PPT Template

Report
Slide 1
SSE-01
Refinery Wide
Performance & Profitability
Joseph McMullen
SimSci-Esscor Product Marketing
Manager
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
Sl
Dominance in Refining
Standardized on SimSci-Esscor
in Refining
Slide 3
Primarily Uses SimSci-Esscor
In Refining
Dominance in Refining
Other Users of SimSci-Esscor
In Refining
Slide 4
SimSci-Esscor is Refining.
Products – Innovation – Experience - Acceptance
Slide 5
Solutions Across the Refining Spectrum
Heavy Oils – Workforce Enablement – Enhanced Performance and Profitability
Slide 6
Heavy Oils
Slide 7
Heavy Oils
Proprietary Property Prediction Technology Aids in Simulation
Superior Heavy Oils modeling provide more
accurate models of heavier feedstock so that
refiners can adapt their processes accordingly
Thermodynamic methods are applicable in various
stages of design, operations, and optimization
Slide 8
Solution
Crude Feed preparation
• Characterization
• Viscosity
• Thermal conductivity
In Progress
March 2010
Upgrading
•Mercury Solubility
• Hydrogen balance
November 2009
•Liquid Thermal
Conductivity
– Hydrogen solubility
Contaminants
•Liquid Viscosity
• Mercury
November
2007
•Characterization
Option
Slide 9
July 2008
•Hydrogen Solubility
Workforce Enablement
Software & Solutions to Train and Enable the Workforce
Operator Training Simulators, mobile workforce
guidance, Wonderware Intelligence dashboards
speeds up operator effectiveness and aids in
knowledge transition
Slide 10
Workforce Enablement
Slide 11
Workforce Enablement
Products & Solutions
1. Operator Training Simulations (OTS)
2. EYESIM
3. ArchestrA Workflow
4. Mobile Workforce Guidance
5. Wonderware Intelligence
Slide 12
Dynamic Simulation Suite – Products,
Services and Training Simulators
Upstream
Gas Processing
Refining
Petrochemicals
Chemicals
Total HPI Projects
17
20
85
29
14
165
Hydrocarbon Processing 165 Projects (with majority in refining)
Power
154 Projects
Over 300 OTS projects delivered to clients
All models suitable for engineering studies and operator training
Slide 13
Operator Training Simulator
Plant
Control system
DCS + ESD
Dynamic Process Model
ACCIDENT PERCENTAGES
Software Emulation
38
Mechanical Failure
26
Operational Error
Operator consoles
HMI
12
Unknown C aus es
10
Proces s Ups ets
7
Natural Hazard
Des ign Error
Ars on/Sabotage
Slide 14
4
3
Same or similar
Immersive Virtual Reality Plant - EYESIM
IMMERSIVE VIRTUAL REALITY PLANT
is a comprehensive solution linking
Control Room Operators…
...to Field Operators
...to Maintenance Operators
...by means of high fidelity Process
Simulation and a Virtual Walkthrough
Plant Environment for complete
PLANT CREW TRAINING
Slide 15
Benefits: Optimize the training period of
all Operators in all activities
Slide 16
•
Provision of more realistic environments for trainees and the
opportunity for practice in training sessions
•
•
React quickly and correctly in medium- and high-stress situations
•
Optimized transfer of skills from the training environment to the
work environment
•
Reliable and valid evaluation of operational procedures and
performance
•
Team training: control room, field, shift and operational managers
(Communications)
Improving skills for rarely-performed, but safety-critical tasks
(e.g. emergency shutdown)
Value Proposition
• Saving time and costs for “on-job-training”
(30- 40%)
• Reducing time of startup (for planned/
unplanned shutdown) from warm/cold
conditions (15-20%)
• Saving on maintenance budget (1-3 %)
E.G.: greenfield refinery 200 K bpd   3 - 4 M $/y
Slide 17
Invensys proprietary &
ArchestrA Workflow –
Business Process Management
Event automatically
captured and context
prepared
Maintenance event
occurs at shop-floor
Workflow
Initiated
Supervisor notified
( SMS, Email )
N
Decision to
HOLD
production
Production
continues
Slide 18
Y
Communication with
context sent to
Maintenance
Maintenance notified
( SMS, Email )
Communication
shared with Supervisor
Maintenance
performs inspection
and submits report
B
P
M
Concurrent
communication with
Production Scheduler
& EAM Application
Maintenance Tech.
receives maintenance
order on mobile device
Communication with
Maintenance Tech.
Maintenance Tech.
completes order
Concurrent
communication with
Production Operator
& EAM Application
Maintenance order
created in EAM app.
Scheduler updates
production schedule
Maintenance order
closed in EAM app.
