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In Refining and Petrochemical Plants
PERFORMANCE IMPROVEMENT CONSULTINGPhil Millette
28 September 2017
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Agenda• How to approach consulting in process plants• Cascade of consulting engagements
- Benchmarking & strategic consulting Key subjects
- Greenfield consulting- KPI Consulting- OEE – Reliability consulting- Operations Mgmt/ Excellence / Alarm mgmt- ORCA- HMI Consulting- Change Mgmt- Competency Mgmt- Process Safety Consultancy
• Proof of Concept approach - Process & Asset Performance- Examples
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Sound
Practical
Supportable
Domain appropriate
• All aspects need to be addressed for the successful consulting
• Too much focus on one aspect detracts from that achievable success
• Need to achieve a balance in order to achieve success
• Not solely technology success
• BUT Success-in-use to the operating facility
Consulting Challenges for Process Plants
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Sound:
Practical
Supportable
Domain appropriate
• Methodology applicable at different levels of detail
• “right” level of approach –formal versus anecdotal
• To level of interest
If Emphasis on Sound – Driven by the Methodology
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Sound
Practical
Supportable
Domain appropriate
• Proven• By Experienced provider• Reliant on known practices –
skills available• Time Usage in busy plants• Using available facilities
Consulting Must be Practical
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Sound
Practical
Supportable
Domain appropriate
• Domain-relevant• Process-relevant• Function-relevant
• Completeness of coverage• Key functions covered• Open to include cross-
function domain effects• Provider’s expertise is evident• Best practices are apparent• Change Mgmt - adoption
Consulting Must be Domain Appropriate
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Sound
Practical
Supportable
Domain appropriate
• Facility success depends on it.• Sets possible project or opex spend direction
• Geographical location – are skills available• System skills versus domain skills• Not purely driven to solution sales• Training, coaching
Consulting Output Must be Supportable
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Sound
Practical
Supportable
Domain appropriate
• Other critical elements suffer• May not be domain appropriate• May not be practically doable• May not be appropriately
supportable
If Driven Purely by ‘big’ Methodology
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
PEOPLE
Key Challenge: Right Decisions at the Right Time:Focused Expertise Needed for Process Industry
ASSETS
PROCESS
PRODUCTION
Need to continually track movement of materialthrough the plant. Need to easily compare planned vs. actual and raw vs. reconciledproduction.
Control systems must be optimized for maximum performance. People need smarter tools to enable them to manage the process more efficiently.
Many assets across multiple locations must run reliably and at highest capacity, optimized against maintenance costs.
People in multiple departments and roles making key decisions.Decisions impact people & plans in other departments.People need accurate information in contextto make informed decisions.
INFORMEDDECISION-MAKING
SUPPLY CHAIN &PRODUCTION MANAGEMENT
OPERATIONSOPTIMISATION
ASSETEFFECTIVENESS
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Benchmarking & Assessments Initial DiscoverySolution WorkshopTargeted Consulting EngagementPrototype/POC DesignProgram Deployment Oversight
Consulting Methodology & Engagement Types
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Assessment team
Update & implement
