Slide 1 SSE-01 Refinery Wide Performance & Profitability Joseph McMullen SimSci-Esscor Product Marketing Manager © 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Sl Dominance in Refining Standardized on SimSci-Esscor in Refining Slide 3 Primarily Uses SimSci-Esscor In Refining Dominance in Refining Other Users of SimSci-Esscor In Refining Slide 4 SimSci-Esscor is Refining. Products – Innovation – Experience - Acceptance Slide 5 Solutions Across the Refining Spectrum Heavy Oils – Workforce Enablement – Enhanced Performance and Profitability Slide 6 Heavy Oils Slide 7 Heavy Oils Proprietary Property Prediction Technology Aids in Simulation Superior Heavy Oils modeling provide more accurate models of heavier feedstock so that refiners can adapt their processes accordingly Thermodynamic methods are applicable in various stages of design, operations, and optimization Slide 8 Solution Crude Feed preparation • Characterization • Viscosity • Thermal conductivity In Progress March 2010 Upgrading •Mercury Solubility • Hydrogen balance November 2009 •Liquid Thermal Conductivity – Hydrogen solubility Contaminants •Liquid Viscosity • Mercury November 2007 •Characterization Option Slide 9 July 2008 •Hydrogen Solubility Workforce Enablement Software & Solutions to Train and Enable the Workforce Operator Training Simulators, mobile workforce guidance, Wonderware Intelligence dashboards speeds up operator effectiveness and aids in knowledge transition Slide 10 Workforce Enablement Slide 11 Workforce Enablement Products & Solutions 1. Operator Training Simulations (OTS) 2. EYESIM 3. ArchestrA Workflow 4. Mobile Workforce Guidance 5. Wonderware Intelligence Slide 12 Dynamic Simulation Suite – Products, Services and Training Simulators Upstream Gas Processing Refining Petrochemicals Chemicals Total HPI Projects 17 20 85 29 14 165 Hydrocarbon Processing 165 Projects (with majority in refining) Power 154 Projects Over 300 OTS projects delivered to clients All models suitable for engineering studies and operator training Slide 13 Operator Training Simulator Plant Control system DCS + ESD Dynamic Process Model ACCIDENT PERCENTAGES Software Emulation 38 Mechanical Failure 26 Operational Error Operator consoles HMI 12 Unknown C aus es 10 Proces s Ups ets 7 Natural Hazard Des ign Error Ars on/Sabotage Slide 14 4 3 Same or similar Immersive Virtual Reality Plant - EYESIM IMMERSIVE VIRTUAL REALITY PLANT is a comprehensive solution linking Control Room Operators… ...to Field Operators ...to Maintenance Operators ...by means of high fidelity Process Simulation and a Virtual Walkthrough Plant Environment for complete PLANT CREW TRAINING Slide 15 Benefits: Optimize the training period of all Operators in all activities Slide 16 • Provision of more realistic environments for trainees and the opportunity for practice in training sessions • • React quickly and correctly in medium- and high-stress situations • Optimized transfer of skills from the training environment to the work environment • Reliable and valid evaluation of operational procedures and performance • Team training: control room, field, shift and operational managers (Communications) Improving skills for rarely-performed, but safety-critical tasks (e.g. emergency shutdown) Value Proposition • Saving time and costs for “on-job-training” (30- 40%) • Reducing time of startup (for planned/ unplanned shutdown) from warm/cold conditions (15-20%) • Saving on maintenance budget (1-3 %) E.G.: greenfield refinery 200 K bpd 3 - 4 M $/y Slide 17 Invensys proprietary & ArchestrA Workflow – Business Process Management Event automatically captured and context prepared Maintenance event occurs at shop-floor Workflow Initiated Supervisor notified ( SMS, Email ) N Decision to HOLD production Production continues Slide 18 Y Communication with context sent to Maintenance Maintenance notified ( SMS, Email ) Communication shared with Supervisor Maintenance performs inspection and submits report B P M Concurrent communication with Production Scheduler & EAM Application Maintenance Tech. receives maintenance order on mobile device Communication with Maintenance Tech. Maintenance Tech. completes order Concurrent communication with Production Operator & EAM Application Maintenance order created in EAM app. Scheduler updates production schedule Maintenance order closed in EAM app. Production Operator notified to start production How It’s Done with IntelaTrac • Field worker logs into Mobile IntelaTrac on handheld computer • Asset is properly identified using RFID or barcode label • Tasks are date/time stamped as completed • Actual field conditions can trigger “focused advice messaging” which directs the field worker to: • Input more information such as notes • Perform a special procedure to mitigate the condition • Take additional measurements Results: •Pump