Advanced Chemical Engineering (ACE)
Plant Optimization & Decision Support Systems
KBR Technology Conference – Delhi 12 September 2013
©2013 KBR, Inc. All Rights Reserved
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Topics
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©2013 KBR, Inc. All Rights Reserved
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What We Will Talk About
Challenges
Who We Are
Value Proposition
Advanced Simulation
Operator Training Simulator
Performance Monitoring
Operations Management Systems
Fertilizer Automation Package
Conclusion
Q&A
What We Will Talk About
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Plant Optimization
Plant optimization is to find an alternative to adjust some specific set of
parameters under given constraints to minimize cost, maximize production
and/or efficiency/energy.
• Equipment Design
• Control Strategy
• Operating Procedures
• …
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Decision Support Systems
Decision Support Systems are information systems which supports business or
organizational decision making – management, operational, planning, etc
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Performance Monitoring Systems
Operations Management Systems
Maintenance Systems
…
©2013 KBR, Inc. All Rights Reserved
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Industry Challenges
General
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Project Complexity – Global Execution
Build Cost Effective Facility – Maximizing Return on Investment (ROI)
Manage Risk at Every Step
Sustain Operations
People
• Availability of Skilled Resources
• Training
Process
• Well Defined Business Processes
• Project Management Processes
• Selection of Process License Technology
Technology • Selection of Information Technology
©2013 KBR, Inc. All Rights Reserved
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Why ACE?
Benchmarking studies show that top performing companies also invest in
building world-class systems and tools to ensure sustainable performance.
Plant Optimization
AND
Decision Support Systems
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Technology Portfolio
Refining
Coal Monetization
• FCC
• TRIG™
• HDP
• Power applications
• ROSE
• Industrial
applications
• VCC
Olefins
Chemicals
• ACO
• Aniline
• SUPERFLEX
• Phenol
• SCORE
• SK-KBR JV
Proprietary
Equipment
• Refining
• Coal
Monetization
• Olefins
• Chemicals
Ammonia and Syngas
Advanced Chemical
Engineering
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Ammonia
Fertilizers
Syngas
Hydrogen
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Advanced Simulation
OTS
OMS
Technical Services
• Ammonia and
Syngas
ACE Services Portfolio
Advanced
Simulation
Operator
Training
Simulator
(OTS)
Operations
Management
Systems
(OMS)
Performance
Monitoring
(PM)
Technical
Services
Fertilizer
Automation
Package
(FAP)
ACE
TECHNOLOGY
OIL & GAS
DOWNSTREAM
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GAS
MONETIZATION
Advanced Chemical Engineering
Advanced
Simulation
• Verify Designs and Control Strategies
• In-Depth Process Knowledge for Operation
• Foundation for Life-Cycle Plant Models
OTS
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OMS
PM
FAP
Operator Training w/ Certification
Improve Plant Start-Up
Consistent Operational Response
Risk free and Safe Environment
• Information transformation between business and
engineering
• Data Repository for operations intelligence
• Intelligence in operations with analytical and
optimization engines
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Analyze Process and Equipment Performance
Business Decisions Based on Real-time Data
Calculation of KPI’s
Weekly & Monthly Reports
• One-Stop Shop for Ammonia Producers
• Embedded KBR Process “Know-How”
• Integrated solution offering
©2013 KBR, Inc. All Rights Reserved
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ACE
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Team of 50 professionals - Houston,
London, India (Delhi, Pune)
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Process technology expertise in
Refining, LNG, Oil & Gas, Ammonia,
Olefins, Phenol, Gasification…
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Experts in plant optimization and
plant safety & reliability
improvement
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KBR Know-How built into solutions
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Proven project management
capabilities
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Software and Information
Technology Independent
ACE and the Project Lifecycle
©2013 KBR, Inc. All Rights Reserved
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Value Proposition
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Optimize investment between CAPEX and OPEX
Make business and operations decisions based on real time data
