve turn-around planning by

managing asset lifecycle

• Gain new reliability insights through data

analytics

Unit-specific Benchmarking*• Improve operations through actionable unit advice

• Set realistic, achievable targets

*in development

The Value in Closing Gapsin an Aromatics Complex

4

UOP 8013C-4

Issue Response Time

Sub-optimal Operation

Assumptions:

400 KMTA PX production, $330/MT Naphtha/PX spread,

Optimization of the Complex at varying feed quality conditions

$3-8 million/yr.

Typical Value Gap

By understanding the various constraints throughout the Aromatics Complex, you are able to optimize the individual units, re-balance the constraints and increase throughput

Knowledge Transfer

How

Early detection of issues allows you to make the appropriate changes faster and potentially before they become costly

Having the right information at the right time is critical for you to sustain knowledge and improve operational awareness

CPS Service Architecture

5

UOP 8013C-5

CPS Videos

6

UOP 8013C-6

• Process Reliability Advisor for a CCR Platforming™ unit

• Process Optimization Advisor for an Aromatics Complex

Process Reliability AdvisorA structured method to present process insights

7

UOP 8013C-7

What does it do?:

• Monitoring of unit performance

• Constraint limitations

• Event detection & mitigation

• Knowledge transfer

What is behind it?:

• Matches unit configuration

• Tuned UOP process models

• Technology specific fault models

• Embedded UOP knowledge, context, and

background

Process Reliability Advisor

8

UOP 8013C-8

Supported by underlying embedded

fault modes

Fault Mode Categories

Product Yields & Quality

Catalyst Health

Rx Pressure & Temperature

CCR Operation

Recycle Gas Moisture

Equipment Health

Debutanizer Column Operation

230+ Root

Causes

What is behind the Service?

9

UOP 8013C-9

Logic developed from:

• Deep process knowledge

• Extensive understanding of catalyst and adsorbents

• Operating best practices

Consist of mitigation paths to assist with

troubleshooting

Process Optimization Advisor

10

UOP 8013C-10

What does it do?:

• Maximize profitability against constraints

• Providing operational recommendations

What is behind it?:

• Rigorous simulation to match unit configuration

• Tuned UOP process models

• SQP Optimizer driving an economic objective

function

• Cloud hosted & Maintained by UOP

Provides Insight in Valuing Potential Feeds

What-IF: Feed Valuation Solution

11

?

Leverages the UOP

Process Model to

determine the optimum

operation with the

alternative feed

Rigorous

Simulation

$

Provides economic

values & potential

product mix enabling

you to determine the

best feed

Economic

Evaluation

User manually modifies

feed characteristics to

be run in the tuned

engine

Feed Information

Modification

How does this work?

12

UOP 8013C-12

• Reactor

• Effluent Yields

• Reactor Temperatures

• Cat Circulation

• Rate

• Reactor Effluent

• Yields

• Reactor Temperatures

• Cat Circulation

• Rate

Feed 2

• Feed Rate

• Feed Characterization

• Product Quality Target (RON)

Case 2

Feed 1

• Feed Rate

• Feed Characterization

• Product Quality Target (RON)

Case 1

As Is• Feed Rate

• Feed Characterization

• Product Quality Target (RON)

As Produced• Rx Effluent Yields

• Operating Conditions

• Cat Circulation Rate

• Energy Usage

• Production Margin

Inputs Outcomes

Right-time Insights to Drive Increased Learning

Improve Knowledge Retention

13

Information Insights

Your Information grouped into related

sections

Information Linked to

UOP InsightsLearning improved by

associating insights to current

information

Embedded UOP insights based on licensor and troubleshooting

experience

Response Time Improvement

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Service

Interaction

OpAwareTM

CPS PRA

Event

Occurs

Collect &

Send DataUOP

Review

UOP Data

Analysis

Time

(typically days or weeks)

Issue

Identification

and Resolution

UOP

Review

UOP Data

Analysis

Issue

Identification

and Resolution

Proactive

Troubleshooting

Event

Detected

Early

Detection

Time

Saved

Time Saved

Incident

Avoidance

Cust. Analysis

Escalate

to UOP

Cust.

Analysi

s

Escalate

to UOP

Customer

Resolved

Customer

Resolved

On-Going Interaction with CPS Specialist

15

UOP 8013C-15

Maintenance Recommendations

Modifications

• Have UOP become part of Your Team

- Early event detection and operational recommendations provided in CPS Dashboard

- Regular interactions to discuss CPS benefits

• Gain from Continuous Innovation

- Added fault model enhancements to the CPS Solutions

- Make minor process configuration updates

• UOP will keep the system running by conducting all needed maintenance of Software & Hardware including tuning of the process models

Project Delivery

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UOP 8013C-16

Meeting at site to capture customer-specific information

System is built based on information gathered during kickoff

Meeting at site to launch customer dashboard & service

Kickoff

Build

Deploy

In Operation

System is live providing on-going services

Anticipated 15

week delivery

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Process Reliability Advisor Use Casefor CCR Platforming units

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UOP 8013C-18

Iss

ue

Recycle Gas Moisture:

• Customer experiencing lower than

expected C5+ & H2 yields

• Indicated Reduction Gas Heater

issues at site

2% Yield Loss

Delta C5+ YieldId

en

tifi

ca

tio

n

• Yield loss is difficult to confirm

• UOP data review revealed a 2%

yield loss

• Further review found low reduction

temperatures which caused high

recycle gas moisture and

inadequate reduction So

luti

on

RG Moisture

With CPS

• Embedded UOP fault model enable early

event detection of critical catalyst health

• Driving pro-active

recommendations

(i.e. chloride level

adjustment)

Process Reliability Advisor Use Casefor CCR Platforming units

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Ide

nti

fic

ati

on • Current performance lower than

expected yields

• Manual troubleshooting looking at

MCH / CH in reformate

• 5% Naphthene bypass hidden by

increased severity So

luti

on

With CPS

• Tuned process model enables detection

of and ability to quantify performance

debits

• Provided troubleshooting paths to

identify root causes

Iss

ue

CFE Leak:

• Customer not noticing specific issues

with operations

• On-going increases in WAIT to meet

product specifications

• Operational adjustments masking

underlying issues

Process Reliability Advisor Use Casefor CCR Platforming units

20

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Ide

nti

fic

ati

on

• Review of regenerator operations

identified frequent slipping of coke

into chlorination zone

• High O2 driving accelerated burn

melting catalyst pills and causing

potential screen damage So

luti

on

With CPS

• On-going monitoring of O2 and catalyst

circulation rate tied to current operations

• Adjustment recommendations to avoid

slipping coke

Iss

ue

Slipping Coke:

• Customer noted performance

degradation

• Catalyst sample showed fused catalyst

Process Reliability Advisor Use Casefor CCR Platforming units

21

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Ide

nti

fic

ati

on

• Site did not have the tools to identify

issue

• UOP manually compared yields

against UOP process model to

diagnose issue

• Identified insufficient chloride

injection So

luti

on

With CPS

• Continuous comparison of operations to

model output drive early identification of

issues (i.e. catalyst health)

• Embedded Fault Models pinpoint root

cause and drive resolution (i.e. poor

chloride injection)

Iss

ue

Chloride Injection:

• Customer noticed RON dropping despite

increase in WAIT

• Reduced feed rate to try and compensate