2012 Honeywell Users Group Asia Pacific Mayur Agrawal The Secret to Effective Process Engineering

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2 Sus tain.ability Honeywell Users Group Asia Pacific Mayur Agrawal The Secret to Effective Process Engineering

3 What is Engineering Effectiveness? Process Engineering focuses on the design, operation, control, and optimization of chemical, physical, and biological processes. It encompasses a vast range of industries, such as Oil and Gas, Refining, LNG, Petrochemical, Mineral processing, food, pharmaceutical, and biotechnological industries. Investment Financials Technical Challenges Global Competition Increasing Engineering Productivity and Efficiency Engineering effectiveness is about improving the productivity and efficiency of Process Engineering workflow. 3

4 Engineering Effectiveness Objectives IT Objectives Standardize Technology across the company Partner with suppliers on key technologies Increase productivity and reducing cost of ownership. Technology Objectives Standardize Engineering Best Practices across the company Manage intellectual property and technical skills Implement Life- Cycle Simulation vision 4

5 Engineering Effectiveness Challenges Managing Technology Suppliers and Partners Support the corporate deployment of software tools, and versions Capitalize on Previous investments Intellectual Property development, deployment and protection Promote the usage of Out-of-the-box tools without loosing competitiveness New Technical Challenges Balancing Technology Demand Alignment with Customer Specifications Life-Cycle Simulation 5

6 Engineering Effectiveness Challenges Suppliers and Partners Honeywell Intellectual Property Support Best-in-class support Out-of-the-box Capitalize Smooth Transition from Aspen HYSYS Technical Challenges (Joint) Development Program Demand Flexible access to technology Customer Specifications Used by global Process Companies Life-Cycle Unique UniSim Life-Cycle vision 6

7 UniSim Design Suite Plant Design and Simulation Products Design (steady-state) Dynamics Options Flare Spirally-Wound Tube Bundle Module 3rd Party Options Equipment Design and Equipment Design and Simulation Products Simulation Products Heat Exchangers Shell-Tube Exchanger Modeler Crossflow Exchanger Modeler Plate-Fin Exchanger Modeler Fired Process Heater Modeler Plate Exchanger Modeler FeedWater Heater Modeler Process Pipeline Modeler Conceptual Design Product ExchangerNet Physical Properties Product ThermoWorkbench 7

8 Integrated with Specialty Third Party Technologies DIPPR Database (Design Institute for Physical Properties) for properties of pure compounds Multiflash (Infochem) used for properties, black-oil translation, and as a PVT engine Xchanger Suite (HTRI) for heat exchangers design and rating Bentley (Bentley) for engineering workflow GAP and Resolve (Petroleuml Experts), for overall O&G field simulation Electrolytes OLI Options (OLI Systems), including OLI engine, database and a corrosion analyzer tool,for electrolyte system modeling Cleopatra (Cost Engineering) for Cost Estimation MySep (Kranji Solutions) Separator Design Software PIPESYS Option (Neotec) for pipeline simulation PVTsim (Calsep) used for properties and as a PVT engine Blackoil Option (Neotec) for upstream fluid modeling OLGA/S Options (SPT) for pipeline simulation Amines Option Comos PIPESIM (Schlumberger DBR) for amine treating process simulation (Siemens) for Plant Engineering (Schlumberger) for pipeline simulation 8

9 Integrated to HON Advanced Solutions Applications Energy Dashboard RPMS Asset Manager UniSim Operate Operator Training UniSim Design Advanced Process Control Corrosion Prediction Realtime Optimization 9

10 A little bit of History Honeywell acquired the following from AspenTech: Intellectual property (ownership) of Hyprotech products Includes entire HYSYS product portfolio Includes a two-year support agreement under which AspenTech will provide Honeywell with source code to for any new developments to Hyprotech products Honeywell hired 17 top HYSYS developers and architects, and the top 10 HYSYS technical support engineers Deal closed December 23, 2004 Information available in public domain. HYSYS name not transferred; Honeywell rebranded into UniSim Design March 2005 First Licence Sales in June

11 UniSim Design Compatibility with Aspen HYSYS Design can read and save Aspen HYSYS cases, based on the compatibility shown herein. It allows opening and saving HYSYS cases from within UniSim Design Usually, the read/save compatibility of a new version will be available in UniSim within about 6 months. E.g. HYSYS v7.3 compatibility will be available in the next UniSim release R410 in June 2012 Both companies are obliged to maintain upcoming XML compatibility UniSim Design Reads Aspen HYSYS cases saved Saves As Aspen HYSYS R350 HYSYS 2004 and earlier HYSYS 2004 R HYSYS 2004 and earlier HYSYS 2004 R350.5 HYSYS and earlier HYSYS R360 HYSYS and earlier HYSYS R360.1 HYSYS and earlier HYSYS R370 HYSYS 2006 and earlier HYSYS 2006 R370.1 HYSYS 2006 and earlier HYSYS 2006 R370.3 HYSYS and earlier HYSYS R380 HYSYS and earlier HYSYS R380.1 R390 R390.1 R400 R410 HYSYS (with some limitations) and earlier HYSYS (with some limitations) and earlier HYSYS 7.1 (with some limitations) and earlier HYSYS 7.2 (with some limitations) and earlier HYSYS v with some limitations) and earlier HYSYS HYSYS HYSYS HYSYS HYSYS This compatibility is maintained for one-off migration purposes, and it is not recommended to use both technologies (Aspen HYSYS and UniSim Design) in the same project

