perry nordh p.eng. - honeywell · perry nordh p.eng. 2 operations excellence. 3 process...
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Process Optimization
Key ProductsControl Performance MonitorProfit® ControllerProfit® OptimizerProfit® Sensor ProProfit® StepperProfit® Expert
3500+
In
sta
lls
MMM: Alcoa*, CodelcoO&G: Shell*, BP, Enterprise Products, Woodside, SyncrudeRefining: ExxonMobil*, ConocoPhillips, Sinopec, IOCL, Tesoro, PDVSA, Saudi AramcoChemicals: Sasol, Petronas, Dow*, Dupont*, Idemistu, SABIC,Braskem, BASF*, Bayer Material Sciences
Sele
ct
Cu
sto
mers
Fact
• Solutions to optimize process
performance and efficiency• Helps protect plant uptime and safety by
reducing losses caused by control
performance • Improves profitability by increasing
production and decreasing costs
What is it?
*Enterprise/Corporate Agreements
Keep your process at optimal performance every minute of every day
>$5B US in measurable benefits has been added to
customers' bottom-lines with Honeywell's Profit®
suite of products.
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Optimization
BusinessDictionary.com:
Finding an alternative with the most cost
effective or
highest achievable performance
under the given constraints,
by maximizing desired factors and
minimizing undesired ones.
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Tangible APC Benefits
Typical Benefits:
• Increased Throughput
• Improved Yields
• Decreased Operating Costs
• Improved Quality Consistency
• Increased Operating Flexibility
• Improved Process Stability
Advanced Control and Optimization benefits are field
proven and generate high rates of return on investment.
Advanced Process Control provides lucrative returns in any economy
Typical Payback:
Oil and Gas 0 to 2 months
Refining3 to 6 months
Chemicals
Petrochem4 to 6 months
MMM
Pulping/Paper 6 to 8 months
Industrial
Power10 to 12 months
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Trends and Challenges in Process Optimization
• Industrial space
– Security and safety
– Cloud based services emerging
– Mobility and social media create easier access to
data/applications
• APC and Optimization
– ARC: APC is an expectation vs. an afterthought
– Application Maintenance and Sustaining Benefits is a concern
– Proving the ongoing benefits (track year over year) is a
requirement
– Shrinking/aging workforces stressing ability to do any/all
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Meeting the Challenges
• Cost Effective Deployment and Sustainment
• Renewed focus on support infrastructure
• Leveraging Enabling Technology
• Integration of Applications
• Multi Unit / Plant Wide Optimization
• Making the Operator More Effective
• Streamlining Work Flow
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Cost Effective Deployment / Sustainment
• Tools for:
– Reducing overall plant test time
– Closed-loop Automated Step
Testing
– Model quality, diagnostics
• Leverage estimated matrices from
simulations
• Faster deployment because of a
quicker ‘diagnose/analyze-identify-
update’ work flow during
commissioning
Rethinking Traditional Methodologies
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Leveraging Enabling Technology
Virtualization
• Reduce hardware footprint and
maintenance costs
• Needs to be supported by DCS for
on-process use
Remote Collaboration
• Cost effective sustainment
• Knowledge Management within an
organization
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Integration of Applications – Simulation
• Steady State Simulation
– Off-line simulation of control schemes
– Leverage models on-line for control and optimization
• Dynamic Simulation
– Re-use investment in the virtual plant
• DesignDeployMaintain
– Advanced integration features for testing
• Reduce implementation time
– Testing control schemes
– Initial controller models
• Improve APC Uptime
– Operator training – improve acceptance
– Performance validation / troubleshooting
Common tools drive improved efficiency and long-term sustainability
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Multi Unit / Plant-Wide Optimization
• Beyond single unit
optimization to maximize
business results
• Global optimization of
constrained and unconstrained
systems
• Dynamic optimization can
deliver significant sustained
benefits, especially when
integrated with APC
*Optimum
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Dash board for the currently
connected application
Dash board for the currently
connected application
Making the Operator More Effective
• Analytical Tools and Decision Support Capabilities
– What-if scenario support
– Easier problem identification and faster diagnostics
• Visualization
– Presentation of information
– Integration / Access to “non-APC” information
Operational Excellence - Empowering the Operator
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Unified Technology Platform
• Technology based on a common workflow
• Control to user specified constraints (limits)
• Optimize operations (economics)
• Standard infrastructure and common features
• Extensible and customizable
Flexible, scalable solution to cover a wide range of applications
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Streamlining Workflow
Detect Diagnose Identify Update Deploy
Runtime
Metrics
Diagnostics
and Analysis
Real-time CLiD Runtime Infrastructure
Automate tasks where sensible
Result:
• Improve Overall Sustainability
• Enable Remote Serviceability
• Enable Remote Collaboration
Profit Suite Engineering Studio
Real-Time Update
Profit Design StudioProfit Stepper
CPM+ PE
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How can Honeywell help?
• Experienced personnel
• Familiar with the right technology
• Deliver the necessary services
• Ensure long-term sustained benefits
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Profit Suite Vision
• One Consistent technology platform
– MPC and Real Time Optimization
– Modeling environment
• Linear State Space
– Linear and Non-Linear control
Seconds Hours/Days
Profit LoopProfit Controller
in C300Profit Suite
SDQP
(Multi-Asset
Optimization)
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Profit Suite Vision
• Lifecycle Management
– Integration of information for better
diagnostics, analytics
– Enabling the work processes
– One “Operating Window” for
implementation and sustainment
– Virtualization
Dash board for the currently
connected application
Dash board for the currently
connected application
Profit Lifecycle
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• TaiJi PID
Profit Stepper
Delivering Value as a Cohesive Solution
• Profit Controller • UniSim Lifecycle Simulation Tools
• Profit Optimizer: Real-time, Dynamic Optimization
*Optimum
Minimum Effort Move
Past Future
Assumed Values
CV
Predicted
Unforced
Response
MV
Control Funnel
Optimal Response
Setpoint • Control Performance Monitor
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Advanced Application Project Services
ConsultingFeasibility Studies
Master Plans
Benefits Audits
Project ImplementationDesign
Implementation
Commissioning
Start-up Training ProgramsOperator Training
Process Simulation
Mega ProgramsOutsourced AutomationTechnology Refresh
More than 3,500 Man-Years
Process Industry Experience
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Wrap-up
• APC benefits are clear, but are often not sustained
• A workflow that integrates all aspects of the APC lifecycle is necessary to sustain APC benefits
• Honeywell has the personnel, experience and technology to help you sustain and improve APC benefits
Global leader – What can we do for you?