Automation Plan
Identify Opportunities
Business Vision
Assess Current
Situation
People & Information
Plant Information
Business goals
Investments database
Current projects
ASM consortium knowledge
Plant model Functional map
Resource & maintenance
data
Plant Information
In-house resources
Solution & Benefits
catalogue
Industry TrendsStrengths/Weak
nesses
Vertical Market
Template
Benchmark Information
Automation Performance
Technology Trends
Change Management
Measure Performance
Business goals
AS-IS benchmark
TO-BE map
Solution capability
Vertical Market knowledge
Organisation Structure
Honeywell
Automation Consulting – Cascade of Possibilities
Issue-specific
engagement
Pain Points
Proof of Concept
Structured rollout
Domain knowledge
Prior experience
Specific Methodologies
Customer
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
• Planning• Scheduling• Operations Management• Process Operations• Offsites Operations• Maintenance• Reliability / process & assets surveillance• Laboratory• Offline Plant Optimization/Simulation• Production Accounting• Safety, Health and Environmental• Engineering and Technical• Performance Monitoring – KPI’s• Control and Instrumentation• APC and Optimization• Information Systems• Practices and Architecture• Organization and Business• Business Incentives• Business Process Efficiency
Business IncentivesTechnology Organization Business
Processes
Safety
Environmental
Reliability
Gross Margin Improvement
Cost Control
Integrity
Functions / Applications
Benchmarking - Functional Areas/Systems
700 750 800 850 900 950 1000 1050 1100
Productive Use
Technology
Automation
Integration
Overall (Weighted)
Low Pacesetter
High Pacesetter
Maximum Possible
931
934
914
925
928
810
972
1 080
Score Summary
5554
4654
5351
5351
5653
5254
5151
4650
5352
5547
4648
5247
5453
5454
5054
4851
4650
5352
5449
4748
5345
5457
5454
5054
5451
4650
5352
5550
5250
5346
5255
5454
5355
4951
4653
5352
0 50 100 150 200
Supply Planning Scheduling
Operations FunctionsOff-sites Operations
MaintenanceLaboratory
Offline Plant Optimization/SimulationProduction Accounting
Safety, Health, Environmental, and FireEngineering and Technical Systems
Performance Monitoring Control & Instrumentation
Advanced Control and OptimizationInformation Systems
Practices and ArchitectureOrganization & Business
Business IncentivesBusiness Process Efficiency
Technology
Automation
Integration
Productive Use
Manufacturing Excellence AssessmentAREAS OF OPPORTUNITY
020406080
100Defining & Preparing
Planning & Scheduling
Basic automation
IT infrastructure
Operational Integrity
Safety, Security, EnvironmentAsset effectiveness
Production effectiveness
Operator effectiveness
performance analysis
Quality Management
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Process Readiness: MAC/TSI FEED Ensures Fit for Purpose Infrastructure Supports OR/BR
OR Consulting: Identifies Operations’ Work Processes
BR Consulting: Identifies Business Processes
Greenfield Consulting – Day ONE Readiness
Operations To Business Integration Production Operations Safety & Security Maintenance & Reliability Facilities & ConstructionHistorian Alarm Management Gas Detection Corrosion Asset TrackingOperations Management Automated Procedural Operations H2S Detections & Monitoring Vehicles Production Planning/Scheduling Mobile Operations Explosibility Management Equipment LIMS Maint. Work Order Entry Personnel Tracking/Personal Gas Detectors Equipment Run Time Networks & Telecommunication Production Reporting & Accounting Mobile DCS Fire Detection & Suppression Plant Asset Management Constructions PhaseOperating Instructions Handhelds for field rounds Process Maintenance Management System (MMS) Operations PhaseShift Hand-Off Integrated Control Safety System (ICSS) Non-Process Parts Management and Warehousing Construction CampsERP Integration Remote Operations Mustering Condition Monitoring System (CMS) Permanent CampMaterial Replenishment Planning (MRP) Process Simulation Video Equipment Health Monitoring (EHM) Lay-down Yard
