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SmartPlant Process Safety Ray Howarth. 21-22 August 2008 Hilton Opera Hotel Hanoi, Vietnam. Operating the Plant. Integrate ALL Information ... DESIGN & PROCESS Create the SMART PLANT of the Future …. Making Plants Smarter, Safer & More Profitable By Design. October 23, 2014. – 2 –. - PowerPoint PPT Presentation

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Slide 1Making Plants Smarter, Safer & More Profitable By Design
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    BASF Sr. Staff Engineer.
Cuts through information overload
“It’s not WHAT you know, it’s WHEN you know it!”
FALCONEER Listens …
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The Virtual Engineer in the Smart Process
The Right Information Automatically Provided at the Right Time
Cost Savings, Increased Production
FALCONEER™IV Process Performance Solution - Making Plants Smarter, Safer & More Profitable by Design
SmartPlant Enterprise Bundle for O/O
SmartPlant Enterprise (SPO) for O/O
Smart Link from Control Systems to SAP
Making Plants Smarter, Safer & More Profitable By Design
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Provide History of the Development of One Solution
Emphasize How It Addresses and Overcomes the Challenges
Process, Power & Marine
Production interruption
Regulatory compliance
Safety Incidents
Knowledgeable Workforce
Turnaround/Outage Planning & Execution
How to retain knowledge
How to regain knowledge
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Process Performance Auditing & Advising Software
Real-time
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THE MFG PROCESS
Making Plants Smarter, Safer & More Profitable By Design
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TAKES DATA => COMPARES WITH EXPECTED OPERATION => ADVISES
Based on Models of Normal Plant Operation and Normal Operating Data Evaluated Continuously in Real-time
Concurrently Determines:
If Models Close (Validation) or Not (Fault Detection);
If Measurements & Conditions In Control or Not (SPC)
Automatically Creates and Evaluates Rules of Fault Hypothesis (Method of Minimal Evidence -patent pending)
Reports Validation, Fault Analysis Diagnosis & SPC Results
MODELS ARE THE KEY
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Prevented unscheduled shutdown saving >$200,000 per day
Improved Power Generation Revenue >$200,000 per year
$30,000 Savings with One Alert on Steam System
Steam Reconciliation Savings of $50,000 in 6 months
Raw Material Savings of >$40,000 per Quarter
Energy Savings Opportunities
> $100,000 per year Pumps & Blowers
The real value of right information at the right time!
A former Foxboro manager appreciates our approach as: “being rigorous enough to identify the problems without being too complex or expensive, combined with being easy enough to configure and maintain.”
“Compared to other approaches, FALCONEER is more fundamental with easily configurable and understandable equations and logic”, according to FMC
Making Plants Smarter, Safer & More Profitable By Design
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Prevented unscheduled shutdown saving >$200,000 per day
Improved Power Generation Revenue >$200,000 per year
$30,000 Savings with One Alert on Steam System
Steam Reconciliation Savings of $50,000 in 6 months
Raw Material Savings of >$40,000 per Quarter
Energy Savings Opportunities
> $100,000 per year Pumps & Blowers
+ IMPROVED SAFETY
The real value of right information at the right time!
Savings per Cost of Production
Low (cents / $)
High (cents / $)
1.6
6.0
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SmartPlant P&ID
SmartPlant Process Safety
Functionality Out-of-the-Box capabilities
Making Plants Smarter, Safer & More Profitable By Design
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The solution components we will be discussing include SmartPlant P&ID, SmartPlant Process Safety, SmartPlant I-Sketch and FALCONEER Process Performance Solution.
Process, Power & Marine
Automating HAZOP Process
Correcting Equipment Performance
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Implementing project also requires updated or new SOPs, Training, PSM Documentation, HAZOP
Process, Power & Marine
Cost savings
Cost of the solution for 3 users $95k (incl. training and few days of consultancy)
ROI with the first year of projects
$113,540 - $95,000= $18,540
plus Cost Avoidance or Opportunity Cost Savings ranging in the hundreds to thousands of dollars per hour that problem persists unrecognized
ROI – Correcting Performance
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Maintain Safe Conditions
Operational Risk Management
Ensure design consistency
Provide consistent P&ID updates
Safety checks on the modifications
Ensure P&ID, process data, Isometrics and safety are all consistent and verified.
