Knowledge - Honeywell Process presentation highlights the total economic benefits to the KPPC Aromatics Complex of the APC application, showing a final predicted payback period of

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Join us at our Honeywell Users Group – 4 till 8 November 2013, Nice, France Keep your company on the forefront of today’s best practices and tomorrow’s developments in process control by attending the Honeywell Users Group Conference. Featuring hands-on demonstrations of the latest technology, one-to-one interaction with products experts, and group discussion with other Honeywell users, this robust technical conference provides invaluable education and insight that can positively impact your bottom line. End User Requirements for Upstream Operations: Steering the Evolution of SCADA/RTU Technology, Abdullah Alkhalifah, Saudi Aramco Over time, upstream oil and gas operations have evolved from simple data monitoring and manual data logging of a few process points at intervals of several days or weeks to the use of complex applications relying on frequent testing, the capture of large amounts of data, and advanced control and automation. The changes reflect the ever-pressing need to prevent accidents and protect the environment, and, accordingly, there is a growing demand for tight integration of basic process control and process safety instrumented systems. This presentation will discuss these types of applications and highlight the typical challenges in meeting end users’ demands for improvements to safety, operational efficiency and life cycle costs. It will look at challenges and possible solutions regarding data transmission networks and communication protocols that can provide a cost effective solution for accessing assets distributed over a wide area and where networking installations are often limited or cost-prohibitive. Implementation and maintenance of Profit Suite Controller on LUKOIL crude distillation units in Russia, Artem Nemtin, Infrastructura TK Over the last four years, three APC projects have been executed at the LUKOIL refinery in Perm, Russia. They have been implemented on the crude distillation units and all use Honeywell software. This presentation details the experience of APC group, special aspects of implementing APC on CDUs, and the results achieved. Information on maintenance after commissioning will also be presented. The Business Benefits of ProfitSuite, Maha Al-Khalaf Al-Saeed, EQUATE Petrochemical Company Manifesting multilateral collaboration, Honeywell’s advanced control and optimization services and solutions were recently installed at the KPPC Aromatics Complex, part of the Greater EQUATE JV fully operated by EQUATE. The project was focused on the Naphtha Prefractionation (Debutanizer & Splitter), Naphtha Unionfining (Stripper), CCR Regenerator, reformate splitter from Xylene fractionation, and Platforming (Platformer, Net Gas & NG Recycle compressor, Recovery Plus, Debutanizer and Platformer Heaters). As the plant’s performance was progressing well towards its objective, the drive for further optimization led it to utilize Honeywell’s process performance solution ProfitSuite, including Profit Controller, Profit Optimizer and Profit SensorPro, to improve the business performance. The complexity of the aromatics plant made it a good candidate for an APC application. The project’s success stemmed from excellent coordination and teamwork between Honeywell, KPPC and EQUATE. Proven benefits were recorded in maintenance of quality specifications, stabilization of

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plant operations and maximization of throughput to the Platformer, aromatics in the reformate stream and C8 split in the reformate splitter. The presentation highlights the total economic benefits to the KPPC Aromatics Complex of the APC application, showing a final predicted payback period of less than three quarters through increased product and LPG yield while conserving energy. This presentation also addresses areas of improvement and shares knowledge with the potential of adding value to any APC project. Optimization of a Refinery Crude Distillation Unit with Honeywell Profit Controller, Giacomo Astolfi, API - Falconara Refinery Using Honeywell’s Profit Controller to develop a model‐based predictive control application, this refinery crude distillation unit realized benefits estimated at more than €1.5 million a year, with a payback period of less than four months. Benefits came through better product quality control, enabling production to shift to distillates with the highest market value, and reduced give away. Furthermore, maximizing the top and bottom pump around saw a reduction of fuel gas consumption in the heater. Finally, the operation has benefited from a reduction in crude switching time. As the presentation details, the success of this advanced process control (APC) application can be attributed to the project execution: its hallmark was close cooperation between the plant’s owner, the system integrator and Honeywell consultants, who supported the project throughout the pre-test, modeling review and commissioning. The result was a project execution far quicker than usual, with APC design and implementation in little more than three months.