Training Process Field Device Management (FDM) Warehouses Operator Training Simulator Security Electrical Diagnostics HVAC Virtual Reality Scenarios Access Control Documentation/Information Asset Management (IAM) Modular Buildings Skills Assessment Plant Drawings Graphic Building Well Pads ProceduresSulfur Terminal Automation Sulfur Terminal Management of ChangeAdvanced Process Control & Optimization (APCO) Payroll/HR Integration MSDSField Real Time Optimization (RTO) Perimeter Security Systems Well Testing/Metering Cameras Networks Integrated Field Modeling (IFM) Radar Databases Slug Management Microwave Project to Ops HandoverPipeline Operations Fence Line Calibration Leak Detection Emergency Response TrainingControl Operator Ergonomics & Interaction Documentation for Safety Shutdown Testing Loop TuningCommissioning Public Address Systems Configuration1st Year Operations Support Operator to Operator Communication System Maintenance
Document Management SecurityWork PermittingRemote Support
Occ
upat
iona
l Saf
ety
Proc
ess
Safe
tyPr
oces
s Sa
fety
Regu
lato
ry C
ompl
ianc
e
Info
rmat
ion
Man
agem
ent
Ope
ratio
ns M
anag
emen
t
Adva
nced
Ala
rm M
anag
emen
t
Asse
t Man
agem
ent
Ope
rato
rs T
rain
ing
Sim
ulat
ors
APC
(Ear
ly Ev
ent D
etec
tion)
Inte
llatra
cO
ne W
irele
ssPr
oced
ural
Ope
ratio
nsAl
arm
Per
form
ance
Ass
essm
ent
Alar
m P
hilo
soph
y W
orks
hop
Alar
m R
atio
naliz
atio
n Se
rvice
Boun
dary
Ass
essm
ent
Benc
hmar
king
/ Gap
Ana
lysis
Proc
edur
al C
onsu
lting
Bene
fit A
nalys
is (s
ite A
dult)
Valu
e Au
dit
Business Drivers Solution Layout Service LayoutCustomer OpportunitiesX Accident Avooidence X X X X X X XX X Downtime Avoidence X X X XX X Loss Prevention X X X X X X X X X Asset Reilability X X X X X
X Boundary Management X X XX Emission Compliance X X X X
X Procedural Management X X X X X XX X Operators Training X X X
X Simulation (Training & validation) XX X X Alarm Rationalization X X X X X
X Alarm Performance Management X X X X XX X X X X Early Process upset Identification X X X X X
X Increase Process Repeatability X X XX Operators data errors X X X
X X X X X Improve Emergency Response X X X X X X X XX X X Auditability X X X
X Safe Profitability X X X X X X X X XX Abnormal Situation Management X X X X X X
Business Drivers Solution Layout Service Layout
Process Readiness
OperationalReadiness
BusinessReadiness
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Targeted Consulting Engagements
13
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
KPI Consultancy
GOALS
OBJECTIVES
LIMITS
KPIS
STRATEGIES
Business Goals
How to reach business goals
What has to be done well to reach goals
What has to be measured to monitor objectives
What are the limits of the measurements
DATA How to ensure quality of measurements
ACTIONS What happens if KPI is out of limits
FinancialCustomerProcesses
Org. Growth
BetterFaster
Cheaper
MISSION
•Align program objectives with enterprise mission•Understand KPIs at function level
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
KPI Consultancy15
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
25Downtime LossRun Rate Loss1st Time Prime Loss
20 Actual Through-put
Max / yr
15
10 Act / yr
OPE=11/18
5 61%
Unit C
MM
kilo
s /Y
r
OEE Consultancy
What are the outcomes?1. Determine OEE and classify the Issues
2. Max Potential Rate is determined
3. Pareto key business opportunitiesa. $ Op Margin per 1% OEEb. $ Maintenance for OEE eventsc. $ Yield loss for OEE events
