Honeywell Technology Summit Kuwait · 2017-10-23 · The Value in Closing Gaps in an Aromatics...
Transcript of Honeywell Technology Summit Kuwait · 2017-10-23 · The Value in Closing Gaps in an Aromatics...
Honeywell Technology Summit Kuwait
Ayman Mehdawe
October 3rd – 4th 2017Connected Performance Services
UOP 8013C-0 Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Introduction Meeting
Expectations
CPS Background &
Video
Discussion and
Next Steps
Agenda
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Connected Performance Services (CPS)Knowledge Delivery as a Service
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The Connected Plant Delivered with CPS
• Analyze plant performance to reveal full potential through a Cloud-
based service
- Around-the-clock monitoring of plant data and rigorous simulations
- Provides on-going, operational recommendations to close performance
gaps
- Leveraging UOP Process Models & longstanding experience in operational
support and troubleshooting
• Combining 100+ years of Oil & Gas processing experience with next-
generation software platforms
• Emission standards
• Energy reduction
• Sub-optimal operations
• Performance vs peers
• Knowledge gaps
• Operational excellence
Key Customer Challenges
Unplanned Downtime Human Capital Challenges
Underperforming Assets
• Process issues
• Equipment failures
Energy and Emissions
CPS PortfolioThe Connected Plant, Delivered:
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Process Reliability Advisor• Pre-empt process issues with embedded root cause analysis
• Operate closer to constraints
• Drive best operating practices
Utilities Management*• Enhance heat recovery, fuel gas and H2 systems management
• Optimize supply and demand balance
Process Optimization Advisor• Maximize profitability through changing process
and economic conditions
• Evaluate new opportunities with “what-if” analysis
Predictive Maintenance*• Improve turn-around planning by
managing asset lifecycle
• Gain new reliability insights through data
analytics
Unit-specific Benchmarking*• Improve operations through actionable unit advice
• Set realistic, achievable targets
*in development
The Value in Closing Gapsin an Aromatics Complex
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Issue Response Time
Sub-optimal Operation
Assumptions:
400 KMTA PX production, $330/MT Naphtha/PX spread,
Optimization of the Complex at varying feed quality conditions
$3-8 million/yr.
Typical Value Gap
By understanding the various constraints throughout the Aromatics Complex, you are able to optimize the individual units, re-balance the constraints and increase throughput
Knowledge Transfer
How
Early detection of issues allows you to make the appropriate changes faster and potentially before they become costly
Having the right information at the right time is critical for you to sustain knowledge and improve operational awareness
CPS Videos
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• Process Reliability Advisor for a CCR Platforming™ unit
• Process Optimization Advisor for an Aromatics Complex
Process Reliability AdvisorA structured method to present process insights
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What does it do?:
• Monitoring of unit performance
• Constraint limitations
• Event detection & mitigation
• Knowledge transfer
What is behind it?:
• Matches unit configuration
• Tuned UOP process models
• Technology specific fault models
• Embedded UOP knowledge, context, and
background
Process Reliability Advisor
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Supported by underlying embedded
fault modes
Fault Mode Categories
Product Yields & Quality
Catalyst Health
Rx Pressure & Temperature
CCR Operation
Recycle Gas Moisture
Equipment Health
Debutanizer Column Operation
230+ Root
Causes
What is behind the Service?
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Logic developed from:
• Deep process knowledge
• Extensive understanding of catalyst and adsorbents
• Operating best practices
Consist of mitigation paths to assist with
troubleshooting
Process Optimization Advisor
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What does it do?:
• Maximize profitability against constraints
• Providing operational recommendations
What is behind it?:
• Rigorous simulation to match unit configuration
• Tuned UOP process models
• SQP Optimizer driving an economic objective
function
• Cloud hosted & Maintained by UOP
Provides Insight in Valuing Potential Feeds
What-IF: Feed Valuation Solution
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?
Leverages the UOP
Process Model to
determine the optimum
operation with the
alternative feed
Rigorous
Simulation
$
Provides economic
values & potential
product mix enabling
you to determine the
best feed
Economic
Evaluation
User manually modifies
feed characteristics to
be run in the tuned
engine
Feed Information
Modification
How does this work?
