pi users conference 20001 elf atochem north america calvert city, kentucky

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


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


Affiliate of TotalFinaElf

• Fourth Largest Oil Company Worldwide

• Oil Exploration, Production, Refining

• Petrochemicals

• Chemicals

• World Wide Operations

• Headquarters Paris, France


Calvert City, Kentucky

• Refrigerants– HFC

– HCFC

• Kynar (PVDF)• HCl• Continuous• Batch


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


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


Elf PI Systems

Shanghai

48 Servers>300,000 Points>225 Clients


PI at Calvert City

• Installed September 1997

• 10,000 DCS Points

• 1,000 Lab Points Interfaced to LIMS

• 15 Pro-Packs


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


Typical PI Administrator


Sharing Information at Calvert City

Operations

Engineering

Purchasing

Maintenance

Logistics Lab

Shift Super

Process TechnologyEnvironmental


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


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


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


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


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


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


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


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


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


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


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


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


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?


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%


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


Separator ProblemAvoided Costs

• PI Data + Intelligent Engineer– If operating parameters

correct:

– Instrument Works

– Separator Works

– No need to spend $250k on separator fix


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


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


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


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


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%


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


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


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


Unfortunately,Incidents Do Happen.It’s critical that you learn from them.


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


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?”


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


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


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


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


How to Maximize ROI

• Site champion(s)• User training• Share information between site/corporate

users– Tips– Tricks– Applications

• Learn VB/VBA!


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.”



“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.”



“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

pi users conference 20001 elf atochem north america calvert city, kentucky

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