process, power & marine - intergraph · improved daily workflow better, more timely...

Process, Power & Marine

SmartPlant Process Safety

Ray Howarth

21-22 August 2008

Hilton Opera Hotel

Hanoi, Vietnam


August 27, 2008 – 2 –

Operating the Plant

Integrate ALL Information ...

DESIGN & PROCESS

Create the SMART PLANT of the Future …

Making Plants Smarter, Safer &More Profitable By Design


August 27, 2008 – 3 –

“The process always tells on itself.”

BASF Sr. Staff Engineer.

Cuts through information overload

“It’s not WHATWHAT you know, it’s WHENWHEN you know it!”

FALCONEER Listens …Making Plants Smarter, Safer &More Profitable By Design


August 27, 2008 – 4 –

Smart Plant of the Future - NOW

The Virtual Engineer in the Smart ProcessThe Right Information Automatically Provided at the RightTime

Cost Savings, Increased Production

Improved Daily Workflow

Better, More Timely Decision-Making

Enhanced Safety

BENEFITS & ROI

FALCONEER™ IV - SPPIDFALCONEER™IV Process Performance Solution - MakingPlants 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


Process, Power & MarineThe Drivers/Challenges

Support of Plant Strategy

Production, quality, safety, resource utilization

Reduce Operational Risks such as:

Production interruption

Regulatory compliance

Safety Incidents

Knowledgeable Workforce

Reduce Engineering Costs such as:

Turnaround/Outage Planning & Execution

Preventative Maintenance Planning & Execution

Inspections

Reduce operational overhead cost (contractors / own staff)

How to retain knowledge

How to regain knowledge


SMART PLANT

PERFECT PLANT

INTELLIGENT PLANT

of the FUTURE


August 27, 2008 – 6 –

Operation at Design

Operation at Capacity

Instrumentation Calibration

Safety Systems

ISO Systems

Environmental Systems

Design Validation & Operational RiskMaking Plants Smarter, Safer &More Profitable By Design

Process, Power & MarineWhat is FALCONEER™

THE VIRTUAL ENGINEERTHE VIRTUAL ENGINEER

The Right Information AutomaticallyProvided at the Right Time!

Process Performance Auditing &Advising Software

Real-time

Process Information Management

Fundamental Engineering Models-based

Patented-Pending



August 27, 2008 – 8 –

CONTROL SYSTEM

• Flow

• Temperature

• Pressure

• Level

SHOULD

WORK

IS

WORKING

ADVICEOK ORPROBLEMS

Process Designand OperationInformation

THE MFGPROCESS

System Auditing

Point Auditing

DIGITAL DASHBOARD

• KPI

• CHARTS

• REPORTS

• EMAILS

How Does FALCONEER™ IV Work? Making Plants Smarter, Safer &More Profitable By Design


August 27, 2008 – 9 –

• WHAT HAPPENED SINCE

YESTERDAY?

• CHECK OPERATIONS

•CONTROL ROOM

•SPREADSHEETS

•DCS TOOLS

• PROBLEMS?

•IMMEDIATE ACTION

•ADDITIONALRESOURCES REQUIRED

•LONGER TERM PLAN

•FORM TEAM

•GATHER INFO

•ANALYZE INFO

•ID CAUSE

•DEVELOP SOLUTIONS

•CREATE PROJECT

• DOCUMENT

•PSM

•ISO

•MOC

•OPERATION NORMAL

•PROJECT WORK

•REPORTS

•MEETINGS

•INTERRUPTIONS

•PROCESS PROBLEMS

•PROCESS OPPORTUNITIES

• IMPLEMENT SOLUTION

•FORM TEAM

•DEVELOP PLAN

•INVESTIGATE

•GATHER INFO

•ANALYZE INFO

•IDENTIFY CAUSE

•DEVELOP SOLUTIONS

•PREPARE FOR TOMORROW

at

Improved Daily Workflow &Information Management Making Plants Smarter, Safer &

More Profitable By Design

Process, Power & MarineREAL BENEFITS!!

