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2013 Honeywell Users Group Europe, Middle East and Africa

1

From Metering to Diagnostics to Operational Excellence

What is the next step?

Martin Bragg

Honeywell Proprietary

Honeywell.com

2 Document control number

Agenda

• Introduction to Engineered Field Solutions (EFS)

• History of diagnostics in measurement

• From diagnostics to operational excellence

• Honeywell’s EFS vision on the future of metering


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Integrated Solutions for Better Performance

• Pressure Reduction & Metering Stations (PRMS), incl. City Gates

• Underground storage

• Biogas

• Compressed Natural Gas (CNG) stations

• Turbo Expander (MTG) stations

Gas Solutions

• Tank inventory management

• Loading/unloading skids

• Metering skids

• Terminal logistics management

• ERP integration

• Integrated terminal automation

Terminal Operations

• Alarm and monitoring systems

• Valve remote control systems

• Tank gauging, cargo & ballast

• Loading integration

• Portable ullage temperature interface systems

• Sampling

Marine Solutions


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Integrated Solutions Across Oil & Gas Supply Chains

PressureReduction

Custody Transfer Metering

DistributedControl System

Simulation Optimization,ERP Software

Fire & GasSystems

SCADA

Gas Processing

Plant

LNG Carrier

LNG Terminal: Receiving

Pipeline Gas Transportation

PowerPlant

LargeIndustrial

Plant

UndergroundStorage

Bio Gas Producer

Power Plant

Pip

elin

e

GAS

Well

OIL Oil Terminal

Oil Tanker

Oil Terminal

Refinery

Transportation Pipeline

Product Terminal

Tanker/ Barge Terminal

Pipeline

Truck/ Rail

ChemicalPlant

ProductRetail

Transportation

Other Industries & Commercial

Well

Security, Surveillance,Access Control

Compressor Station

PumpingStation

City Gate Station

PowerPlant

Commercial Plant

IndustrialPlant

Residential Plant

LNG Terminal: Export


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The Performance Link

Honeywell’s Engineered Field Solutions links each step of the oil and gas supply chain, start to finish.

• Integrated storage, transport and distribution processes

• Fluid custody transfer, guaranteed compliance and accuracy

• Higher safety, higher security

Performance makes the difference


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Terminal Operations

• Oil transportation, distribution and storage

• Global service coverage, domain knowledge

• Complete portfolio, wide ranges of technologies

• Custody transfer applications

• Compliance with legal metrology & safety standards

• Terminal automation

• Tank storage, loading, metering skids

• Meter proving

Serving Oil Logistics Worldwide

Better Resources, Better Results


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Marine Solutions

• Our equipment and marine solutions are sailing on 8,000 ships worldwide

• Global service around the world

• Tankers, bulkers, container ship barges, offshore support vessels

• High tech vessels: LNG, FPSO, FSO

• Cargo, ballast, slop, fuel, fresh water tanks


Serving Ships Worldwide


Honeywell Marine


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Gas Technology

• Gas transportation, distribution and underground storage

• Global service coverage, domain knowledge

• Complete portfolio, wide ranges of technologies

• Pressure reduction and metering stations


• Smart metering

Broad Portfolio for the Gas Industry Worldwide



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History of Diagnostics in Measurement


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Metering Principles in Oil & Gas Industry

• Orifice & Venturi

• Orifice on-line, real-time diagnostics available (DPD Prognosis)

• Rotary meters

• Off-line remote diagnostics available from Elster-Instromet

• On-line, real-time diagnostics available

• Condition-based monitoring is a key driver

• Emerson released diagnostic tool for the Micro-Motion meter

Differential Pressure

Positive Displacement

TurbineUltrasonic Metering

Coriolis


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Evolution of USM Diagnostics

Traditional analog diagnostics with oscilloscope and multi-meter.

Digital diagnostics with meter dashboards like RMG-view, and many other meter diagnostic packages.

Integrated system diagnostics.

The Total Energy Measurement concept is Extended Data Mining


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Mutually Exclusive Events?

Yes: With Two Different Metering Technologies

Field Verification and Validation of an

Energy Measurement System

after: Herwijn, 2008.

Total Energy Concept System (AGA 2011)

after: Bragg, et al.