4. Basis for determining / justifying TacticalProjects and future Strategic Plans to grow OEE.
• Enables jump start to grow OEE without waiting for data to accumulate
5. Basis for prioritizing limited $$ funding and professional resources
6. Basis for modeling the new system for OEE data collection and analysis
7. Timetablea. ~4 wks prior to workshop, data
gatheringb. ~2 days for on-site workshop
depending on complexity
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
OEE & Maintenance Process Overview
AssetManagement
Proactive Reliability
Maintenance Execution ProcessCMMS, Asset Ledger hierarchy
Day-to-day Work Identification,Work Prioritization
Planning, Materials procurement, Plant Stores management
PM workis priority
Work permits, Work execution
Record job reliability data, Close work order
Manage KPIs, Audit work process,
Manage Change
Apply RCM to top 5% critical equipment
OEE Gap Analysis, Equip Criticality Analysis
Apply Reliability Strategiesto balance of critical equipment• Condition Monitoring• Preventive Maintenance• Operator Driven Reliability and TPM
Validate Crafts Competencies
OEE Optimized Maintenance
Manage KPIs,• Audit Compliance
• Manage deficiencies• Root Cause Analysis
Apply RBI to corrosion / erosion and vessel statutory
Operations Coordination, Backlog Mgmt, Scheduling
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Operating Excellence Review – Alarm & Operations Mgmt18
• METHOD1 – Classic• METHOD2 – Remote• METHOD3 – Most Frequent• METHOD4 – Survey• METHOD5 – Operator Assist• METHOD6 – Using Classes• OTHER – Consequential Analysis
EEMUA target
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
ORCA – Operator Responsibility & Complexity Analysis
Scenario 1: Expanded, no new CR
Access P/L As -Is
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Operator Role Complexity Attainment = (4-Score)/3
Posi
tion
Scor
e
ORCA Score - Customer
Q1
Q2
Q3
Q4
Higher risk of operator overload during abnormal situations
Low productivity -operator could handle larger span of control
- ORCA Outcome -• Ensure Operators can make better decisions faster- Evaluate 5 Areas & 16 Attributes that control
an operator’s performance- Rank these based on impact on site- Assess performance- Make recommendations to improve Operator
Performance - Assist in defining an improved “Can-Be” (i.e.
future) state- Build a roadmap to achieve the “Can-Be” State
• Considering various upgrade scenarios
• Set of recommendations- Improve Control Safety & Security- Improve Alarm Management- Improve Visual Display
- Business Driver -
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HMI Consulting – Human Factors / ASM• Interaction Requirements Analysis (IRA)
workshop performed for each process unit• Console Operator Span of Control and Asset
Hierarchy• Display Hierarchy and Operational
workspace• L1 display definitions, KPIs and Critical
parameters• L2 display interaction requirements and
critical loops• Abnormal situation management
requirements• Scope for Operator Training• Scope for Procedural Automation• Scope for Process Optimization
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Change Enablement Consulting
Define Change
Build Roadmap
Communicate & Engage
Align & Enable
Monitor & Sustain
Guiding CoalitionSense of UrgencyCreate Vision
Compelling StoryMessaging/ChannelsEmployee Participation
Impact AssessmentExecution Plans
MeasurementsContinuous Improvement
Reinforcing MechanismsTraining & DevAccess Expertise
Successful change programs drive the organization to the
new situation quickly, efficiently and
effectively with the least disruption and at
lowest cost
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
12 competencies 46 behavioral indicatorsConsole
7competencies 16 behavioral indicatorsFoundation
10 competencies 37 behavioral indicators Core
Competency Management Consulting
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servicesComplementary Consulting & Lifecycle support
IEC 61511 Safety Consulting
Pre-assessment
Hazard and risk analysis
Allocation ofsafety functions
to protection layers
Design andengineering of
safety instrumented system
Installation, commissioningand validation
Operation and maintenance
Modification
Decommissioning
Design anddevelopment
of other meansof risk reduction
Safety requirementsspecification for the
safety instrumented system Managementof functionalsafety andfunctional
safetyassessmentand auditing
Safetylife-cyclestructure
andplanning
Verification
10 11
5
6
7
8
4
3
1
2
9
Compliance assessment and TÜV certification
Training&
Tools
\Over protected! No change
Under protected!