Global Industry Benchmarks(BASF, FMC, PPG, Taiwan, India)

Prevented unscheduled shutdownsaving >$200,000 per day

Improved Power GenerationRevenue >$200,000 per year

$30,000 Savings with One Alert onSteam System

Steam Reconciliation Savings of$50,000 in 6 months

Raw Material Savings of >$40,000per Quarter

Energy Savings Opportunities> $70,000 per Month w/ Natural Gas

> $100,000 per year Pumps & Blowers

The real value of right information at the right time!


A former Foxboro managerappreciates 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

Process, Power & MarineREAL BENEFITS!!

Global Industry Benchmarks(BASF, FMC, PPG, Taiwan, India)

Prevented unscheduled shutdownsaving >$200,000 per day

Improved Power GenerationRevenue >$200,000 per year

$30,000 Savings with One Alert onSteam System

Steam Reconciliation Savings of$50,000 in 6 months

Raw Material Savings of >$40,000per Quarter

Energy Savings Opportunities> $70,000 per Month w/ Natural Gas

> $100,000 per year Pumps & Blowers

Savings per Costof Production

Low(cents /$)

High(cents /$)

Operating CostsReduction

0.1 2.0

Maintenance CostsReduction

0.1 0.5

Improved Efficiencies 0.3 1.0Addl Product Sales 1.0 2.0Reduced Energy Usage 0.1 0.5OVERALL ANNUALCOST SAVINGSPOTENTIAL

1.6 6.0

% UNIT COSTImprovement

1.6% 6.0%

+ IMPROVED SAFETY+ IMPROVED SAFETY

The real value of right information at the right time!



FALCONEER

THE FUTURE IS NOW!

FALCONEER IS SAP’S & INTERGRAPH’S DIRECT LINK

TO THE PLANT FLOOR AND CONTROL SYSTEM.

Benefits of adding the FALCONEER business package to your SPO Core solution:

PLANT OPTIMIZATION

ASSISTANT

ENGINEERING ASSISTANT FOR

RELIABILITY

Virtual Engineer

Mass & Energy Balance Engine

Statistical & Model Based Trending

Save Hundreds of Thousands of $$$

Real-time Sensor & Process Validation

Soft & Inferential Sensors for Reliability

Abnormal Condition & Fault Detection

Prevent Downtime, Accidents, Releases

The SmartPlant® Enterprise for Owner Operators (SPO) Operating Plant Solution builds upon the SPO Core Solution and provides business packages such as FALCONEER to support common, critical work processes for the operating plant.


August 27, 2008 – 13 –

OO Bundle Solution Components

Engineering tasks that made up the solution:SmartPlant P&ID

Rule and asset based intelligent P&ID solutionSmartPlant Process Safety

Knowledgebase HAZOP analysis solutionSmartPlant Isometrics (formerly I-Sketch)

Specification driven Isometric solution

FALCONEER Process PerformanceValidation, Abnormal Condition Detection &Optimization

Functionality Out-of-the-Box capabilities

Flexibility to be configured to meet specific user demands



August 27, 2008 – 14 –

Design to Operations Business Cases

Add Monitoring System for Compliance

Automating HAZOP Process

Correcting Equipment PerformanceCorrecting Equipment Performance

Support Systems•PID

•Equipment Spec

•Instrument Specs

•Predictive / Preventive Maintenance

•Simulations

•Excel

•Pilot Study Reports

•SOPS



August 27, 2008 – 15 –

Intelligent

P&ID’s

Existing

P&ID’s

Implement

Project

Develop Solution

1) Design Modification

2) Process Change

DCS

Historian

Data Consolidation

Specifications

Controls

Piping

Other

Correcting PerformanceEquipment or Process Unit

Underperforming

DCS

HistorianID Problem & Root Cause

Validate

Solution

Engineering Models

Spreadsheets,

Simulations

Maintain & Optimize

Improved or Design Performance

Real-Time Performance

Monitoring & Auditing

Safety

check



August 27, 2008 – 16 –

Cost savings

Cost of the solution for 3 users$95k (incl. training and fewdays of consultancy)

ROI with the first year ofprojects

$113,540 - $95,000= $18,540

plus Cost Avoidance orOpportunity Cost Savingsranging in the hundreds tothousands of dollars per hourthat problem persistsunrecognized

