Emerson Eng

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Ach ieving Operat ionalExcel lenceMarch, 2006


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Copyright Emerson Process Management March 2006 Slide 2

The World Has Gone DIGITAL !


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Law Of Accelerat ing Returns

Analysis shows thatTechnological

change isexponential


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Disposable printers?

Storage is free: $65

My old PC


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Greenfield

34%

Expansion/

Modernization

66%

We Have To Serve Both Greenf ield and B row nf ieldCustomers

World Area O & G Refining Pharma Chemical Power W & W

NA

LA

W Europe

E Europe

ME

Africa

AP


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CopyrightEmerson Process Management, March 2006, Slide 7

The Techno logy Universe

Parallel computing

Moores Law

.NET

ArtificialIntelligence

HART

Process Diagnostics

Predictive Algorithms

Energy Scavenging

DSPs

Enhanced EDDL

Ultrasonic

Fuel Cells

MP3

802.11 (beyond G)

802.15.4

GPSFoundationFieldbus

.NETModel BaseProgramming

MEMS

ScaleableGraphics - Avalon

Motes

FireFox

Advanced Signal Processing

OPC UA

Smart Objects

GPRS

PAT

Security S99

Bit Torrent

AES

RSS

XML

UML

Security

VistaSOA

AVALON

W-bluetooth

SkypeOPML


8/58CopyrightEmerson Process Management, March 2006, Slide 8

Operational Excel lence

P

rofit

Cost

$time

Safer operation

Fewer unscheduled outages

Shorter scheduledoutage

Higher sustained

production withminimize costs

Longer duration toscheduled outage

Faster time-to profit



Smart cars

monitor tirepressure

Tire icon indicates

low pressure

Car advises driver of abnormal situation madepossible via disruptive technologies



Smart Car MessagesSeat belt

Cargo door openPassenger door openWiper fluid lowTurn signal onRight rear tire pressure low

Change engine oilFuel low

Messages I do not get Check engineBig red oil light



Two requirements:- Sensing technology- Presentation to user at the right time



Early

warn ing

Oil Pressure Alarm

time

CarPerfor

mance

Sequence Of Events

Change Oil Light

Major PerformanceImpact

Safety incident



We Help Our CustomersDeploy Smart Digital Plants



SMARTMACHINERY HEALTH

MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL

SMARTSAFETYSMARTSAFETY

Smart Plant Arch itectu re

SMART

ASSET OPTIMIZATION

SMARTFINAL CONTROL

SMARTFINAL CONTROL

SMART

DIGITAL CONTROL

SAFETY



Todays Smart Field Devices Predict AbnormalSituat ions

On-board computing power enablesstep changes in functionality

Often have more than one processvariable for a single pipe intrusion

Full with diagnostics

health of deviceis known

health of the applicationis

monitored health of the processis monitored

At 12:45 tomorrow, this valve will fail



Early warning

Device failure

time

PlantPerf

ormance

In tel l igent Devices Repo rt Health

Device alert

Process Impact

Safety Incident




MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


Smart Plant Arch itectu re

SMARTASSET OPTIMIZATION

SMARTFINAL CONTROL

SMARTFINAL CONTROL

SMART

DIGITAL CONTROL

SAFETY



Smart Predict ive AlertsPressure Transm it ter Examp le

Sensor failure



Smart Predict ive AlertsPressure Transm it ter Examp le

Process problem



Smart Predict ive AlertsValve Example

Valve is performing sub-optimally



Smart Predict ive AlertsValve Example

Valve needs maintenance



Smart Predict ive AlertsCompresso r Protect ion Example

Compressor needs maintenance



10 Year Old Plants Do Not Have Predict iv eCapabil i t ies

Process view is fuzzy Process view clear


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Motor Overheating

time

DevicePerformance

Alarms To Operator?Example shown : NO

Impellor Imbalance

Process Impact

Time For Act ion > 6 months

Early alarm to MAINTENANCE only asthere is a long time before process impact.


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time

DevicePerformance

Alarms To Operator?Examp le shown: NO (long time before failure)

Valve frozen open inutilities plant

Process impact

Time For Act ion > 1 year

Early alarm to MAINTENANCE only as there islong time before process impact


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time

DevicePerformance

Failure of a Crit icalValve Colum nImpacts The Process Immediately

Valve frozen open indistillation column

Process impact

Time For Act ion < 30 minutes

Early alarm to MAINTENANCE and OPERATORas action is required immediately to prevent

process problems


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Plants Must Have An A larm Message Map

Cost ofIgnoringAlarm

Time To Avoid Process/Safety Impact

A larm Dest inat ion Map

High Priority Medium Priority

Low PriorityMedium Priority

Operator

Maintenance Optimization Personnel Safety Personnel

Maintenance Optimization Personnel History Collection

Operator Maintenance Safety Personnel


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The Impo rtance Of A larm Hand l ing

In the last 11 minutes before explosion, the operators had torecognize, acknowledge and act on 276 alarms

Milford Haven was 25x therecommended maximum


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MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