12 Case Study - Linde Challenge: Deploy Linde s Intellectual Property easily and safely across all the offices worldwide Use a commercial simulation tool that can be aligned with Linde s process design workflow specificities Solution Applied Design Suite Joint Development Program Key Results Increased efficiency, by improving access and maintenance of Linde s Intellectual property to the 500+ users worldwide. Increased Reliability and efficiency by using a commercial software together with the aligned development provided by the Joint Development program. 12

13 Case Study Shell E&P Challenge: Standardize on a single software simulation provider for all Oil & Gas Exploration and Production applications. Smoothly integrate Shell s intellectual property to the simulation environment. Solution Applied Design Suite Joint Development Program Key Results Confirmed usage by 3,000+ engineers worldwide. Increased Reliability and efficiency by aligned development goals provided by the Joint Development program. 13

14 Simulation Balance Tool The Simulation Balance Tool provides a mechanism to check for material and energy balances within the UniSim Design flowsheets. It is aimed to gain a rapid overview of all entities which could be sources of flowsheeting errors, even if the simulation is converged. You can select to validate any combination of mass, mole, heat and component balances and using absolute and relative tolerances. 14

15 Case Scenario Management The Case Scenario Manager is an engineering tool developed to enable effective modeling and facilitate engineering workflow, especially for large projects involving multi-phase deliverables and a team of process engineers. It is commonly used for comparing separately developed, but similar simulation models in a single workspace, and for propagating changes of user-modifiable variables from one simulation model to others. You are able to: Set up input/output variables to be used in case comparison Select the simulation files that will be used in the comparison Select the Master Case that will be used as a reference in the comparison Detect changes in topology and variables values Push changes in the input variables from the Master Case to the affiliate cases. 15

16 USE-IT (UniSim Excel Interface) MS Excel is commonly used by process engineers to perform calculations, analyze and report data. USE IT allows engineers to easily export process simulation data to Excel, smoothing the data gathering process. It also creates a live link between the applications, making it easy to run sensitivity analysis directly from Excel, saving significant time, and improving the efficiency of the engineering workflow 16

17 Adjust/Recycle Manager The Adjust-Recycle Manager, which has been added to the simulation management tools, improves flexibility and controllability of flow sheet convergence. It enables power users to configure networks of Adjust/Recycle blocks to achieve more robust and faster convergence for large, complex flow sheets. You can temporarily ignore/segregate the adjust/recycle blocks to better control the convergence. 17

18 Gasifier Unit Operation & Coal Analysis tool A tool for Gasification process simulation (SS & Dynamics run) Pyrolysis Gasification Quench Coal Analysis tool Define a Solid Hypo as a Coal compound Based on provided coal Proximate & Ultimate Analysis data Generate thermo properties for the coal compound Tutorial 18

19 Spirally Wound Tube Bundle Module Primary application is in modeling of the Main Cryogenic Heat Exchanger (MCHE) of LNG processes Spirally-wound heat exchanger with four streams (Fredheim and Fuchs, 1990) Propane pre-cooled, mixed-refrigerant liquefaction process (Edwards et al., 1984) 19

20 20 Binary Interaction Parameter (BIP) Optimization

21 21 UniSim Design for the LNG Industry

22 Flexible licensing Standalone License is associated to a given hardware (local PC or dongle) Network License is associated to given server, allowing access from anywhere in the network Tokens License is associated to a given server, allowing access from anywhere in the network. It provides the ability to Shift usage amongst products over term of contract, increasing usage flexibility 22

23 Global Process Clients Eni Tebodin Praxair WorleyParsons Casale Group Petrochina Sabic Bluewater Energy SOFCON ACEC ADMA-OPCO TAKREER EQUATE KJO PDO Jacobs Engineering TGE Gas Engineering Voith Industrial Services Engineering GmbH Mott MacDonald & Company LLC CITGO Shell Linde Total BG International Limited BG OKLNG Balboa Refinery Optimus Air Liquide Performance Improvements Petrofac Engineering UOP Addax Petroleum Services DPS Pertamina Impac Engineering Saipem GDF Suez Thomassen Compression Systems National Petrochemical Co - NatPet ILF Beratende Ingenieure GmbH HuR ChemPharm GmbH 23

24 The Simulation Lifecycle Approach Concept Selection FEED Detailed Engineering Construction & Commissioning Operations Expansion Operations Modelling Tool Tool Modelling Tool Modelling Tool Modelling Tool Modelling Tool Tighter design Investment Decisions Controllability Early APC Improve Procedures Operator Training Asset Monitoring RTO De-bottlenecking Operator Tools 24

25 If you want to know more Business Manager Rafael Coronel Tel: Cell: rafael.coronel@honeywell.com Product Manager Martin Ross Tel: Martin.ross@honeywell.com Sales Queries Americas Peter de Jonge Tel: Cell: Peter.dejonge@honeywell.com Sales Queries EMEA Michael Brodkorb Cell: Michael.brodkorb@honeywell.com Sales Queries Asia Pacific Mayur Agrawal Cell: Mayur.agrawala@honeywell.com Technical Support Helpdesk unisim.support@honeywell.com unisim.supportportal.com Marcom liliana.pereira@honeywelll.com marty.israels@honeywell.com Additional sales information 25