Task Today Smart Plant

Problem Analysis & ID 16 $1,600 2 $200

As-built 40 $2,400 10 $600

Safety Check 100 $6,000 40$2,40

0

Process Validation 125 $7,500 35$2,10

0

Update design 80 $4,800 40$2,40

0

Commissioning 24 $1,440 12 $720

Update documentation 25 $1,500 10 $600

Savings $25,240$9,02

0

*based on estimates

Savings $16,220

Workflow cases per year 7 $113,540

ROI – Correcting Performance Making Plants Smarter, Safer &More Profitable By Design


August 27, 2008 – 17 –

Business Case –Correcting Performance

Benefits

Virtual Engineer - Analyze process performance

Maintain Safe ConditionsOperational Risk Management

Abnormal Condition Detection & Reporting

Fault & Failure Detection & Reporting

Validation of Safety Critical Instrumentation

Provide recommendations to improve output

Ensure design consistency

Provide consistent P&ID updates

Safety checks on the modifications

Ensure P&ID, process data, Isometrics and safety areall consistent and verified.



August 27, 2008 – 18 –

ROI Recap on 3 Business Cases

Automating HAZOP Process 168,000

Add Monitoring System for Compliance $139,500

Correcting Equipment Performance 113,540

Total ROI $421,040

Less Cost 95,000

Total ROI 1st Year of Projects $326,040

Plus Cost Avoidance or Opportunity Cost Savingsranging in the hundreds to thousands of dollars per

hour that problems persist unrecognized



August 27, 2008 – 19 –

FALCONEER Case Studies

A former Foxboro manager appreciates our approach as “being

rigorous enough to identify the problems without being toocomplex or expensive, combined with being easy enough toconfigure and maintain.”

Chemical\Petrochemical

•Solid Oxidizer Plant

•EO Plant

•Polymerization Plants

•Incinerators

•Pipelines (Oil & Gas)

•Salt Plant

Water & Waste Water

•Utilities

•Chemicals

•Energy

Power Generation

•Co-Generation

•Boiler Systems

Pulp & Paper

•Pulp Mill


Process, Power & MarineCUSTOMER WANTS…

• 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

$$$


SAP

SmartPlantEnterprise


August 27, 2008 – 21 –

Smart Plant of the Future - NOW

FALCONEER Business Package Delivers

Smart Link from Control System to SAP & Intergraph Enterprise

Mass & Energy Balance Engine for optimizing energy utilization, costs,production

Monitor, Report, Trend key performance indicators (KPI) and metrics inreal time

Energy & Raw Material Use & Cost

Instrumentation & Equipment Condition

Production Capacity & Utilization

Receive proactive notifications of under-performing assets before theyimpact the bottom line

Capture, retain & use aging workforce knowledge base

REDUCED OPERATIONAL RISKREDUCED OPERATIONAL RISK

ENSURING OPERATIONS PER DESIGN!ENSURING OPERATIONS PER DESIGN!



August 27, 2008 – 22 –

INTERGRAPH 2008

Presenter: Dr. Doug Lenz

Q & A


www.falconeertech.com


August 27, 2008 – 23 –

FALCONEER Process Performance Solution

Models Are the Key

Material Balances

Energy Balances

Performance Equations

Soft Sensor Models

Six Sigma Transfer Functions

Heuristics

Empirical Equations / Correlations

Multivariate Statistical Models

PCA Models



August 27, 2008 – 24 –

Method Of Minimal Evidence Example

Secondary Model (Eliminates Flow1)

SM1 = 0 = Flow2 * cp * (Temp2 – Temp1)

– Flow3 * cp * (Temp3 – Temp1)

Primary Models (Mass and Energy

Balances)

PM1 = 0 = Flow1 + Flow2 – Flow3 – Leaks

PM2 = 0 = Flow1 * cp * Temperature1

+ Flow2 * cp * Temperature2

– Flow3 * cp * Temperature3

– Leaks * cp * Temperatures



August 27, 2008 – 25 –

Virtual Statistical Process Control (V-SPC)

