1 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS Maximize Business Performance with Measurable Results Invensys is now Advanced Automation and Information Solutions for Petroleum Refiners and Petrochemical Producers
2 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS DRAMATICALLY IMPROVE BUSINESS PERFORMANCE The Challenge Today s dynamic hydrocarbon landscape is rife with challenges and opportunities. These include supply-demand imbalances, dislocations in the global economy, pressures to reduce greenhouse gas emissions, and significant shifts in the demographics of the workforce. Petroleum refiners and petrochemical producers face the enormous task of quickly and correctly responding to rapidly changing market conditions, driving ever greater value from existing (and future) assets all while reducing operating costs at every turn. Overcome these hurdles, and you are ahead of the competition. How can you successfully meet this overwhelming challenge? The Answer Hydrocarbon Processing Industry (HPI) Solutions from Invensys Operations Management. Our solutions are deployed by the industry s most experienced and knowledgeable engineers, consultants and service teams who understand your particular blend of challenges and how to transform them into opportunities. These solutions are the most comprehensive and combine the industry s deepest portfolio of hardware, software, services, performance measures and the InFusion Enterprise Control System. InFusion Enterprise Control System The world s first and only Enterprise Control System. The InFusion Enterprise Control System is the first solution that easily integrates all of today s process automation systems regardless of supplier into one unified business environment resulting in faster, clearer visibility into operations and enhanced decision making. A Revolution in Performance Dramatically improve the business performance of your people, equipment, energy and inventories in one unified business environment. Invensys delivers integrated and innovative solutions to help capture every opportunity and resolve all challenges, at every level of your operation from a single piece of equipment, to groups of assets, up through multiple plant sites and business units. Asset Performance Management As the world leader in Asset Performance Management, Invensys approach is simple and powerful: maximize the business value of all your assets by balancing the trade-offs between asset availability and utilization. The result: your business performance increases and costs are reduced. Key Components of Invensys Hydrocarbon Processing Solutions Business Performance Consulting Equipment Condition Monitoring Operations Performance Consulting Abnormal Situation Management InFusion Enterprise Control System Enterprise Asset Management ArchestrA Workflow Management Automated Rigorous Performance Monitoring Wonderware Intelligence Multivariable Control Loop and Alarm Management ROMeo Online Optimization
3 KNOW MORE, ACT FASTER What if you could empower plant personnel at all levels to make faster, better business decisions, at the right time and in the right context? Anticipate market fluctuations and supply chain demands? Exploit opportunities before they vanish? Predict problems before they cause significant negative consequences? Now you can. By incorporating the power of Wonderware Intelligence, ArchestrA Workflow Management and Dynamic Performance Measures, Invensys HPI solutions allow you to observe plant and business information, and respond to problems or capitalize on opportunities in ways never before possible. Integration of information and automation solutions into one unified business environment enables our HPI solutions to dramatically enhance visibility into business intelligence throughout the enterprise. This opens up a new world of understanding and insight so you can take the appropriate actions. TRANSFORM PLANT PERSONNEL INTO INFORMED BUSINESS DECISION MAKERS Now, for the first time, Invensys HPI solutions allow plant personnel at all levels to see the right business intelligence in the right business context. This results in far more effective, accurate and agile decision making that allows people to predict and prevent problems instead of causing them. An Invensys HPI solution empowers plant personal to make better business decisions and accomplish these goals: Improve reliability, safety and environmental compliance Reduce manufacturing costs Achieve higher product yields and overall plant output See, track and measure performance more easily, clearly and accurately Respond with greater agility to opportunities Identify and resolve problems before they impact performance Capture and keep knowledge that enables best practices