Safety Manager Universal Safety I/O: Linking Safety from Tank Farm to Loading Terminal, Antonio Yangüez, BP

Honeywell’s Universal Safety I/O solution was installed at BP Castellon Refinery site’s New Port Facilities Project. After HAZOP & LOPA studies, with SIS integrity level requirements determined to be SIL 2, the operator sought a TÜV approved Safety Manager SIL 3 application using the Universal Safety I/O solution with remote capabilities.

The remotely installed Universal Safety I/O modules were needed for sending and receiving products (crude oil, fuel oil, gasoline, diesel, kerosene and LPG) from and to a new loading terminal, about 3.5 km from the tank farm on site. This was required to act as an independent safety system, protecting both elements on site and at the loading terminal.

Using Safety Manager Universal Safety I/O, all the objectives were met: the modules could be geographically distributed between the tank farm and the loading terminal, all sharing the same Safety Manager controller, and with high availability due to their redundant design in a low demand operating mode.

At the same time, the solution brought benefits to safety compared with a traditional solution using several Safety Manager Controllers linked by a communications network. It did, however, require a significant investment in fiber optics for the infrastructure supporting all the network architecture to connect the remote I/O modules to the controller.






This presentation describes the project’s implementation, lessons learnt, and the economic and strategic benefits of using Safety Manager Universal Safety I/O technology.

Modernization of Supervisory Control Systems: Upgrading TDC2000 to Experion at Zakum Development Company, Mahdi S. A. Tammam, ZADCO ZADCO is a leading oil production company, developing and operating the largest oil field in Abu Dhabi – the fourth largest offshore field in the world – and exporting oil to over 30 different countries. Honeywell successfully executed the modernization of the Supervisory and Control Systems project at the Upper Zakum oil & gas offshore facilities. The upgrade works included replacement of legacy TDC2000 DCS, MATRA SCADA systems, various PLC systems and associated infrastructure at the FCC, Central Complex, Satellites and Interface to the existing Hydril RTUs, located at the wellhead platforms. The first phase of the system has been in operation since 2010. The major challenges of the project were to implement the project while the plant was operational, involving substantial hot changeover activities, and ensuring the existing plant Operating and Control Philosophy remained largely unchanged. This presentation covers the project implementation experience and knowledge gained from this on-process migration. It also briefly shares the project benefits, key challenges, customized solutions, lessons learnt, and the efforts and commitment displayed throughout the journey. Introducing Virtualization in a Process Environment, Cobus van Dyk, SASOL Virtualization has been around for some time, yet remains relatively new in the process control domain. Here, developments by Honeywell have opened up many new implementation options. Sasol’s Synfuels CTL Site in Secunda has utilized virtualization as a key technology in the upgrade of its plant-wide Microsoft Domain infrastructure. With 41 distributed control systems, this spans more than 600 windows-based nodes utilized by an even greater number of users. Virtualization lowered the risk of an impact on production and allowed the project to be completed by the year-end. This presentation looks at various aspects of the experience of introducing virtualization in a process environment. These include technology churn, the required skill sets, technology acceptance and the impact in keeping upgrade costs down. The presentation also covers quick-wins, easy risk reductions and the potential pitfalls of virtualization. Some of the challenges faced during the project included creating confidence in the organization to use and rely on the new technology, and dealing with the risks associated with a big, complex process control network. The success of this project can be attributed to the use of virtualization as an enabler during the project execution and as a risk reduction agent. Finally, other uses of virtualization, as organizational readiness increases, are also suggested.