FIC6725

0

5

10

15

20

25

5/30/02 0:00 6/1/02 0:00 6/3/02 0:00 6/5/02 0:00 6/7/02 0:00 6/9/02 0:00 6/11/02 0:00 6/13/02 0:00

TIME

RE

AL

DA

TA

CURR V

EWMA V

LCL

Y_LCL

Y_UCL

UCL

Controlled Process Variable

Virtual EWMA Chart

Flow meter

D IC 6034

1 .2 5

1 .2 6

1 .2 7

1 .2 8

1 .2 9

1 .3

1 .3 1

1 .3 2

1 .3 3

1 .3 4

1 .3 5

1 /4 /0 2 0 :0 0 1 /6 /0 2 0 :0 0 1 /8 /0 2 0 :00 1 /1 0 /0 2 0:0 0 1 /1 2/ 02 0 :0 0 1 /1 4 /02 0 :0 0 1 /16 /0 2 0 :0 0 1 /1 8/ 02 0 :0 0 1/ 20 /0 2 0 :0 0

TIM E

RE

AL

DA

TA

C U RR V

E W M A V

L C L

Y _ L C L

Y _ U C L

U C L

Controlled Process Variable

Flow Meter

Failure - 12 Hours before TDCAlarm Indication



August 27, 2008 – 26 –

Why Can’t our DCS / SCADA do this?

DCS/SCADA monitors individual points only – FALCONEER monitors entireprocess and interactions between points as well

Patent Pending Method and SystemAdds “wisdom” or intelligence to the raw information.

Automatic model & rule generation for enhanced cross-checking

High Level Auditing & AdvisingAccounts for ALL Information from Process

More than just Individual High/Low Alarm Limits and Trending

Statistical-based and Model-based Trending

Real-time Continuous vs. Manual or Scheduled

Proactive and Preemptive versus After-The-FactWHAT & WHEN & WHY

Certain Functions Possible (SPC, KPI, HART)Requires Significantly More Time, Effort, Long-Term Support to Configure & Maintain

Older systems may not even be possible



August 27, 2008 – 27 –

A Powerful Union

The Power of InformationCaptured in SmartPlant P&ID

The Goldmine of Information& Wisdom Provided byFALCONEER ProcessPerformance Auditing



August 27, 2008 – 28 –

ROI – Automating HAZOP & Beyond

Cost savings

Cost of the solution for 3 users$95k (incl. training and fewdays of consultancy)

ROI with the first year ofprojects

$168,000 - $95,000=$73,000

Task Today Smart Plant

Safety Study 500 $30,000 230 $13,800

Design updates 100 $6,000 40 $2,400

Process Validation 200 $12,000 75 $4,500

Update documentation 75 $4,500 20 $1,200

Isometric updates 75 $4,500 25 $1,500

Commissioning

Savings $57,000 $23,400

*based on estimates

Savings $33,600

Workflow cases peryear 5 $168,000



August 27, 2008 – 29 –

Business CaseAutomating HAZOP Process & Beyond

Benefits

Increase the plant safety

Reduce risk of production interruption

Execute safety study faster and with consistentapproach

Consistent and auditable study

MOC

Making resource available for operational tasks



August 27, 2008 – 30 –

Engineering & Process DataWorking Together

100

PT

100

FE

100

FY

100

FIC

100

FT

100

PI

FROM V-8

100

V1V1

Measured Calculated Real-time Cost Daily Cost Monthly Cost Yearly Cost

Real-Time PV 305 SCFH 300 SCFH $45 / hr $1,080 $32,400 $394 K

Design PV 325 SCFH

Deviation + 5 SCFH - 20 SCFH

TOTAL Cost $45 / hr $180 / hr $225 / hr $5,400 $162,000 $1.97 M

• Calibration Error Cost $394 K, Underperforming Asset $1.97 M

• Incinerator Performance – Environmental Liability, Gas Consumption



SmartPlant Process Safety

Ray Howarth

21-22 August 2008

Hilton Opera Hotel

Hanoi, Vietnam

process, power & marine - intergraph · improved daily workflow better, more timely...

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