Mitigate risk throughout the project life cycle – Licensor Support
Train operators with consistent operations guidelines
Agility to respond to business climate changes
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Achieve Top Tier Performance
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Optimize
Stabilize
©2013 KBR, Inc. All Rights Reserved
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Sustained
Growth
ADVANCED SIMULATION
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Advanced Simulation
Advanced Simulation
ASV
HGBP
Dynamic Simulation
TI
IBV
In the last 10 years
HV-861
PI
PI
FI
TI
100+ Dynamic Studies
Discrete Simulation
50+ Liquid Transient
Studies
Liquid Transient Analysis
7 km
Mix er
36"
parallel
loading
lines
1 km
60"
On-s hore ESD
shore
Computational Fluid Dynamics
©2013 KBR, Inc. All Rights Reserved
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Platform
R Vs
7 km
On-s hore
R Vs
36"
Surge v es s el
Off-s hore ESD
platf orm
30+ Logistics Studies
Over 150+ CFD Studies
Advanced Simulation
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A critical link between design and safe operation
Benefits:
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Understanding of complex problems and accurate diagnostics
Critical equipment sizing & design confidence
Process control & system validation
Execution consistency
Operations assistance
Field trouble shooting
Address key risks
Operational optimization
Process knowledge for operator training
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Plantwide Dynamic Modeling
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Better understanding of process and controls
• Study dynamic response of the overall system to various plant upsets
• Establish operational guidelines to minimize pressure excursions during
upset conditions
• Minimize steam venting
• Reduce potential for process trips
• Minimize unit-to-unit interactions
• Validate control philosophy and valve sizes
• Establish minimum ramp up rates for boilers
• Establish requirements for swing boilers
• Validate procedures for startup
• Establish minimum firing rates for standby boilers
• Establish reasonable tuning parameters for controllers
Typical Conceptual Scope of KBR Ammonia OTS
Fuel Gas
Gas
Compression
Primary
Reformer
Secondary
Reformer
1st Stg
Water
Removal
Shift
Conversion
CO2
Removal
2nd Stg
Water
Removal
Air
Compression
Steam System
Methanation
Dehydration
Ammonia
Refrigeration
H2 Recovery
Ammonia
Recovery
Purifier
Syngas
Compression
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Ammonia
Converter
Ammonia
Cooling
Ammonia
Chiller
Ammonia
Knockout
Ammonia
Storage
Advanced Simulation Offerings
Dynamic Simulation
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Steam system dynamics
Plant wide flare and relief systems analysis & design
Emergency depressuring
Control strategy studies
ASV
HGBP
TI
IBV
HV-861
PI
PI
FI
TI
Logistics Studies
• Plant throughput, availability and supply chain studies
• Optimize sizing of storage and transportation resources
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Computational Fluid Dynamics
• In-depth analysis of fluid flow, thermal and heat transfer issues
7 km
Mix er
36"
parallel
loading
lines
1 km
60"
On-s hore
RVs
On-s hore ESD
shore
©2013 KBR, Inc. All Rights Reserved
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Platform
RVs
7 km
36"
Surge v es sel
Off-s hore ESD
platform
OPERATOR TRAINING SIMULATORS
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Training Methodologies
Classroom Training
Simulator Training
Builds Knowledge
Accelerates development of unit
specific Skills and Knowledge
Provides consistency to strengthen
Behaviors
Lacks “hands-on” element to develop
and reinforce Skills
Behaviors
Knowledge
On-The-Job Training
Enhancement of Skills through wide
range of scenarios
Knowledge reinforced through
practical exercises
Focus on reasoning and judgment
promote desired Behaviors
Skills
Strengthens Behaviors such as
teamwork and confidence
Development of Skills and Knowledge
through mentoring
Risk free and safe environment
Subject to variability of student /
mentor Behaviors
Assess and certify competence
Skills limited to actual plant events so
duration extended
©2013 KBR, Inc. All Rights Reserved
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Operator Training Simulator (OTS)
Plant
Plant Dynamic Model
Instructor
Plant DCS consoles
Training DCS Consoles
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OTS Training Program
Unit
Familiarization
Scenarios
Startup &
Shutdown
• Panel Familiarization
• Major control loops
• Major shutdown logics
• Production changes
• Feed changes
• Utility changes
• Reactors
• Separation systems
• Integrated plant
Emergency
Situations
• Compressor trip
• Equipment malfunction
• Power loss
Dynamic model inclusive of all basic controls, all field
operations, all panel operations and relevant safety logic.