4 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS CHALLENGES GROWING BY THE BARREL FULL Change is a fact, particularly in the Hydrocarbon Processing business. Over the past decade, HPI has seen its business landscape undergo dramatic shifts and upheavals. These changes continue at an ever-accelerating rate, bringing with them a host of new challenges for petroleum refiners and petrochemical producers. Meeting Environmental and Regulatory Requirements Changes in climate, crude slate and environmental attitudes all have a profound effect on business. Additionally, there s the challenge of cost-effectively producing low sulfur fuels, incorporating renewable fuels and satisfying environmental standards and public demands including compliance with multiple governmental regulations on exploration and production. Protecting and Maximizing Your Assets Globally the workforce is getting older. How do you fill the void left by retiring experienced personnel and the intellectual property that goes with them? How do you ensure the reliability and maximize the performance of aging equipment while protecting your people and assets from catastrophic plant failures? Balancing Business Challenges You re not just running a plant. You re running a business ideally, a profitable one. This means you re dealing with business issues on a daily basis, including variability in the price of crude and natural gas, heightened competition from producers with access to lower cost feedstocks, and the impact of changing demand patterns for hydrocarbon-based fuels and consumer goods. In the past your primary concern was reducing process variability since both the cost and availability of energy and feedstocks were relatively constant. Today this is no longer the case both business and process variables are constantly changing, making it very difficult to maintain control not just of your processes but of your entire enterprise. How do you precisely determine which areas are profitable and where you re leaking money? Pressure Points for Refiners and Petrochemical Producers: Effectively competing with producers who have access to low cost feedstocks Avoiding catastrophic equipment and/or plant failures Managing the impact of supply-demand imbalances on operating strategies Graying of the work force and shortage of qualified replacement manpower Ensuring the reliability and optimizing the performance of aging equipment Dealing with government regulations on exploration and production Balancing energy security, energy availability and cost affordability Measuring, tracking and providing visibility to plant performance metrics in real time
5 INDUSTRY DRIVERS AND TRENDS Innovative Solutions for an Industry in Flux In the face of ongoing change one constant remains: in your business, you re compelled to improve the economic performance of your enterprise to keep your shareholders happy. The question is how. Current competitive and market pressures are forcing petroleum refiners and petrochemical producers to completely rethink the way they run their enterprises. These key industry drivers have led to a number of trends that necessitate a new breed of business solutions. HPI Drivers Foresight vs. Hindsight You need to improve your ability to predict future behavior of plant performance to enable your business to quickly and correctly respond to short-term market opportunities, rather than relying on past knowledge, to deliver the right quantity and quality of product. Collaboration You must find ways to exploit the intellectual talents of your people, through enhanced collaboration across organizational boundaries, yielding better business decision making. License to Operate You re no longer just meeting government regulations: you must also meet the approval of a public demanding greater safety and environmental accountability, as well as lower fuel prices. Squeezing every Drop of Value You need to track the economic impact of the changes made to every molecule of feed to maximize the payback of manufacturing costs. HPI Trends ROI, ASAP Uncertainties in the global HPI market like variability in the cost of crude oil and natural gas are increasing pressure to generate a return on capital investments now, if not sooner. Labor Shortage Thanks to the perception of poor safety and less than ideal environmental care, the pipeline of HPI workers continues to shrink, widening the gap between labor supply and demand. Plants under Pressure Plants are being operated with fewer turnarounds to reduce capital costs and maintenance expenses, to maximize revenue and to minimize disruptions to the supply chain; however this philosophy can put plant reliability at risk. Managing Assets Plants must balance the availability and utilization of assets, while also contending with volatility in feedstock supply so they can keep up with product demand in the most efficient and cost-effective manner. Measuring Up To compete and instill investor confidence, plants must be able to measure and track performance in real time. Operator as Proprietor Operators must now also be stewards of their processes and have responsibility for contributing to the business performance of all assets.
