Process, Power & Marine

SmartPlant Process Safety

Ray Howarth

21-22 August 2008

Hilton Opera Hotel

Hanoi, Vietnam

Process, Power & Marine

April 20, 2023 – 2 –

Operating the Plant

Integrate ALL Information ...

DESIGN & PROCESS

Create the SMART PLANT of the Future …

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 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

Process, Power & Marine

April 20, 2023 – 4 –

Smart Plant of the Future - NOW

The Virtual Engineer in the Smart Process The Right Information Automatically Provided at the Right Time Cost Savings, Increased Production Improved Daily Workflow Better, More Timely Decision-Making Enhanced Safety

BENEFITS & ROI

FALCONEER™ IV - SPPID 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

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

Making Plants Smarter, Safer & More Profitable By Design

SMART PLANT

PERFECT PLANT

INTELLIGENT PLANT

of the FUTURE

SMART PLANT

PERFECT PLANT

INTELLIGENT PLANT

of the FUTURE

Process, Power & Marine

April 20, 2023 – 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 ENGINEERThe Right Information Automatically

Provided at the Right Time!

Process Performance Auditing & Advising Software

Real-time Process Information Management Fundamental Engineering Models-

based Patented-Pending

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 8 –

CONTROL SYSTEM• Flow

• Temperature

• Pressure

• Level

SHOULD

WORK

IS

WORKING

ADVICEOK OR PROBLEMS

Process Design and Operation Information

THE MFG PROCESS

System AuditingPoint Auditing

DIGITAL DASHBOARD

• KPI

• CHARTS

• REPORTS

• EMAILS

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

Process, Power & Marine

April 20, 2023 – 9 –

• WHAT HAPPENED SINCE YESTERDAY?

• CHECK OPERATIONS

•CONTROL ROOM

•SPREADSHEETS

•DCS TOOLS

• PROBLEMS?

•IMMEDIATE ACTION

•ADDITIONAL RESOURCES 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 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

> $70,000 per Month w/ Natural Gas > $100,000 per year Pumps & Blowers

The real value of right information at the right time!

Making Plants Smarter, Safer & More Profitable By Design

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

Process, Power & MarineREAL BENEFITS!!

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

> $70,000 per Month w/ Natural Gas > $100,000 per year Pumps & Blowers

Savings per Cost of Production

Low(cents / $)

High(cents / $)

Operating Costs Reduction 0.1 2.0 Maintenance Costs Reduction 0.1 0.5 Improved Efficiencies 0.3 1.0 Addl Product Sales 1.0 2.0 Reduced Energy Usage 0.1 0.5 OVERALL ANNUAL COST SAVINGS POTENTIAL

1.6 6.0

% UNIT COST Improvement 1.6% 6.0%

+ IMPROVED SAFETY+ IMPROVED SAFETY

The real value of right information at the right time!

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

FALCONEER THE FUTURE I S 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.

Process, Power & Marine

April 20, 2023 – 13 –

OO Bundle Solution Components

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

Rule and asset based intelligent P&ID solution SmartPlant Process Safety

Knowledgebase HAZOP analysis solution SmartPlant Isometrics (formerly I-Sketch)

Specification driven Isometric solutionFALCONEER Process Performance

Validation, Abnormal Condition Detection & Optimization

Functionality Out-of-the-Box capabilities

Flexibility to be configured to meet specific user demands

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 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

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 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

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 16 –

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

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

Process, Power & Marine

April 20, 2023 – 17 –

Business Case – Correcting Performance

Benefits Virtual Engineer - Analyze process performance Maintain Safe Conditions

Operational 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 are

all consistent and verified.

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 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 Savings ranging in the hundreds to thousands of dollars per hour that

problems persist unrecognized

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 19 –

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

•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

Making Plants Smarter, Safer & More Profitable By Design

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

$$$

Making Plants Smarter, Safer & More Profitable By Design

SAP

SmartPlant Enterprise

Process, Power & Marine

April 20, 2023 – 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 in

real time Energy & Raw Material Use & Cost Instrumentation & Equipment Condition Production Capacity & Utilization

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

Capture, retain & use aging workforce knowledge base

REDUCED OPERATIONAL RISKREDUCED OPERATIONAL RISK

ENSURING OPERATIONS PER DESIGN!ENSURING OPERATIONS PER DESIGN!

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 22 –

INTERGRAPH 2008

Presenter: Dr. Doug Lenz

Q & A

Making Plants Smarter, Safer & More Profitable By Design

www.falconeertech.com

Process, Power & Marine

April 20, 2023 – 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

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 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

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 25 –

Virtual Statistical Process Control (V-SPC)FIC672 5

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

DIC6034

1.25

1.26

1.27

1.28

1.29

1.3

1.31

1.32

1.33

1.34

1.35

1/4/02 0:00 1/6/02 0:00 1/8/02 0:00 1/10/02 0:00 1/12/02 0:00 1/14/02 0:00 1/16/02 0:00 1/18/02 0:00 1/20/02 0:00

TIME

RE

AL

DA

TA CURR V

EWMA V

LCL

Y_LCL

Y_UCL

UCL

Controlled Process Variable Flow Meter Failure - 12 Hours before TDC Alarm Indication

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

April 20, 2023 – 26 –

Why Can’t our DCS / SCADA do this?

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 Accounts 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-Fact WHAT & 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

Making Plants Smarter, Safer & More Profitable By Design

Process, Power & Marine

SmartPlant Process Safety

Ray Howarth

21-22 August 2008

Hilton Opera Hotel

Hanoi, Vietnam