Making Plants Smarter, Safer & More Profitable By Design
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Automating HAZOP Process 168,000
Correcting Equipment Performance 113,540
Total ROI 1st Year of Projects $326,040
Plus Cost Avoidance or Opportunity Cost Savings ranging in the hundreds to thousands of dollars per hour that problems persist unrecognized
Making Plants Smarter, Safer & More Profitable By Design
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FALCONEER Case Studies
A former Foxboro manager appreciates our approach as “being rigorous enough to identify the problems without being too complex or expensive, combined with being easy enough to configure and maintain.”
Chemical\Petrochemical
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Process Information (Asset) Management
Real-Time Smart Link for Process Data to SAP to SP Enterprise to User
Automated Process Performance Auditing & Advising
Leveraging Design Information with Process Information
USER
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Identify energy saving opportunities
Reduce operating costs by finding potential operational issues before the actually occur
Improve process and instrumentation reliability
Prevent safety incidents and environmental releases
Leverage process data & knowledge to provide critical solutions in a timely and cost-effective way
Process, Power & Marine
FALCONEER Business Package Delivers
Mass & Energy Balance Engine for optimizing energy utilization, costs, production
Monitor, Report, Trend key performance indicators (KPI) and metrics in real time
Energy & Raw Material Use & Cost
Instrumentation & Equipment Condition
Production Capacity & Utilization
Capture, retain & use aging workforce knowledge base
REDUCED OPERATIONAL RISK
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Process, Power & Marine
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Secondary Model (Eliminates Flow1)
– Flow3 * cp * (Temp3 – Temp1)
PM2 = 0 = Flow1 * cp * Temperature1
+ Flow2 * cp * Temperature2
– Flow3 * cp * Temperature3
– Leaks * cp * Temperatures
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Method of Minimal Evidence (MOME) is that it provides a uniform framework for examining process models and their associated modeling assumption variables.
All unevaluated process models describing normal process operation can be characterized as functions of the following quantities (see above).
Once evaluated with actual process data and standard or extreme values of unmeasured parameters, a residual results (i.e., (i) below) which is just a function of process sensor noise and any currently occurring modeling assumption deviations..
Process engineers provide the primary process models, which are all linearly independent of each other.
The MOME methodology derives and adds additional, secondary process models from combining primary models, which improve the discrimination ability of the process model set.
The patterns of expected residual behavior that result from applying this method (e.g., the diagnostic rules) contain the minimum patterns required to diagnose each of the possible fault situations.
This directly maximizes the sensitivity of the fault analyzer for these various faults, maximizes the resolution (discrimination between various possible faults and non-fault events) of that analysis, and optimizes its overall competence when confronted with multiple assumption deviations.
Process, Power & Marine
Controlled Process Variable
Virtual EWMA Chart
Making Plants Smarter, Safer & More Profitable By Design
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DCS/SCADA monitors individual points only – FALCONEER monitors entire process and interactions between points as well
Patent Pending Method and System
Adds “wisdom” or intelligence to the raw information.
Automatic model & rule generation for enhanced cross-checking
High Level Auditing & Advising
More than just Individual High/Low Alarm Limits and Trending
Statistical-based and Model-based Trending
Proactive and Preemptive versus After-The-Fact
WHAT & WHEN & WHY
Requires Significantly More Time, Effort, Long-Term Support to Configure & Maintain
Older systems may not even be possible
Making Plants Smarter, Safer & More Profitable By Design
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The Goldmine of Information & Wisdom Provided by FALCONEER Process Performance Auditing
Making Plants Smarter, Safer & More Profitable By Design
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Shares P&ID Data with All Stakeholders
Reduces Start-up Time
INTEGRATED FUNCTIONS
Soft Sensors
Digital Dashboard
Process, Power & Marine
Cost savings
Cost of the solution for 3 users $95k (incl. training and few days of consultancy)
ROI with the first year of projects
$168,000 - $95,000=$73,000
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Execute safety study faster and with consistent approach
Consistent and auditable study
Making Plants Smarter, Safer & More Profitable By Design
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Incinerator Performance – Environmental Liability, Gas Consumption
Measured
Calculated
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Maintenance
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builds upon the SP
O Core Solution and
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