A larm Messaging Map


SMARTFINAL CONTROL

SMARTFINAL CONTROL

SMART

DIGITAL CONTROL

SAFETY

Predictive AbnormalSituation Alarms

Degraded SafetyAlarms

Asset Health


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PT-101

Alert The Operator Before Process Impact

Operator Interface


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MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


Al l A sset Alarms To Maintenance


SMARTFINAL CONTROL

SMARTFINAL CONTROL

SMARTDIGITAL CONTROL

SAFETY

ASSET INTERFACE


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Maintenance / ReliabilityDashboard


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MANAGEMENT

SMARTMEASUREMENT

SMARTMEASUREMENT

SMARTANALYTICAL

SMARTANALYTICAL


A ll Safety A larms To Safety Personnel


SMARTFINAL CONTROL

SMARTFINAL CONTROL

SMARTDIGITAL CONTROL

SAFETY

Degraded SafetyAlarms


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Safety Personnel Are Roam ing

Cell phone, pager, email Detailed Summary


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Exceed EEMUA guidelines

Alarm AnalysisDashboard

I A S t Pl t D Th N b Of Al T


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In A Smart Plant, Does The Number Of Alarms Tothe Operator Inc rease?

No

Best practices areestablished in the design ofthe alarm system

EEMUA

Alarm Map

Early warning alarmsproperly acted on mayactually decreasetheincoming alarms asprocess alarms may be

avoided

P H lth D l i U t i f t R l t A t 200


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Poo r Health Del ivers Unsat isfactory Resu lts A t 200kph !! !

E pect Poor Performance In Plants With Poo r A sset


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Mercury FilledTransmitters & Switches

DisconnectedDamper Drive

Leaking ValveBody

Expect Poor Performance In Plants With Poo r AssetHealth

Poor Equipment Results in PoorPerformance and Unsafe Plants

Expect Poor Performance In Plants With Poo r A sset


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Expect Poor Performance In Plants With Poo r AssetHealth

Poorly performing control is identified

Advanced ControlDashboard


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Some Smart Plant Bui lders

Shell- Deer Park,Tx** $32M*(vs. HW)- FCCU, HydrocrackerPetrobras Brazil(3)** $17M(displaced Bailey)- Coker, Blending, Crude

Pemex- Tula $3M(displaced HW)- Alkylation UnitShell Motiva Norco $17M*(displaced HW)- Reformers(2), DHT, NHT, SMR, HCPdvsa, Curacao** $5M*(displaced Foxboro)- SRU(4), H2 Plant, HydrocrackerMOL PLC, Hungary $10M*(vs. YEW, HW)- Diesel Hydrotreater, Sulfur PlantRompetrol(Romania) $20M(Modernization)- Entire RefineryBP SECCO $30M(vs. YEW)- Ethylene ComplexCenex, Montana $1.5M(vs. Moore)- DesulfurizationScanraff, Lysekil $1M(vs HW)- Merox, Propylene, FCCU***Yukos, Odessa $2M(vs HW, YEW)- Isomerization, Reformer*-MAC Scope of supply **- Facility in operation ***- Portion of FCCU

-64 Refineries with PlantWeb last 30 months, over 500 PlantWeb installations in Refining-Process units: FCCU, Hydrotreaters(Diesel and Naphtha), SRU, H2 Plant, SMR, AlkylationUnits, Crude Unit, Vacuum Unit, Asphalt unit, Delayed Coker, Hydrocracker,

Reformer


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Shell Deer Park Revamp 2003


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Shell Deer Park Refining CompanyDeer Park Refining Limited Partnership

Our Vision Shell Deer Park

Use the newest technology to create the Refinery of theFuture

Concentrate on safetyand environmental concernsSystem must be robust

Focus on costLow life cycle cost Manpower trainingMust be easyto operate and

maintain

Obsolesce resistancemust be based on industrystandard software norms


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Contro l Room

BEFORE AFTER



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Cabinet

BEFORE AFTER



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Field Junct ion

BEFORE AFTER



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Resu lts Delivered

Operational Excellence

Safety: No OSHAs

Environmental: No Incidents

State of the art operating interfaces

Financial

1% maintenance cost reduction achieved(3%+ is believed possible)

Overall 1-3% utilization improvement

Improved unit reliability

Greatly improved maintenance effectiveness

Huge project savings by reutilizing previous engineering

BARRIERS


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BARRIERSTo Operat ional Excel lence

Overly aggressive focus onCAPEX

The technology change is theeasiest

In plant visionaries arenecessary and hard to find

Management support is critical

The human resistance tochange is greater than you think


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Satellite Service Providers Know Tire Pressure

What use is there for the old-fashioned tire gauge?


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Change Or Be Changed There are two kinds of organizations in today's world:

those that are changing

those that are going out of business

Similarly, there are also two kinds of people

Those who are changing

Those who are setting themselves up to be victims of change

Jim Clemmerhttp://www.clemmer.net
http://www.clemmer.net/http://www.clemmer.net/


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Cannot Be Done Without TechnologyCannot Be Done With Technology Alone


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Technology And Experience Deliver Performance


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