Comprehensive training of plant operators
Validation and optimization of plant operating procedures
Control system refinement Strengthen
IMPROVED PLANT SAFETY AND RELIABILITY
©2013 KBR, Inc. All Rights Reserved
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Top Reasons to Have OTS
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Efficient & faster start-up – Well Trained Operators
Onboard new hires more quickly & efficiently with
certification
Mimic look and feel of the real plant DCS and Control System
Validate control strategy
Perform engineering studies / analysis
Built-in KBR knowledge & experience
©2013 KBR, Inc. All Rights Reserved
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PERFORMANCE MONITORING
©2013 KBR, Inc. All Rights Reserved
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Performance Monitoring
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A continuous and comprehensive
equipment and process oversight
solution incorporating KBR expertise
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Provides operational intelligence to
ensure ideal performance and
confidence in meeting production
targets
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Real-time data availability to make
business decisions
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Web based, secure and user friendly
©2013 KBR, Inc. All Rights Reserved
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Performance Monitoring System
Performance Dashboard
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KPIs
Alerts
Access To Performance
Reports
KBR Technical Library
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KBR Technical Bulletins
Simulation
Results
©2013 KBR, Inc. All Rights Reserved
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Interact With KBR
Process Specialists
Technical Manuals
Technical Papers
Procedures
Performance
Monitoring
System
Collaborate With
Other Operators
Plant Data
Plant Data
Your Specialist Has Your
Data At His Finger
Tips
Performance Monitoring
System Architecture & Security
Key FEATURES
Performance Monitoring
Customer Plant
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Process Data Sent to Central
Data Center via secure link
daily
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Daily calculations performed
and results published on Web
server
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Monthly review of summarized
data utilizing Plant simulation
software and proprietary
analysis tools performed by
KBR experts. Results published
on Web server
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Report produced summarizing
results and recommendations
published on Web server
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Customer views calculation
results and reports using Web
browser
Hosting Service
Web
Technician
Process
Engineer
Firewall
Firewall
Web Access
DCS
Secure VPN
Tunnel
DCS Data
Collector
PI Server
DCS
Operator
PROII
Simulation
Workstation
KBR
PI Server
Firewall
Ammonia
Expert
Simulation Server
(Future)
©2013 KBR, Inc. All Rights Reserved
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Performance monitoring
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KBR Expert
• Review process and
equipment performance
• Customized reports on plant
performance and equipment
performance
• Advice and recommendations
on process improvements
• Site visits
©2013 KBR, Inc. All Rights Reserved
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PM System
• Comprehensive calculations
around critical equipment
• Secure trending and
visualization of key
performance indicators
• Summary dashboard
• Production, Energy
Utilization, EHS, etc reports
OPERATIONS MANAGEMENT SYSTEMS
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Business Processes
Invoices
Analysis
Performance
Customers
Business Enterprise
Shipment
Information
Turnaround
Schedule Quality
Production
Equipment Orders
Process Data
Operating Data
Knowledge
SOPs
Environmental
Reports
Maintenance
Lab
Lab
Results
Compressor
Data
Training
Operator
REFINERY
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Inventory
Position
Emissions
Data
EH&S
Tank Farm
Transportation
Operations Management Systems (OMS)
Production Operations
Asset Reliability &
Integrity
Planning & Scheduling
Inventory Operations
Quality
Operations
Regulatory Compliance
Process Control Systems (DCS)
©2013 KBR, Inc. All Rights Reserved
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Enterprise Visibility
Integration & Work Flow
Business Systems (ERP)
Operations Management System (OMS)
Information Technology / Telecommunications
Level 4
Level 3
Manufacturing
Operations Management
Business Planning
& Logistics
Level 3
Manufacturing
Operations Management
4 – Establishing the basic plant schedule –
production, material use,
delivery, and shipping.
Determining inventory le
Time Frame – Months, Weeks, days
3 – Work flow / recipe control to produce the desire
end products. Maintaining
records and optimizing the
production process.
Time Frame – Days, shifts, hours,minutes,econds
Level 2
Discrete
Control
Continuous
Control
Level 1
3 – Work flow / recipe control to produce the
Level 0
desire end products. Maintaining
records and optimizing the
production process.
Batch
Control
2 – Monitoring, supervisory control and automated
control of the production
process
Time Frame – Hours, minutes, econds,ubseconds
1 – Sensing the production process, manipulating
the production process
0 – The actual production process
Time Frame – Days, shifts, hours, minutes,
seconds
Technology Advances
Fast connection of data sources, complex
manipulation and intelligent presentation of
information
©2013 KBR, Inc. All Rights Reserved
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Standard Functional Hierarchy
ISA 95
Level 3 – Manufacturing Operations Management
What is Operations Management System?