GAS METER STANDARD GAS PROPERTY STANDARD

Turbine Meter

AGA 7

Compressibility

SGERG88

ISO 9951 SGERG91

EN 12261 MGERG

Ultrasonic Meter

AGA 9 AGA NX 19

ISO 17089-1 AGA 8

EN 14236 Base Conditions ISO 6976

Orifice Plate

AGA 3

Composition

ISO 6974

ISO 5167 ISO 10723

Conversion Device EN 12405 ASTM 1945

Calorific Value

ISO 6976

GPA 2145

GPA 2172

Speed-of-sound AGA 10

Specific Heat AGA 10


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Why Diagnostics?

Standards and compliance through type-testing is critical to quality and the minimum entry requirement to market

Ensure accuracy of the operational metering system:

• Prove your metering is accurate throughout its useful life-cycle

• Signal when operational accuracy is affected

• Caused by process condition or metering defect


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USM Diagnostics – Overall ApproachUSM Diagnostics – Overall Approach

Key Observations

• Most manufacturers provide similar diagnostic methods

• Inference based on various parameters is mostly done by experts

• Inference tools are emerging as key trends, e.g. Artificial Neural Networks

• Enhancing inference engine to reflect clear maintenance action

Tech Trend: Inference Tools for Fault Isolation

• Performs analysis to infer the fault and its source

• Mostly manual

• Early tech trend new method in ANN*

* ANN: Artificial Neural Networks

Inference Engine

• SNR

• VoS to AGA 10

• Asymmetry

• Profile factors

• Swirl angle

• Performance

• Turbulence

Processing(Diagnostics)

• Fluid velocity

• Pressure

• Temperature

• Transit times

• Path velocities

• Delta times

Measurements What is Next?


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Evolution of Orifice Diagnostics

Traditional diagnostics only for the DP tansmitters. Plates inspected visually.

Now digital diagnostics with a meter dashboard called Prognosis.


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From Meter to Diagnostics - What’s Next?

What is Next?

Orifice Meter

(Shale Gas)

Prognosis Diagnostics Software


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Industry Concerns and Challenges

• Increased complexity

• Reducing and aging workforce

• Reduction in operating budgets

• Greater geographic challenges

• Increased need for faster, more precise decision-making

• Stricter compliance on emissions and safety

Our customers under increasing pressure

Need to achieve and deliver in the face of:

• Improve productivity

• Increase yields

• Reduce waste

• Reduce raw material usage

• Maximize utilization of assets

• Minimize energy usage and carbon footprint

• Eliminate safety incidents/process excursions

• Adhere to increasingly stringent HSE, regulatory compliance requirements


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From Diagnostics to Operational Excellence


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Oil & Gas Production

Well 1

Well 2

Well 3

Well 4

Well 5

Well 6Oil Export

Metering

Export

Pumps

Sat Field A

Prod Sep

Sat Field B

Prod Sep

M

M

M

M

Water Treatment

Plant

M

M

M

M M

M M

M

Gas Treatment

Plant

Gas Export Metering

Gas Compressor

Fuel Gas

M

M

M

M

M

M

M

M

M

Test Sep

1st Stage

Separator

2nd Stage

Separator


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Where is My Information?

Valuable information is all around in your plant and compartmentalised

• On-board meter diagnostics

• Process instrument diagnostics

• Flow computers

• Metering supervisory computers

• Process information

Compare with a MIS

• Consolidate all available information

• Valuable insights on how to

optimise business

• Impossible when looking at individual

bits of information


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What if You Could?

Promote optimal operations while at the same time protecting

your people, the environment and your

reputation?

Solve the challenge of remote operations

and limited expertise?

Overcome ‘analysis paralysis’ and start

making the right decisions at

the right time?

Unleash the knowledge tied up in all your

metering and control components?

Operate at ‘maximum efficiency’

all the time with integrated real-

time data?