PHD Alarm through GSM Notification, Mohamed Amine Kaddour Brahim, Sonatrach

Cellular communications are one of the fastest growing and most challenging telecommunication applications ever. Cellular digital technology may become the universal method of communication, with countless uses. In the process industries, one is to facilitate alarms and alerts management. Companies can use SMS services to respond to alarms and disaster events more rapidly. For these reasons, Sonatrach was led to think about how to use SMS to quickly send critical process data, system alarms and trip parameters to managers and maintenance engineers to facilitate a faster response – again instigated by SMS. We aim to share our experiences on maximizing profits from the opportunities offered by Honeywell PHD software, and the steps and phases to set up rapid alarm and event notifications from PHD using the new communication and technology tools. The project uses a GSM communication mode to make data from the process available and alert the end-user, manager or maintenance engineer as quickly as possible. Meanwhile, the project also enables the plant manager to send critical commands to the process, such as a process trip command, from embedded smart phone software. Finally, though the TPS may be seen as a closed system, the PHD system is one means of using new communication breakthroughs and mobility smart devices with Honeywell systems.

PHD R300 Upgrade Across Three Offshore Oil and Gas Platforms, David Bruce, Marathon Oil Marathon Oil is an international oil and gas exploration and production company. In the UK, Marathon operates the Brae Offshore oil & gas field, which consists of three fixed production platforms, multiple subsea tiebacks and pipeline infrastructure. All three platforms have a combined DCS infrastructure with various generations of Honeywell controllers, from TDC2000 through to C300 being used with an Experion HMI. The PHD system collects data from the Experion servers for historisation. AFM is used with over 80 libraries performing calculations on the PHD data. To ensure continued support of the system, Marathon decided to upgrade the existing PHD system to the latest revision and carry out a hardware refresh. A number of changes were made to the network architecture to improve system security and performance. The original Uniformance desktop tools were replaced with UPS, and Production Control Centre (PCC) and Workcenter were replaced with eServer to enhance the desktop users’ experience and access to DCS graphics. This presentation will discuss the upgrade project from planning through to execution.

Simulation of a Steam Unit Generator under Experion PKS, Bachir Benasla, Sonatrach The object of this project was to develop a simulator under Honeywell’s EPKS DCS of a steam generator unit in the Arzew refinery to help anticipate disruptions, support effective decisions, and improve process optimization. This work also provides a foundation for other simulation work, and the basis for DCS operator training.






The current petrochemical industry continues to grow in complexity as a result of economic pressures, increased competition, product diversity and quality demands. Oil refineries are a typical example of the complex systems involved, dealing with a wide variety of product flows through programmed sequences of production, including cyclical phases, while maintaining maximum productivity at the lowest possible cost. Failure to master these production systems results in control problems with serious economic impacts. Simulation is arguably one of the most common techniques for flow analysis in production systems and for designing a suitable control policy. It is a powerful tool due to its flexibility and ability to represent virtually any system. At the same time, evolution in computer sciences and the introduction of virtual machines enables creation of simulators that exactly represent the industrial reality. The simulator presented offers the advantage of being performed under a Honeywell DCS virtualized environment and validated from a real process. It incorporates a boiler as the main equipment; it is fully modeled; and all systems that manage the process (including combustion control, BMS and ESD) are integrated into the simulation database. The simulator is also being used for operator training and development.

APC in CDU: A New Approach to Project Execution, Elena Braceras Hoyuelos, CEPSA Refineria La Rábida

Honeywell's APC application implemented recently in the new crude distillation unit at Cepsa La Rabida followed an innovative approach.

The execution model involved a mixed team from the customer and the technology provider. Its success can be attributed to the team-work between experienced process and advanced control engineers from Cepsa and Honeywell’s APC principal consultant. The combination resulted in a committed team, a timely implementation, efficient knowledge transfer and the successful completion of all objectives.

The Cepsa team managed and led the project, with remote support from Honeywell consultants during all project phases via periodic teleconferences. This included desktop sharing to discuss the main activities and results. These teleconferences ensured the effectiveness of Honeywell’s site activities, such as the kick off meeting, step test and commissioning, all also undertaken working together with Cepsa to complete the project.