6 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS HPI SOLUTIONS Integrated. Innovative. Intelligent. With Invensys, you re empowered to experience profound changes in the way business intelligence is shared. Transform how, where and when your people work together to resolve challenges and capture opportunities. Give them the ability to see business intelligence in an understandable and meaningful business context. Make smarter, faster business decisions that improve performance and efficiency. Managed asset performance Invensys HPI solutions help reconcile the competing goals between asset availability and utilization by optimizing both. By balancing the trade-offs between plant utilization and equipment availability, our solutions significantly improve economic performance by getting the most from your people, equipment, energy and inventories. REFINERY-WIDE PERFORMANCE OPTIMIZATION Enabling Action with Insight into Improvements
7 WHAT IT DOES: Allows petroleum refining companies to maximize the value add from their refinery operations given the currently available crude slate. This solution brings together management, crude traders, production planners, process engineers, control engineers and operations into a coherent team, enabling best practices and realizing refinery wide performance optimization. It also provides near real time visibility across the enterprise of plan versus actual performance e.g., product yields, unit operating costs, product giveaway, energy intensity of a refinery or fleet of refineries so that any significant deviations can be detected and corrected in a timely manner, thereby helping to ensure the greatest value add. Of significant note is the recently announced agreement between ExxonMobil and Invensys whereby Invensys can now offer its clients ExxonMobil s industry leading refinery reactor kinetic models for use in on-line process performance monitoring and process optimization as well as off-line modeling and simulation for process analysis, troubleshooting, etc. WHAT IT DELIVERS: For a medium complexity refinery with a crude processing capacity of ~100,000 BPD, a fullydeployed Refinery-Wide Performance Optimization Solution would conservatively deliver an estimated annual value of between $7-10 million. For a high complexity refinery with a crude processing capacity of ~100,000, a fullydeployed Refinery-Wide Performance Optimization Solution would conservatively deliver an estimated annual value of between $10-20 million. Additional benefits will become available in future years as the scope of the integrated solution broadens to include refinery off-sites management, asset management and other components. Stepwise deployment can be tailored to ensure positive cash flow as soon as possible after project kick-off (often within 6 months or less). Industry leaders (e.g., ExxonMobil) have already embraced this solution concept. ENERGY MANAGEMENT Culture and Technology Working Together to Conserve Energy WHAT IT DOES: The Invensys approach to Energy Management consists of multiple components so that the implemented solution is compatible with the client s business and operational strategies. A successful energy management solution must enable operations personnel to minimize the energy-related component of operating costs by effectively controlling energy production, distribution and usage in light of volatility in energy costs. The Invensys real-time energy optimization strategy considers production value, energy cost, and material cost within the constraints of environmental stewardship and safety.
8 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS WHAT IT DELIVERS: By integrating process measurement and control systems with turbomachinery and steam optimization applications in the context of an energy-focused, employee-empowered culture, plant personnel can now quantify and control a plant s energy supply-demand balance in real-time, then develop and implement strategies to optimize the balance for maximum profitability. Plants implementing this solution have seen energy cost reductions of up to 15% of their energy bill without sacrificing throughput, product yield or quality. OPERATIONS MANAGEMENT SYSTEM (OMS) Orchestrating Complex Systems to Work as One WHAT IT DOES: Provides a common data model to underpin the integration and unification of the applications used for automation of mission critical business processes and workflow management, and thereby enables streamlined, consistent execution of best practices for optimal business performance. It also provides the ability to measure and track business performance in near real time using client-validated metrics, and gives complete visibility of consistent contextualized and actionable information to those people with a need to know.
9 WHAT IT DELIVERS: The value of an Operations Management System results in large part from the availability of consistent, contextualized and actionable information across the entire enterprise. Typically, the return on investment (ROI) from integrated OMS is 6 to 12 months, but often the real savings are realized for years after the go-live date through the ease of implementing changes and adding additional systems. The following table contains benchmarks (from SAP Value Engineering) of the benefits that have been achieved by companies that implemented Operations Management Systems. Tangible Benefits % Impact Revenue Increase in customer satisfaction 3-10% Reduction in manufacturing cycle times 10-40% Incremental revenue opportunities 5-20 Operating Costs Reduction in expedition costs 3-20% Reduction in defects, re-work and short runs 5-25% Reduction in information delivery cost to employees 5-10 Reduction in production cost variances 3-15% Working Capital Reduction in material inventory levels 3-20% Reduction in finished goods inventory 10-20% TURBOMACHINERY CONTROL Managing the Performance and Protecting the Safety of Critical Rotating Equipment
10 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS WHAT IT DOES: Provides engineering and control system solutions for critical and general purpose turbomachinery including: Steam turbines single valve, multi valves, extraction, admission, double extraction, reheat Gas turbines industrial frame type and aeroderivative Compressors Generators It also provides integrated turbine/load control solutions such as anti-surge protection for turbine-compressor sets. WHAT IT DELIVERS: Clients that have utilized Invensys engineering design services and/or implemented Invensys control systems for turbomachinery equipment have realized some or all of the following benefits: Lower capital expenditure Lower operating costs Shorter commissioning times Increased safety Increased reliability Increased availability Collectively these benefits can translate into millions of dollars of savings and/or increased revenue. OPERATOR TRAINING Improving Operator Effectiveness WHAT IT DOES: Provides a comprehensive, sustainable methodology and tool set for training new operators, enhancing the skills of experienced operators and building effective teams of control room operators, field operators and maintenance personnel. It combines dynamic simulators with virtual reality capabilities to support basic, intermediate and advanced training schema, and is designed to move operators up the learning curve faster and with greater retention of knowledge and skills than traditional classroom training programs.