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The Metering Community Changes

• Metering guru

• Lifetime employee

• Experienced

• Plant or remote-office based

• Solid & reliable

Going


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The Metering Community Changes

• More likely to work from a local support office close to site though able to support from remote locations

• A champion of new technology

• Systems / control engineer capable of using standard interfaces and supporting the platform rather than the device

Now


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Honeywell’s Vision for the Future of Metering


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Our Vision

Provide fully compliant metering

Connectivity supporting data integration

Provide real-time analysis tools


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Compliant Metering Products

• Flow meters: rotary, turbine, ultrasonic

• Flow computers

• Gas analysis

• Electronic volume correctors

• Telemetry

• Data collection and management

http://www.rmg.com/uploads/tx_a1teasermenu/USZ_08_imRaum.jpg

http://www.rmg.com/uploads/tx_a1teasermenu/RMG_Trz03k_f1_2008_03.jpg

http://www.rmg.com/uploads/tx_a1teasermenu/PCG_9000.jpg

http://www.mercuryinstruments.com/media/products/tci/pics.php?current=TCI_Thumb1_NEW_Lg


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DCS Embedded Fiscal Metering

MeterSuiteTM


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DCS Integrated Flow Computation

• Secure Totalisation• Fiscal Accuracy• Reporting• Proving• Sampling• Chromatograph• etc.

MeterSuiteTM


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Honeywell MeterSuite™ Approvals

MeterSuite™ is fully:

• MID approved

• OIML R117 Approved

• ERCB Directive 017 compliant

All Calculations Meet:

API Standards

ISO Standards

AGA Standards


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Intuition® Executive

Microsoft®

SharePoint® portal brings together web parts and displays from Honeywell and non-Honeywell systems.

Visualize & act on data from multiple sources

Engage your experts when needed for maximum impact through integrated instant messaging and email

Organize your company’s knowledge to learn from experience with document libraries, task lists and wiki communication tools

Get from data to decision faster with visual key report analysis & diagnostic data

Collaborate across functional silos by integrating data from multiple sources and channels of communication

Enable remote operations & collaboration through online workspaces & meeting rooms

Squeeze more value out of your current investments: bring in data from current systems and infrastructure


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Anticipate.

Now You Can

Predict problems & identify opportunities in time to act on them

• Visualise and act on data federated from multiple sources

• Organise your company’s knowledge to learn from experience

Collaborate.

Capture knowledge & share information and best practices for smarter, more agile decisions

• Enable remote operations & collaboration

• Engage your experts as needed for maximum impact

• Collaborate across functional silos

Act.

Drive performance with work processes - ensure that knowledge is acted upon

• Get from data to decision faster

• Stop reinventing and start reusing - squeeze more value out of your current investments

Collaborate.Anticipate. Act.


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Anticipate.


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Capture Expert Knowledge

• Identify opportunities and avoid problems that previously passed unnoticed

– Avoid significant environmental or safety infractions

• Capture the knowledge of your experts with collaborative tools

– Training junior staff for when experts are unavailable

• Improve personnel productivity

– Searchable information resides in document libraries, wikis

• Tools for the end-user to collaborate with other peers and experts


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34 Document control number34

CUSTOMER CHALLENGES: Coal Bed methane

production in Australia, needed to implement a remote surveillance

solution to assess/optimize performance of hundreds of wells;

increase safety and reduce production downtime; and promote

collaboration to increase operational efficiency.

HONEYWELL SOLUTION: Turn-key system

integration, Intuition and Well Performance Monitor solution, data

acquisition solution, data historian, and integration with third-party

systems including a production data management system.

CUSTOMER RESULTS: Anticipated Reduced

production downtime; improved safety via faster identification of

integrity issues; more surveillance with less people; and achieved

an enhanced collaboration.

Customer Success Story

Application: Coal Bed Methane – Unconventional Gas

Result: Project is Ongoing, start up late 2012

Goal: Operational Excellence


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It started with the meter…

To operational metering excellence bringing together all that has gone before plus a host of disparate systems into one and mining the ‘enterprise’ to enable you to Anticipate, Collaborate and Act!

Operational Excellence in Metering

Progressed to on-board and remote diagnostics• Data archives historian with trends analysis• Artifical Neural Network application to 3D data

Extended to other measurements for confidence• Mutually exclusive events and truth tables• ‘Pay and Check’ metering


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Summary Conclusions

• The traditional meter manufacturer had to look toward a total solution beyond the meter itself

– To provide a confidence that the operational meter is working within its original design specification

– Developing diagnostics and condition based monitoring

• The manufacturer is moving towards “operational excellence partnering” through extending its systems and data mining with software such as Intuition®

Executive to enable Anticipation, Collaboration and, subsequently, acting rapidly to improve productivity

• Valuable information is often locked within many disparate systems

Partnering in Operational Metering Excellence

Thank you

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