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• Reactor
• Effluent Yields
• Reactor Temperatures
• Cat Circulation
• Rate
• Reactor Effluent
• Yields
• Reactor Temperatures
• Cat Circulation
• Rate
Feed 2
• Feed Rate
• Feed Characterization
• Product Quality Target (RON)
Case 2
Feed 1
• Feed Rate
• Feed Characterization
• Product Quality Target (RON)
Case 1
As Is• Feed Rate
• Feed Characterization
• Product Quality Target (RON)
As Produced• Rx Effluent Yields
• Operating Conditions
• Cat Circulation Rate
• Energy Usage
• Production Margin
Inputs Outcomes
Right-time Insights to Drive Increased Learning
Improve Knowledge Retention
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Information Insights
Your Information grouped into related
sections
Information Linked to
UOP InsightsLearning improved by
associating insights to current
information
Embedded UOP insights based on licensor and troubleshooting
experience
Response Time Improvement
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Service
Interaction
OpAwareTM
CPS PRA
Event
Occurs
Collect &
Send DataUOP
Review
UOP Data
Analysis
Time
(typically days or weeks)
Issue
Identification
and Resolution
UOP
Review
UOP Data
Analysis
Issue
Identification
and Resolution
Proactive
Troubleshooting
Event
Detected
Early
Detection
Time
Saved
Time Saved
Incident
Avoidance
Cust. Analysis
Escalate
to UOP
Cust.
Analysi
s
Escalate
to UOP
Customer
Resolved
Customer
Resolved
On-Going Interaction with CPS Specialist
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Maintenance Recommendations
Modifications
• Have UOP become part of Your Team
- Early event detection and operational recommendations provided in CPS Dashboard
- Regular interactions to discuss CPS benefits
• Gain from Continuous Innovation
- Added fault model enhancements to the CPS Solutions
- Make minor process configuration updates
• UOP will keep the system running by conducting all needed maintenance of Software & Hardware including tuning of the process models
Project Delivery
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Meeting at site to capture customer-specific information
System is built based on information gathered during kickoff
Meeting at site to launch customer dashboard & service
Kickoff
Build
Deploy
In Operation
System is live providing on-going services
Anticipated 15
week delivery
Process Reliability Advisor Use Casefor CCR Platforming units
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Iss
ue
Recycle Gas Moisture:
• Customer experiencing lower than
expected C5+ & H2 yields
• Indicated Reduction Gas Heater
issues at site
2% Yield Loss
Delta C5+ YieldId
en
tifi
ca
tio
n
• Yield loss is difficult to confirm
• UOP data review revealed a 2%
yield loss
• Further review found low reduction
temperatures which caused high
recycle gas moisture and
inadequate reduction So
luti
on
RG Moisture
With CPS
• Embedded UOP fault model enable early
event detection of critical catalyst health
• Driving pro-active
recommendations
(i.e. chloride level
adjustment)
Process Reliability Advisor Use Casefor CCR Platforming units
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Ide
nti
fic
ati
on • Current performance lower than
expected yields
• Manual troubleshooting looking at
MCH / CH in reformate
• 5% Naphthene bypass hidden by
increased severity So
luti
on
With CPS
• Tuned process model enables detection
of and ability to quantify performance
debits
• Provided troubleshooting paths to
identify root causes
Iss
ue
CFE Leak:
• Customer not noticing specific issues
with operations
• On-going increases in WAIT to meet
product specifications
• Operational adjustments masking
underlying issues
Process Reliability Advisor Use Casefor CCR Platforming units
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Ide
nti
fic
ati
on
• Review of regenerator operations
identified frequent slipping of coke
into chlorination zone
• High O2 driving accelerated burn
melting catalyst pills and causing
potential screen damage So
luti
on
With CPS
• On-going monitoring of O2 and catalyst
circulation rate tied to current operations
• Adjustment recommendations to avoid
slipping coke
Iss
ue
Slipping Coke:
• Customer noted performance
degradation
• Catalyst sample showed fused catalyst
Process Reliability Advisor Use Casefor CCR Platforming units
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Ide
nti
fic
ati
on
• Site did not have the tools to identify
issue
• UOP manually compared yields
against UOP process model to
diagnose issue
• Identified insufficient chloride
injection So
luti
on
With CPS
• Continuous comparison of operations to
model output drive early identification of
issues (i.e. catalyst health)
• Embedded Fault Models pinpoint root
cause and drive resolution (i.e. poor
chloride injection)
Iss
ue
Chloride Injection:
• Customer noticed RON dropping despite
increase in WAIT
• Reduced feed rate to try and compensate