Basic Process Control Systems Non-safety Process alarms
Operator Supervision
PREVENTION
Safety Critical Process AlarmsSafety Instrumented Systems
MITIGATIONMechanical Mitigation Systems
Fire and Gas Systems
PLANT EMERGENCY RESPONSE
COMMUNITY EMERGENCY RESPONSE
Process Design
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Fire & Gas Consulting
Consultation & FEED• Analysis and Risk Assessment• Recommendation on Type,
quantities and locations of F&G devices
• Support in F&G specifications• Site Survey and inspections• Following Codes &
Standards
Design & Engineering• Basic Design• Detailed Design• Engineering
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Cyber Security Consulting
The First Step to Security Is Understanding the Current Environment
Customer problems solved/needs addressed:– Identifying and prioritizing the biggest risks– Meeting industry/government regulations and
guidelines– Finding which systems and devices are the most
exposed, and the most vulnerable– Prioritizing cyber security efforts for the maximum
return
Honeywell Offerings:– Network Assessment– Wireless Assessment– Security Assessment SAL2 (coincidental & intentional
attacks using simple means)– Security Assessment SAL3 (targeted attacks using
sophisticated means)– Compliance Assessments & Reports
Assessments& Audits
Architecture & Design
NetworkSecurity
EndpointProtection
SituationalAwareness
TECHNOLOGY
Response& Recovery
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Energy Management Consulting • Study one of more aspects:- Production- Consumption- Forecasting- Data sources, cleansing, usage- Optimization potential
• Capture possible opportunities• Analytics proof of concept
Structuring elements to ISO 50001
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
• Proof Of Concept Approach- process reliability & Analytics Workshop- Best Practice
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Proof of Concept - Workshop Process – Analytics Example
Finding the right candidates to show value
28
Functional Session Interview
Functional Session Primer
Functional Session Generate
Ideas
Functional Session elaborate
ideas
Functional Session Top 4 Opportunities
POC Opportunity review
POC Opportunity evaluate
POC Select POC Planning
Workshop read out
Honeywell data strategy
What Data analytics can solve
Customer Candidates
Customer Valuable Business Challenge
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Idea Generation Workshop (recent example)• 140 ideas generated• Moneyball
- visualization/ report to understand why target are not met- production loss vs bad actors reasons by cost and frequency- daily tracking of in conformance PONC against targets visible to operations- $ amounts vs target off- better tracking of target deltas and why- Manage economics target as we manage limits / boundaries (operating
windows)- production planning : Analytics to monitor GAPS in target attainment- I would easily know $$ impact of abnormal situation or event
• Cracked up- Coke Drum cracks
• Risky Business- Reduce uncertainty of probability- Maximize Risk reduction- Easy way to better estimate the probability of failure/risk part of the risk score- develop better understanding of larger term failure - big ticket long term - I would never have unpredicted events or misunderstood events the data would
tell • I-robot
- automate repetitive task - let machine do what they do well- faster engineering analysis- retrospective automated causal analysis of events and upsets - automate problem identification gives more time for solution
• Minecraft- Mine MTA Bad actor- Mine MVA DB for high impact items and link to root cause automate this- Correlation based first principle
• Sensing- Early identification of control hardware problem- be able to tell when a transmitter gives false reading based on disagreement
with other indication- plant data transmitter vs correlated process variable- Understand instrumentation contribution
• Crystal Ball- CGH gasoline key parameter understanding Octane destruction vs temp., H2
PP vs S & Feed quality: what is going on main Fractionation, trade off effect on downstream
- Build catalyst deactivation model for predictive maintenance- Predictive analysis for slope of deactivation- visualize catalyst deactivation- HCU cloud pt prediction and control- Projected / predicted - CCU exchanger proactive monitoring of Fouling - Improve ability reverse production impacts
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Process Plant Data Analytics / Performance Consulting30
Graphic from “Big Data Industry Insights”, Lisa Kart, Gartner webinar, 2015.
• The goal of analytics is to provide information for improved decisions and actions for economic benefit.
• Note that maximizing automation and minimizing human input are not always the goals → analytics should be suited to the use case.