This presentation details the experiences and lessons learnt in this successful CDU APC project implementation approach, which is now also being used to execute an ongoing Hydrocraker Unit Advanced Process Control project.

Process Stabilization and Optimization in the Case of Raw Material Purity Changes, Jan Najemnik, Momentive Specialty Chemicals, a.s. Costs are the key focus in chemical industry manufacturing processes today. However, the opportunity to use cheaper raw materials raises issues that must be tackled to avoid negative impacts on process efficiency.






Momentive tested a lower quality raw material at its acrylic acid plant initially in 2009. During the tests, a significant influence was detected on production capacity and the overall efficiency of the reaction. Big changes in the temperature profiles of oxidation reactors, caused by feed changes, were limiting the plant load due to the danger of insufficient control of process safety parameters. Several options for solving the problem were studied, resulting in the plant opting for Advanced Process Control. In cooperation with Honeywell, the project was completed in 2011. The primary goal was to understand process behavior during raw material quality changes and define process parameter adjustments to compensate for these as far as possible. A second objective was to define key process parameters for maintaining process efficiency and an optimized reaction process throughout the operation. The paper illustrates the process of APC implementation and demonstrates results from its successful execution at Momentive’s acrylic acid plant in Sokolov, Czech Republic. The Business Benefits of Advanced Process Control (APC) Daniel Grela, Zaklady Chemiczne Police (ZCH) s.a,

Honeywell’s APC application was recently installed in the ZCH Police ammonia production plant. The plant has two identical trains producing ammonia that is used for fertilizer production. It uses methane as a feed source, but methane is also used as a heat input to the reformer processes (burned) on both ammonia trains. The recent high market prices of the methane, therefore, as well as the loop interactions and a process complexity that includes reforming, high and low temperature conversions, Benfield reactions and nitrogen high pressure synthesis, made this plant the best candidate for our first APC application.

The APC application was led by the Honeywell team in close cooperation with ZCH Police management, and process and automation engineers, from the pre-test phase up to commissioning and post auditing of the APC controller. As a result, the APC application brought significant benefits.

This presentation will show the total economic benefits of the APC application at the ZCH Police Ammonia plant, gained mainly through reducing methane consumption. During execution of this project some important lessons were learned, which will be also presented and will be especially helpful for those considering implementing an APC solution at ammonia plants on their sites

An Integrated Approach to Closed Loop Step Testing and Modeling, Feras Al-Anazi and Rohit Patwardhan, Ras Tanura Refinery

Ras Tanura Refinery has a plant-wide deployment of Honeywell Advanced Process Control (APC) technology. As part of the current campaign to sustain APC utilization and benefits, all APC applications are being monitored and periodically revamped, as necessary, to ensure good performance.






The Platformer APC is designed to meet Octane no. targets on the plat formate, which is used for gasoline blending. A thorough review of the Platformer APC was carried out to understand the key issues affecting controller performance. Regulatory control issues and modeling issues were flagged, and a need to identify key models was identified.

Step testing and modeling are often the most time-consuming phases of an APC project, whether it is a grassroots implementation or a revamp. Closed loop technology can bring significant efficiencies to this activity. As part of the revamp, a closed loop multivariate stepping and modeling technology, Profit Stepper, was used to develop new models for the Platformer APC. This is the first instance of the Profit Stepper technology being deployed at Saudi Aramco. The presentation will discuss key implementation aspects and the lessons learnt from the technology deployment.