11 WHAT IT DELIVERS: The Invensys solution for Operator Training delivers efficient knowledge development and transfer designed to quickly and consistently improve operators skills and performance. Board and field operators can be trained simultaneously to greatly enhance the teamwork of operating crews. Documentation of training and operator activities is automatically generated. As an added benefit dynamic simulators can be used for checkout and validation of new and/or upgraded control strategies. LIFECYCLE SAFETY MANAGEMENT Ensuring Process Reliability and Sustained, Safe Operation WHAT IT DOES: Sustainable safety assurance requires a holistic and integrated approach to process safety management. It takes safety beyond the traditional safety instrumented function and extends into everyday operations, maintenance and management. Sustainable safety assurance comprises an industry-leading safety culture along with the implementation of best practices to proactively plan and manage operational risk, effectively reduce production outage, equipment damage, environmental issues and danger to personnel. While a safety culture is created and maintained by client leadership, Invensys Operations Management provides a comprehensive set of process and functional safety management capabilities to establish sustainable safety assurance. These capabilities include leading and lagging safety indicators that can be visualized in real time to identify how safely your plant is operating in order to reduce plant downtime and unsafe or high-risk startup conditions.
12 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS WHAT IT DELIVERS: Invensys Operations Management s Process Safety Management solution helps operators quickly discover and correctly respond to potential critical situations well in advance of process alarms, and has technologies that track plant staff and locate them on site and in real time should an unsafe condition occur. The Invensys approach fosters an environment where everyone is proactively engaged in the safety of the asset, while highlighting the relevant time and safety information to facilitate the lowest-risk decision. This solution enables the integration of process measurement and control systems, with safety shutdown systems, equipment condition monitoring and rigorous process models both steady-state and dynamic. As a result, plants can detect and correct situations before they become critical and before triggering a nuisance trip. A world-scale olefins plant reported a reduction of nuisance trips from 96 to 1 over a four-year period, with cost savings in excess of $50 million/year! FLARE RELIEF SYSTEM ANALYSIS Improving the Design and Performance of Plant Relief Systems WHAT IT DOES: This solution uses Invensys process modeling and simulation tools to evaluate flare system back pressures for plant-wide relief scenarios, identify columns that lead to high back pressures and use dynamic simulation to improve the accuracy of calculation with the goal of reducing the magnitude of the relief. For the case of plant retrofits this solution is able to re-evaluate flare system back pressures with new estimated maximum flows such that any required expansion of the existing flare system is made as cost effectively as possible. WHAT IT DELIVERS: Accurate calculation of column relief loads can reduce the cost of plant retrofits since the original flare system was probably over designed. Production increases have been achieved for those cases when production was previously constrained by over-conservative relief calculations. The Invensys solution for Flare Relief System Analysis has been used to validate safe designs during Hazop studies by simulating what actually happens during relief scenarios. Following are representative load reductions from flare relief system analyses performed by Invensys: 70% Heavy Oil Upgrader Prefractionator 70% RFCCU Main Fractionator 65% Benzene Column 60% Delayed Coker Fractionator 60% Ethylene Plant Pyrolysis Fractionator 50% FCCU Gas Plant Debutanizer 30% Crude Unit 7% Xylene Splitter with Fired Heater Reboiler
13 INFUSION An Integrated, Flexible Information and Automation Solution A powerful component of the Invensys suite of HPI solutions is the InFusion Enterprise Control System, the world s first and only Enterprise Control System. A field proven, easy to deploy integration platform, the InFusion Enterprise Control System is the first system that enables all of today s process automation and information systems to work together regardless of supplier or age as one unified business environment. Highly scalable and extensible, InFusion lets you exploit what you already have and incorporate what you need, without hefty engineering and integration costs. Engineering becomes cheaper, easier and more productive by shifting the emphasis away from programming and toward the rapid assembly of reusable objects. InFusion leverages the ArchestrA architecture which delivers a standardized plant object model, to facilitate ease of use, reusability and an extensible environment to closely couple the two worlds as if they were one. The InFusion Enterprise Control System includes a series of functional and system components. The functional components leverage the impressive portfolio of leading brands that comprise the Invensys portfolio including: Avantis enterprise asset management software Eurotherm industrial control and monitoring solutions Foxboro distributed control, measurements and instrumentation IMServ carbon and energy management solutions SimSci-Esscor simulation and optimization software Triconex critical control and safety systems Wonderware plant intelligence software Enhance the decisionmaking process.