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Business Objectives
• Information transformation between business objectives and engineering
control targets
• Repository for granular process data to support regulatory compliance and
foundation for operations intelligence
• Intelligence in operations with analytical and optimization engines
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Technically
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Set of industry standard software applications
Configured together to provide intelligence to refinery/plant operations
With connections of applications from DCS to ERP
In the ISA 95 MOM Level 3 domain area
Characteristics
• Finite number of Commercial Off-the-shelf products available
• Each implementation is unique to specific business strategies
©2013 KBR, Inc. All Rights Reserved
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Rollout Synchronization Of OMS Components
Deploy Capability
Production
Operations
Functional
Area
OMS
JIT Deployment
DeploymentofofSub
Sub
Functional Areas
R
e
v
i
e
w
Initiation &
Planning
B
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i
l
d
S
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p
p
o
r
t
Deploy
Timeline
R
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q
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H
a
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d
o
v
e
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Emissions Monitoring
T
e
s
t
Operations Support
T
e
s
t
Lab System
Hydrocarbon Accounting
Real Time Historian
Systems Project
P
l
a
n
Requirement
s Definition
System Track
System Project Management
D
e
s
i
g
n
KPI Improvement
Asset Reliability
First Product
Pre-commissioning
Commissioning
Design
Construction
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Commissioning
Start-up
Mechanical Completion
Ready For Startup
Operate & Maintain
EPC Project
Timeline
OMS Implementation Methodology
Scoping Study /
Conceptual Design
Functional Design
Procurement /
Detail Design
Development /
Configure
Deploy / Test
Support
Program / Project Management
Strategic Problem
Study
Detailed
Requirements
Operational Work
Processes
Development
Infrastructure
Operational
Infrastructure
Infrastructure
Support
Business
Opportunity
Functional
Architecture
Functional Design
Proof Of Concept
Installation
Software Support
Project Charter
Interaction Plan
Vendor Selection
Configuration
Integration
Application
Support
Project Roadmap
Project Roadmap
Detailed Design
Integration
Development
Commissioning &
Go Live
Preliminary
Estimate
Logical
Infrastructure
Roll Out Plan
Testing
Testing
Scope Definition
Budgetary Estimate
Support Plan
Data Migration
Data Migration
Plan
Owner Resource
Plan
Data Quality
Validation
Data Population
Handover
Training
Management Of Change
Risk Management
©2013 KBR, Inc. All Rights Reserved
32
KBR OMS Projects
Sadara Petrochemical
Complex
Jazan Refinery
Complete Refinery
Jazan IGCC
Kitimat LNG
YASREF
Ammonia Plants (4)
©2013 KBR, Inc. All Rights Reserved
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• Manufacturing Operations Management (MOM) Specification & Design
• Engineering Systems Specification
• Program Management
• Integrated Refinery Information System (IRIS) Specification & Design
• Four phase design and implementation
• Handle commercial aspects
• IRIS Specification & Design
• Grassroots Liquefied Natural Gas (LNG) Export Facility
• Operator Management System (OMS) Specification and Implementation
Strategy
• Program Management and Implementation Support
• Grassroots Ammonia Plants
• Performance Monitoring System Implementation
FERTILIZER AUTOMATION PACKAGE
©2013 KBR, Inc. All Rights Reserved
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Fertilizer Automation Package
Layered
Applications
Automation
Systems
©2013 KBR, Inc. All Rights Reserved
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Fertilizer Business Offering
Fertilizer Automation Package
DCS and Safety
Systems
• DCS, SIS, F&G
• Yokogawa Alliance
©2013 KBR, Inc. All Rights Reserved
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Integrated
Analyzers
• Integrated Analyzers
for Ammonia
Process
Critical
Valves
• Critical / Severe
Service Valves for
Ammonia Process
KBR
Playbook
• KBR ‘Know-How’
For Ammonia
Captured in a
Playbook
• Graphics
• Control Strategies
• Reports and
Calculations
Layered
Applications
• KBR Developed
Applications
• OTS
• Performance
Monitoring
• APC
Summary/Conclusion
Working as a team with expertise, knowledge, and experience ACE can help:

Minimize CAPEX and OPEX
Accelerate business and operations decisions based on real time data
Mitigate risk throughout the project life cycle – Licensor Support
Train operators with consistent operations guidelines
Provide agile response to business climate changes

Achieve Top Tier Performance




Optimize
Stabilize
©2013 KBR, Inc. All Rights Reserved
38
Sustained
Growth
Q&A
©2013 KBR, Inc. All Rights Reserved
39