A Common Process Information and Automation Strategy and Operation Driven by Honeywell Solutions at MOL Plc., Tibor Komróczki, MOL Plc Since the start of 2013, the Process Information and Process Automation departments at MOL Plc have been operating in an integrated department, named Process Information & Automation. The objective was to increase synergies between colleagues and between different refinery information and automation systems. Despite the significant challenges, intensive monitoring and reporting through Honeywell solutions has helped ensure it was a success for the business. This presentation will detail the main objectives of the new operation, looking at knowledge sharing; the difficulties of different working cultures; awakening new ideas; support for new downstream program activities; safety and process safety actions; and help for the Lean project members and programs. It will also look at the realization of these ideas with Honeywell solutions, and the benefits in reduced quality giveaway, alarm management, interlock reports, energy monitoring and reports, and training for end users. The presentation will detail some project plans for the near future, including the roll out of an alarm management system in three new plants; improvements to PSM dashboards with new alarm indicators; implementation of an OTS system in a new plant; and improvements to training topics, efficiency and frequency to support Lean and new downstream program actions. Finally, it examines the business plan for next year, including energy monitoring implementation in other business units. Alarm Management and Control Performance Monitor Implementation, Jozef Horvath, Slovnaft, a.s.

Safety at refineries is ever more critical. Slovnaft, however, found that its current alarms setting, priority and number did not support its ideal of a safe production unit at its refinery. It therefore implemented an alarm management (AM) tool. This began at the same time as a parallel project of loop monitoring and tuning. Fortunately, the two solutions identified independently for these projects came from the same vendor, with both AM and control performance monitoring (CPM) software supplied by Honeywell, powered by Matrikon. The first implementation was completed at LCN2 in 2011. This covered FCC-VGH-HPP-ETBE-Alkylation units. Within the scope of the AM/CPM implementation, the DCS and APC upgrade was completed within






two months. The second implementation phase was completed at LCN1 in 2012, covering RHC-SRU-SAR-GRU-GDU units. The really hard work started after AM/CPM training in 2012. An alarm management rationalization team was created, and activities began in accordance with the EEMUA 191 recommendations. The full rationalization began with the FCC unit, because operators could change the status of alarms and alarm limit values. Now alarm rationalization is in the execution phase, but there is still a long way to go to reach an ideal state. This presentation details the implementation experience for both alarm management and control performance management activities at the refinery APC Implementation re-focusing on Energy Efficiency and Catalyst Life Protection Included in APC Objectives, Judita Feketeova, Slovnaft a.s.

Several years ago, APC targets in Slovnaft Refinery consisted of increasing the benefit by throughput maximisation and by maximisation of more valuable products at the expense of products with lower value. These days, due to the increasing price of inputs, cost optimization has also become an important goal. For APC this means the addition of new targets, including energy saving and catalyst life protection. Last year, an APC evaluation attracted the refinery management’s attention due to new APC target results. The furnace flue gas O2 content, reactor temperature profile, make up H2 to feed ratio and reactor severity control resulted in energy saving, H2 saving, and catalyst life protection. Although the biggest benefits of last year’s APC implementation and APC revamp projects came from traditional APC targets, the energy saving was not negligible. These results encouraged us to deal not only with reactor temperature profile control but to extend it to reactor system control, and to deal not only with furnace pass balancing and flue gas O2 content control, but to extend it to furnace system run optimization. Extension of existing APC targets by flue gas O2 content control is planned for GHCK, RHC and VGH Units. This paper compares the original APC targets with the new ones, deals with APC benefits achieved and with the extension of the existing APC to improve energy efficiency. Features and Influences Expected from Improved OTS Training, Tibor Szabó, MOL PLC This presentation outlines a new training approach being used by MOL. It will detail the main challenges that prompted the special training sessions, and the advantages of the W.H.O.M. training program. The first operator training simulator (OTS) was implemented at MOL in 2007 in the FCC unit at the MOL Danube Refinery by Honeywell. This system implementation was followed by a further seven plant models. Today we operate eight OTS systems across four plants. Additionally, a new project is in preparation. The presentation will look at effectiveness and the optimization and show what it means to “break with traditions” in OTS training. It will examine the main goals of this kind of training, and how we can hand over useful knowledge and information to trainees.