Production Operator
notified to start
production
How It’s Done with IntelaTrac
• Field worker logs into Mobile IntelaTrac on handheld computer
• Asset is properly identified using RFID or barcode label
• Tasks are date/time stamped as completed
• Actual field conditions can trigger “focused advice messaging” which
directs the field worker to:
• Input more information such as notes
• Perform a special procedure to mitigate the condition
• Take additional measurements
Results:
•Pump Repair $10K
•Exchanger Repair $0K
•Lost Production $0K
Savings = $210k
Slide 19
Wonderware Intelligence
User-friendly
Configuration &
Administration
Production/Process
Information Platform
Wonderware &
Non-Wonderware
Data sources
Slide 20
Share content
& Collaborate
Incremental approach
Self-service access
to information
& content authoring
Performance and Profitability
Optimize Operations of Enhanced Profitability
Refinery-wide Optimization solutions aid in
performance enhancements to various processes
that yield enhanced profitability
Slide 21
Performance & Profitability
Slide 22
Performance & Profitability
Products & Solutions
1. Dynamic Simulation Suite (DSS)
2. ACA.HF
3. Off-sites Solutions
4. ROMeo
5. Integrated Off-sites to ROMeo
6. Invensys Yield Accounting Solution
7. Wonderware Intelligence
8. Connoisseur
9. Condition Manager
10.ArchestrA Workflow
Slide 23
Dynamic Simulation: DESIGN to TRAINING
Highlights of Where we are Today
PROCESS
DESIGN
Distillation
Column Relief
Load Calculation
Reduction
- Over twenty users
Compressor Triconex
TMC Checkout
Slide 24
DCS
CONFIGURATION
DCS Checkout
against dynamic
models reduce
commissioning
time in the field.
STARTUP and
TRAINING
Training
Simulators to
replace a retiring
work force
PLANT
OPERATION
Over 200 DYNSIM/
FSIM Plus / TRISIM
Plus simulators
provide more than
just training:
- PC Power Plants
- Refinery Units
- LNG
- IGCC
- Ethylene
Integrated control
room / outside operator
training using
3D Virtual Reality
Logic Validator
Automated test harness integrated with simulation geared toward
Safety Instrumented System (SIS) verification and validation
• Tests and documents SIS logic in an emulated environment
• Easy to configure and use Excel-based interface to build logic
validation scripts
• Connects to SIS/PLC/DCS emulators either directly or via OPC UA,
DA and Modbus protocols
• Soft emulators include Triconex, Allen-Bradley, Modicon, GE
Siemens, CCC, Woodward, Foxboro, ABB, Emerson, Yokogawa,
Honeywell, etc.
• Connect to real hardware, if necessary
Slide 25
ACA.HF
The ACA.HF Measurement Solution
● SAFE & SIMPLE online analysis of %HF,
%Water and %ASO in HF alkylation catalyst
● Affordable alternative to FTNIR² with reliable
accuracy
● Exceeds the precision of HF analysis with FTNIR
● A multivariable analyzer¹ based on the
application of proven Foxboro measurement
technologies that are long-established in HF
service
The ACA.HF is the new standard in safety, simplicity,
reliability, and accuracy for HF catalyst analysis
¹ Slide
Patent
Pending; international rights apply
26
² ABB FTPA2000-HP20 FTNIR-based HF Acid Analyzer
Off-sites
Off-sites refers to the tank farm
that contains the crude
feedstock oil that feeds the
refinery and the tank farm that
contains the products of a
refinery (gasoline, diesel, etc)
Slide 27
ROMeo
ROMeo Process Optimization
software would optimize the
actual refining process,
everything in blue.
Slide 28
Integrated Off-sites
Slide 29
Yield Accounting
Yield Accounting works to
develop a material balance, or
a record of everything that
comes into the red dotted line
(refinery) versus everything
that leaves the red dotted line.
In a typical process,
in = out
You can’t produce more than
you put into the process, and
everything you put in has to
come out eventually
A typical 250,000 bbl/day refinery could save $8.5 Million
USD/yr by cutting their unaccounted material loss by 0.5%
Slide 30
ROMeo + Wonderware Intelligence
InFusion
Enterprise Control System
User-friendly
Configuration &
Administration
Portal/Case
Manager
WW
Historian
SharePoint
ROMeo
Automatically
Trend and Store
Advanced Application
Data
Real-Time
System Scheduler
Plant Technical Details
Slide 31
Real-time Plant Information and
Measurements
Intelligence
Server
Analytics
Dashboard
Real-Time Analysis
Information Display
Real-time Actionable Plant Details and
Key Performance Indicators (KPI’s)
Wonderware Intelligence Dashboard
Slide 32
Advanced Process Control
Connoisseur improves process
profitability by enhancing quality,
increasing throughput, and
reducing energy usage – all by
accurately controlling your
process within a tighter tolerance
Slide 33
Avantis Condition Manager
• Condition monitoring and management capabilities turn huge
volumes of production data into actionable asset intelligence
in real-time, enabling informed decision-making at every
level of the production enterprise.
• Key benefits include:
• Increased operational safety
• Optimized costs of maintenance
• Improved sustainability of operations
• Lower energy consumption
• Reduced variance in the response of the maintenance personnel
Slide 34
Refinery Wide Performance &
Profitability Resources
WEBINARS
PROMOTIONAL
WEBSITE
Slide 35
$$$
ENHANCED
PERFORMANCE
& PROFITABILITY
AHEAD
PRODUCT
VIDEOS
WHITE
PAPERS
Thank you!
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

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