• Key Questions:1. What is the underlying business issue and
value to the customer?In terms of Question, Decision, and Action
2. What data do you need in order to answer the question? Which data do we have? What new do we need?
3. How will you use the answer?Insight only? Part of a business workflow?
Complexity
POC selection / evaluationValue
Impact-Financial-Permit to operate (Other KPI)
Time to ValueStrategic Fit (scaling up)
ExecutionTechnical Complexity
Number of data sourcesAnalytics techniques used
Execution/Adoption Complexity Can the analytic be deployed and How?
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Performance Improvement via Analytics - Best PracticesProof of Concept Approach
• Key to success is to have a well defined scope & desired outcome- Need to have answers to the 3 questions
• Data analytics projects are often underestimated. - Start with a reasonable impact but low complexity candidate
• Outcome data is very important, but is also sometimes overlooked. E.g. if we want to mine data and train models for faults, then the time & cause of faults must be present in the historical data.
• Complexity increases with the number of data sources integrated.• A good project will consist of a Honeywell SME(s), data analytics expert(s), and a site SME(s).
Facilitation is important.• Domain knowledge and amount of data are complementary.
- If you have only a handful of outcome events (eg asset failures) then you need to incorporate human insight.• Plan that ~80% of the project is spent wrangling data and ~20% on the analytics.• Especially for larger projects – take an iterative approach.
- Discover quickly whether question is feasible. If not then stop or pivot.
31
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Proof of Concept Approach• Candidate name – recent example
- Reliability CGH Temp control -> loss of reaction CCU riser vs gas octane Pentanes in n-butane - Alky c4/c5 splitter, DIP Predict j-98 compressor decline Spent acid alky / acid demand prediction Furnace flooding Reformer H2/Oil Transmitter correlation flow
Deliver an analytics model that will predict likelihood of fuel flooding in furnace 20 minutes prior to event occurring in order to reduce incidents of furnace shutdown, lost production time, and equipment damage
• 1-3 furnaces in Refinery facility
Object ive
Scope
Key Del iverab lesAggregated DatasetDataset to be used as the foundation for predictive modeling solutions:• Cleansed and profiled dataset containing all of the historical data
used in modeling• Data exploration report, listing data sources, linkages and ETL
transformationsAnalytical Models• Description of techniques, key variables, performance and actual
code – for generating predictions• Predictions addressing the chosen use caseData Visualization• Appropriate visualizations of data describing insights per chosen use
cases• Output of analytical modeling demonstrating predictions in format
that can be imbedded in current Shell workflowWorkflow Integration• A high-level roll-out plan for operationalizing and scaling the
solution
• Sample candidates:- Visual Analytics for Condition
Monitoring- Visual Exploratory Analytics
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Proof of Concept Approach: Fuel Flooding 33
Develop a deep understanding of the relevant data sources, including:• Relevant data
sources, including fuel/gas data, pressure data, alarm data, sensor data, operational data, repair data
• Current workflow, including data gathering, monitoring and intervention
• Measure the completeness and veracity of each source
• Develop rules for handling missing, incomplete, and uncertain data
• Identify or construct unique keys to link data sets
• Load data and conduct statistical quality checks
Build the Data Ecosystem
Create independent variables using the data ecosystem.• The variables will
include raw information, such as fuel/gas data, pressure data, sensor data
• Continue building new variables with feedback from customer and as modeling develops
Engineer Variables for
ModelingCreate data visualization of data ecosystem to visualize insights from data profiling• Explore initial
insights from data profiling
• Present and discuss findings with customer to help shape analytical modeling
Create Data Visualization
Employ one or more class of analytical models to build new, machine-generated alerts:• Identify the target• Choose analytical
technique(s)• Conduct variable
selection to choose the most predictive variables
• Iteratively train and evaluate the models on the training and test sets
Create and Train Analytical
Models Develop a high-level work plan for expanding and operationalizing the results of the project:• Operationalizing
data aggregation, model refresh, etc.
• Deploying machine-generated predictive scoring into current customer workflow
Develop High-Level Roll-Out
Plan
Identify Existing Data Sources
Engagement begins with a face-to-face kick-off meeting to align on project approach
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