The second part gives an overview of the extended functions of the training simulator. It looks at how we can use these “hidden” functions for dealing with the optimization question; how to minimize waste and control energy consumption through well-prepared training; how we can deepen knowledge of energy efficient system utilization; and, finally, how we can minimize sources of error in setting APC parameters. Implementation of Profit Suite Applications on a Crude Atmospheric and Vacuum Distillation Complex at Petrotel-Lukoil Refinery Ploiesti, Romania, Costin Dumitrache, S.C. Petrotel-Lukoil S.A. Petrotel Lukoil Refinery has benefited from the successful implementation of Honeywell’s Profit Suite APC applications at its crude distillation complex’s Atmospheric and Vacuum Units. These units are critically important to the refinery process flow, with operational objectives determined by market conditions and directly impacting on refinery profitability. The main objectives for the APC applications were improvement of the crude fractionation, or higher yield of the most valuable products; specific energy consumption reduction; and stabilization of plant process control. All objectives have been met successfully and proved by post-audit. Honeywell’s Advanced Solutions were smoothly integrated with the existing third-party DCS, providing effective interface and control for operators. Project deliverables included four Profit Controllers covering the crude preheating section, heaters, and atmospheric and vacuum columns; one Profit Optimiser for coordinating all the Profit Controllers in a multi-unit optimization; 16 Profit Sensor Pro quality inferentials; and the Matrikon TaiJi PID Loop Tuning application. A number of challenges were tackled during the project. These included sudden changes in the water-content in the crude, as well as the crude composition, creating disturbance in the APC application. Customized toolkits linked to APC were used to minimize these effects. The APC system brings a different way operators control the production processes, so a key part of the success was to ensure the operators understand the value of the new system and accept it. This required extended training and additional intuitive information displayed at the DCS level. Honeywell’s Profit Suite APC system proved a valuable tool for stabilizing the operation of these units, pushing the quality parameters towards specifications while giving operators high confidence in the APC system. This was aided by a good collaboration between Honeywell’s implementation and Petrotel’s operations teams to drive the process to the optimum operating area. APC Solution for an Industrial Power Plant Unit, Pavel Pustejovsky, DEZA DEZA, a. s. is a producer of basic aromatic chemicals designated for further chemical use. Based in Valašské Meziřící in the Moravian region of the Czech Republic, DEZA successfully completed an advanced process control project with Honeywell at its Industrial Power Plant (IPP) unit. The project covered the Industrial Heat Plant and the Tail-gas Incineration Plant. The advanced control and optimization is handled by the Advanced Energy solution within the Honeywell Profit® Suite R410 controllers. The solution consists of the master tail-gas header pressure controller, steam header pressure controller and the boiler controllers. The solution’s main goal was the real-time economical






optimization of the tail-gas and natural gas co-firing in three boilers, the control of the tail-gas header pressure and the optimal allocation of boiler demands based on boilers' efficiency. Operating the APC has resulted in higher boiler efficiency and thus increased steam production. Furthermore, with the solution the steam header advanced pressure control can now be maintained by the tail-gas incinerator plant boilers. Smoother Refinery Plant Operation by Averaging Level Control: Comparison of Different Approaches, including Profit® Loop, Rainer Dittmar, West Coast University of Applied Sciences Control Engineering Level control systems are common within the process industries. Maintaining a vessel’s level at a set point or within desired limits is critical to the successful operation of process plants. In many cases, the level is controlled by manipulating the outlet flow rate using a variable speed pump or underlying flow control loop. The major disturbance variable is the inlet flow rate. Regarding the control objectives, one has to distinguish between tight and averaging level control: In tight level control, the level controller will be tuned to minimize the control error when subject to disturbances, without consideration of the variation in the manipulated variable. In averaging level control, the level may fluctuate freely provided it remains within user-specified upper and lower bounds. The overriding objective here is to ensure the outlet flow rate does not experience rapid variations. This is advantageous when the outlet flow is being processed in downstream units, since averaging level control minimizes inlet flow disturbances to those units and contributes to a smoother and more stable unit operation. In practice, level controllers often are not designed and tuned optimally with respect to the control objective. At the same time, different approaches to averaging level control have been developed in control theory: PI controller tuning rules specifically devoted to averaging level control; nonlinear level control algorithms, in particular error-squared control; and application of model predictive control algorithms for range control. A broader application of these concepts in industry could substantially improve plant operation. In this presentation, these three approaches are compared by simulating vessel averaging level control applications on Experion PKS and Matlab/Simulink. For PI controller tuning, different specific tuning rules have been used. The error-squared option provided by the standard PID controller function block in Experion PKS was used as a nonlinear control algorithm. The Profit® Loop controller of Experion PKS was applied for single-input, single-output model predictive level range control. Furthermore, these control strategies have also been applied and compared in an industrial-scale refinery unit at Refinery Heide/Germany. The comparisons include the performance of the closed loops for input disturbance step responses; the robustness with respect to plant-model mismatch; and the effort required in design, implementation, tuning and maintenance. Based on both the simulation and industrial application results, recommendations are given on which averaging level control approach should be used in different situations.