Repair $10K •Exchanger Repair $0K •Lost Production $0K Savings = $210k Slide 19 Wonderware Intelligence User-friendly Configuration & Administration Production/Process Information Platform Wonderware & Non-Wonderware Data sources Slide 20 Share content & Collaborate Incremental approach Self-service access to information & content authoring Performance and Profitability Optimize Operations of Enhanced Profitability Refinery-wide Optimization solutions aid in performance enhancements to various processes that yield enhanced profitability Slide 21 Performance & Profitability Slide 22 Performance & Profitability Products & Solutions 1. Dynamic Simulation Suite (DSS) 2. ACA.HF 3. Off-sites Solutions 4. ROMeo 5. Integrated Off-sites to ROMeo 6. Invensys Yield Accounting Solution 7. Wonderware Intelligence 8. Connoisseur 9. Condition Manager 10.ArchestrA Workflow Slide 23 Dynamic Simulation: DESIGN to TRAINING Highlights of Where we are Today PROCESS DESIGN Distillation Column Relief Load Calculation Reduction - Over twenty users Compressor Triconex TMC Checkout Slide 24 DCS CONFIGURATION DCS Checkout against dynamic models reduce commissioning time in the field. STARTUP and TRAINING Training Simulators to replace a retiring work force PLANT OPERATION Over 200 DYNSIM/ FSIM Plus / TRISIM Plus simulators provide more than just training: - PC Power Plants - Refinery Units - LNG - IGCC - Ethylene Integrated control room / outside operator training using 3D Virtual Reality Logic Validator Automated test harness integrated with simulation geared toward Safety Instrumented System (SIS) verification and validation • Tests and documents SIS logic in an emulated environment • Easy to configure and use Excel-based interface to build logic validation scripts • Connects to SIS/PLC/DCS emulators either directly or via OPC UA, DA and Modbus protocols • Soft emulators include Triconex, Allen-Bradley, Modicon, GE Siemens, CCC, Woodward, Foxboro, ABB, Emerson, Yokogawa, Honeywell, etc. • Connect to real hardware, if necessary Slide 25 ACA.HF The ACA.HF Measurement Solution ● SAFE & SIMPLE online analysis of %HF, %Water and %ASO in HF alkylation catalyst ● Affordable alternative to FTNIR² with reliable accuracy ● Exceeds the precision of HF analysis with FTNIR ● A multivariable analyzer¹ based on the application of proven Foxboro measurement technologies that are long-established in HF service The ACA.HF is the new standard in safety, simplicity, reliability, and accuracy for HF catalyst analysis ¹ Slide Patent Pending; international rights apply 26 ² ABB FTPA2000-HP20 FTNIR-based HF Acid Analyzer Off-sites Off-sites refers to the tank farm that contains the crude feedstock oil that feeds the refinery and the tank farm that contains the products of a refinery (gasoline, diesel, etc) Slide 27 ROMeo ROMeo Process Optimization software would optimize the actual refining process, everything in blue. Slide 28 Integrated Off-sites Slide 29 Yield Accounting Yield Accounting works to develop a material balance, or a record of everything that comes into the red dotted line (refinery) versus everything that leaves the red dotted line. In a typical process, in = out You can’t produce more than you put into the process, and everything you put in has to come out eventually A typical 250,000 bbl/day refinery could save $8.5 Million USD/yr by cutting their unaccounted material loss by 0.5% Slide 30 ROMeo + Wonderware Intelligence InFusion Enterprise Control System User-friendly Configuration & Administration Portal/Case Manager WW Historian SharePoint ROMeo Automatically Trend and Store Advanced Application Data Real-Time System Scheduler Plant Technical Details Slide 31 Real-time Plant Information and Measurements Intelligence Server Analytics Dashboard Real-Time Analysis Information Display Real-time Actionable Plant Details and Key Performance Indicators (KPI’s) Wonderware Intelligence Dashboard Slide 32 Advanced Process Control Connoisseur improves process profitability by enhancing quality, increasing throughput, and reducing energy usage – all by accurately controlling your process within a tighter tolerance Slide 33 Avantis Condition Manager • Condition monitoring and management capabilities turn huge volumes of production data into actionable asset intelligence in real-time, enabling informed decision-making at every level of the production enterprise. • Key benefits include: • Increased operational safety • Optimized costs of maintenance • Improved sustainability of operations • Lower energy consumption • Reduced variance in the response of the maintenance personnel Slide 34 Refinery Wide Performance & Profitability Resources WEBINARS PROMOTIONAL WEBSITE Slide 35 $$$ ENHANCED PERFORMANCE & PROFITABILITY AHEAD PRODUCT VIDEOS WHITE PAPERS Thank you! © 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.