14 HYDROCARBON PROCESSING INDUSTRY SOLUTIONS MEANINGFUL BUSINESS INTELLIGENCE While greatly simplifying engineering tasks, and reducing engineering costs, the InFusion Enterprise Control System also dramatically enhances visibility across the enterprise from the process level to the executive level. Allowing the right people to see the right business intelligence at the right time and, most importantly, in the right context. HPI solutions enabled by the InFusion Enterprise Control System give you the power to automate and close the Business Control Loop. Leveraging the InFusion Enterprise Control System, you can determine how information is organized, distributed and made more meaningful for specific personnel and teams. It will also allow greater collaboration between product development, operations and maintenance. Business Control Loop Heirarchy They ll see the information they need. You ll see improved product yield, as well as short- and longterm asset performance with: Accelerated scheduling, quality, throughput and efficiency Greater ability to meet shortterm production obligations and long-term maintenance and overhaul goals Better measurement and operation of cycling assets through ranges of throughput rate change Significantly reduced spurious production PV SP interruptions Plant and business personnel benefit from understanding what data really means within the context of business objectives. The transformation from data to wisdom is critical to identifying and eradicating hidden costs as well as closing the gap between a process variable and a set point.
15 APPLICATION SOLUTIONS Invensys HPI solutions in action From a singe piece of plant equipment to groups of assets to multiple sites and industry units, Invensys HPI solutions deliver demonstrated value and returns through enhanced collaboration, smarter decision making, faster problem solving and the simultaneous optimization of asset availability and utilization. Here are just a few examples of how we ve measurably improved our clients economic performance. Reducing the cost of energy supply A Japanese refinery implemented a utilities optimization system based on SimSci s ROMeo software which was used in a real time closed-loop operation. Power contracts were modeled based on the time of day. Variables optimized included boiler and turbine load distributions, fuel mix, and power purchases and sales. This system resulted in a 5% reduction in energy cost for the refinery. Optimal regulatory control One of the world s top refining companies implemented a loop management solution supplied by Invensys, and estimates benefits in the order of $1 to $5 million per year are being realized in each refinery by deploying the technology and understanding how to use it to full advantage. Optimizing the feed rate to a Fluidized Catalytic Cracking Unit SimSci s ROMeo software was used by a world-class refining company to implement a closed-loop, real time optimizer on an FCCU at one of its US-based refineries. Compared to the fixed feed rate strategy that was the preferred mode of operation for the this unit, periodic adjustment of the feed rate by the real time optimizer in response to changes in key process and business variables resulted in a benefit of more then $14 million/year. Naphtha production profit optimizer Invensys helped a leading refinery develop and implement an application designed to enhance the collaboration and optimization of its naphtha production. This application encompassed all major process units that produced naphtha streams for further conversion as well as final blending. The goal: to maximize the revenue generated from every barrel of naphtha produced, while meeting quantity and quality requirements. Comparing its profitability before and after the implementation, the refinery measured the ROI of their optimizer at $0.05 per barrel. Minimizing the cost of hydrogen supply A major US-based refining company recently implemented a ROMeo-based refinery-wide optimization system to manage its supply, distribution and consumption of hydrogen. The system rigorously tracks hydrogen purity across the refinery from purchase to fuel gas purge, and predicts the approach to unit constraints, such as hydrogen partial pressure. In addition to a benefit of 10% savings in hydrogen purchases the system keeps the hydrogen system feasible and optimized in response to ongoing disturbances, balances purchase or production of hydrogen versus additional purging to fuel gas, minimizes hydrogen plant costs by optimizing feed mix and operating conditions and ensures that the hydrotreaters receive optimum hydrogen purity. Smarter business decisions. Starting now Put Invensys HPI solutions to work in your plant or, better yet, throughout the enterprise. Contact Invensys today and learn how our HPI solutions deliver greater, faster, measurable business performance.
16 Invensys Operations Management 5601 Granite Parkway III, Suite 1000 Plano, Texas U.S.A iom.invensys.com Invensys, the Invensys logo, ArchestrA, Avantis, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Skelta, Triconex, and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be the trademarks or service marks of their representative owners Invensys Systems, Inc. All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing from Invensys Systems, Inc. PN I-HP-0102 Rev. 04/15