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Professional Service for

Profitability Improvement

26th Jan. 2017

35th JCCP International Symposium

Y. Mizuguchi,

General Manager,

No.1 Process Dept., JGC Corporation

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Contents

1. Introduction

2. Example our Professional Services

Big Data Solutions

Plant Life Extension Program

CFD Analysis

3. Summary & Conclusion

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Challenges for Profitability Improvement

Improve plant availability

Enhance reliability and safety

Minimize maintenance cost

Save energy cost

Minimize catalyst & chemical cost

Profitability Improvement during operation phase

FSFEED/

EPCOperation & Maintenance

1-2

Years

3-5

Years30-50

Years

Total OPEX for Plant life cycle may be over 200% of CAPEX!

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Plant Life Cycle Solution Provider

Planning

FEED

EPCO&M

Operation Improvement

Maximizing Client’s Asset Value

FS

Configuration Study

Market Analysis

Basis Design

License Arrangement

Finance Arrangement

Project Management

Engineering

Procurement

Construction

Commissioning

Trouble Shooting

HSE

Reliability improvement

Availability improvement

Capacity expansion

Energy saving

High value product

EPC ServiceOperation Excellence Service

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Professional Services

5

Profitability

Improvement

IoT, AI

Engineering

ExpertiseAnalysis/

Simulation

Digitalization

Data centric

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Big Data Solutions

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• Downtime reduction

• Smooth start-up

• Enhance safety

Anomaly Detection

Longevity Prediction

• Right time maintenance

• Maintenance cost reduction

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Approach for Big Data Analysis

Digital

Value

Creation

Operation & Maintenance Experiences

Process Knowledge

Data Analysis

Deep Learning

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Functional Failure!!

Operation Record

Diagnostic Analysis

Predictive Analysis

Anomaly detected !at locations separate from the functional failure, 17 hours before it occurred.

Root cause foundThe causal factor are found 30 hours prior to the functional occurring

Time >>

No indication of upcoming functional failure…

Anomaly Detection

Studied for 5 Refineries, 1 LNG, 1 Chemical Plant

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Increased annual LNG production at existing plants for two clients

Studied over 10 FEED/EPC Projects

So far…

And

beyond

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Plant Life Extension Program

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Time

Fa

ilure

Ra

te Normal inspection and repairs cannot extend plant life

Substantial Integrity issues happen at the end of plant life

Plant life extension can be achieved if appropriate

equipment replacement and material upgrading are

carried out

Plant Life Extension Program

Plant Life Extension Program

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Integrity Improvement

Initiative (III)

Life Extension

Program (LEP)

Plant Integrity

Assessment (PIA)

Assessment Steps

• Kick Off Meeting

• Data Review

• Site Survey

• Assessment

• Recommendation• Action Plan Workshop

• On-stream Inspection

• Turnaround Inspection

• Data Evaluation

• Remaining Life

Evaluation

• Long Term Strategy

Development

• Budgeting for

Rejuvenation

• FEED

• EPC

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Intelligent

Operation

&

Maintenanc

e

Helps inspection engineers in every phase of maintenance activities

Precise estimation of corrosion rate

Cost and time efficient maintenance planning

Used by 80% of petrochemical and refining companies in Japan

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Data Digitalizing Service

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Intelligent O&M Service

Visualize Information

Plant Life Extension

Program

Supported by our specialists

and engineering knowhow

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CFD Analysis

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Example : Mixing of Hot and Cold Fluids

CFD (Computational Flow Dynamics)

Strong tool for engineering and trouble shooting to

demonstrate fluid dynamic behavior

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Example : Distribution of Fluid Density in Reactor

CFD (Computational Flow Dynamics)

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Summary and Conclusions

JGC can provide the optimum solutions to enhance client’s business value.

Build a strong partnership with Client to realize a business innovation for petroleum industry

0

50

100

150

200

250

300

350

400

450

0 10 20 30 40 50DUTY[MW]

TE

MP

ER

AT

UR

E[D

EG

.C]

3D Laser Scan

4D Model

HSE and Risk

Management

Energy Saving /

Pinch Study

Plant Life Extension

Program

CFD

Analysis

Asset Management

System

IoT / Big Data

Solution

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Summary and Conclusions

Development of IT will bring a lot of possibility for

petroleum industry

However, the most important thing is the integration

of various industries based on deep engineering

expertise Owne

r

Engineering

Contractor

Licenso

r

Vendor

IT

Vendor

Software

Licensor

Engineering

Contractor

Owner

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Please contact us:

JGC Webpage :

http://www.jgc.com/en/index.html

Tel (Main Line) :+81-45-682-1111

The JGC Way

Engineering the Future