Implementation experiences for Experion PKS SCADA at Saudi Aramco’s OSPAS facility, Abdulmajeed Abdulhadi, Aramco The Oil Supply and Planning and Scheduling Department (OSPAS) is the nerve centre of Saudi Aramco. The group’s central control room, it oversees all oil and gas production in Saudi Arabia, tracking every drop and cubic foot in the kingdom, from extraction to export terminals. Using the system, OSPAS technicians monitor, control and plan all Saudi Aramco’s supply and distribution operations in real time across crude oil, gas, NGL, terminals, refined products and power. Highly complex, the system collects information from 44,000 real-time data points from plants, refineries, gas-oil separation plants, terminals, pipelines and electrical power operations, and displays it on the OSPAS digital wall – a massive digital screen, 70 meters wide and three meters high. Giving centralized control and monitoring of the entire hydrocarbon journey in Saudi Arabia, data is updated every 15 seconds. This presentation will detail the complexities, as well as the challenges and experiences during Honeywell’s successful replacement of the existing SCADA system with Experion PKS SCADA at this benchmark facility. Migration Planning and Execution: Forties Pipeline System (FPS) Kinneil Terminal Critical Instrument Infrastructure Upgrade, Ricky Saez, BP The BP Kinneil Terminal in Grangemouth is an integral part of the North Sea oil and gas supply chain. Incorporating three separation trains and associated gas processing systems, recent offshore projects have extended its anticipated life by up to 25 years. The Critical Instrumentation Infrastructure Upgrade (CIIU) Project saw a programme of upgrades to Kinneil automation and protective systems. The Project consists of five key upgrades: · Upgrade of the legacy TDC3000 distributed control system (DCS) to the Honeywell Experion PKS DCS with ASM Compliant HMI in a remodeled control room environment, and integration of legacy programmable electronic systems (PES)/package PLCs. · Upgrade of the legacy Triconex V7 safety instrumented system (SIS) to Honeywell Safety Manager · Upgrade of the GP-Elliott G120 fire and gas (F&G) system to Honeywell Safety Manager, and additional field devices to provide increased coverage and addition of a site wide integrated (Honeywell Digital Video Manager) closed circuit television (CCTV) system for emergency response support · Upgrade of the uninterruptable power supplies (UPS) to provide assured power to all new protective and control platforms · Enabling works to ensure the four major scopes can be implemented, including fibre infrastructure, building fabric improvements and HVAC To ensure there is no interruption to processing availability, the project has utilized turnaround (TAR) windows, process slowdowns and hot cutovers. Upon completion of the CIIU Project, the automation and protective systems will provide a safe and supportable operating platform for the extended life of the asset and future decommissioning strategies. The overall upgrade will provide the Kinneil asset with a modern system for future use and for implementing continuous improvements, where identified.






This presentation will discuss the complexities and interdependencies involved in undertaking the various upgrades while maintaining throughput and without restricting the capabilities of offshore operators utilizing the FPS infrastructure. It will also review how this migration has equipped us as an enabler for future functionality and dealt with equipment obsolescence and legacy systems knowledge. Finally, it will examine the lessons learnt that can be applied to other users’ migration strategies. Alarm Management Improvements: TPS to R400/R410, George Barr, BP BP Grangemouth FPS Oil & Gas Terminal is currently undergoing a major critical infrastructure and instrumentation upgrade covering the DCS, SIS and F&G systems. The scope of the project was to migrate the Kinneil terminal from TPS to Experion; upgrading the infrastructure and hardware; and integrating with nine other FPS Experion systems. This presentation will cover the lessons learnt and key advantages gained by migrating to the new platform. In particular, it will show that migrating all legacy systems into C300 PCDI and splitting the server databases across SCADA and PCDI provides an opportunity to reduce current standing alarms by 90%. It will also look at current plans to take all systems onto R410 under our new alarm management project, which includes buying AAM/ACM. The Story of OTS Systems in Grupa LOTOS: from Training Needs to OTS Training Center, Tomasz Bytner, Grupa Lotos S.A. It has been five years since Grupa LOTOS decided to implement its first operator training simulator (OTS) system with Honeywell. It is now using five simulators for training operators and other purposes. OTS has proven an excellent tool for training and evaluating panel operators. This presentation will provide a summary of the simulator implementation experience and share lessons learnt from the OTS projects and training practices. Future plans will also be discussed. APC Upgrades, Milosz Sabik, Grupa Lotos S.A. In 2011 the LOTOS refinery finished one of the largest investment projects in Europe, the "10+ Program" Because the newly constructed refinery units are controlled by Honeywell’s Experion system, the APC team faced the challenge of preparing a new platform for controllers based on Profit Controller release version 400 and the EAS Experion server. The decision to migrate the existing controllers was driven by the need for functionalities included in the new release. These included more useful and engineering-friendly features and tools, better visualization options for operators, custom functions, and integration with third-party Windows-based applications. Moreover, the migration was required to maintain compatibility with the new units’ controllers and to simplify maintenance procedures.






The presentation will focus on the migration process, and explain the steps taken in preparing and performing it. On the basis of the results received, it will highlights the key challenges and problems identified and advantages of migrating Profit Controller applications to the latest software release. LCN Network Split Project for TPS system of PDH/PP Plant, Dipesh Prajapati, Tasnee This presentation will detail work at Tasnee Propane Dehydrogenation (PDH) and Polypropylene Plant (PP) in Jubail industrial city, Saudi Arabia. The LCN network load in the TotalPlant® Solution (TPS) system at this plant exceeded the recommended LCN bandwidth. At the same time, High Performance Process Manager (HPM) controllers were working at the boundary of recommended processor control limits and further bulk additions of filed instruments / DCS logics are not recommended in these controllers. Following a system performance baseline study, and seeking to avoid adding to tags in the HPM, Honeywell recommended splitting the LCN network for the Propane Dehydrogenation (PDH) and Polypropylene Plant (PP) plants. Currently under execution, the project is due for completion in June 2013. The presentation will discuss the project, the challenges and lessons learnt, as well as the results anticipated. Alarm Management System: Reduced and Modified Alarms in Danube Refinery, Attila Poszmik, MOL PLC This presentation will begin by focusing on the ISA 18.2 standard and the introduction of an alarm philosophy at the Danube refinery. It details findings from the assessment of alarms in some key units, including alarm loads and floods, and shows how far these were from the limits outlined in the ISA standard. The second part summarizes the pilot alarm management (AM) project implemented by Honeywell in 2011 in the FCC unit. Following its success, another seven units are to be added to the project by the end of this year. The details of this new project, particularly in relation to the newly implemented industrial network and new possibilities, will be elaborated. Finally, the session will look at alarm rationalization techniques, and detail the results to date. This will look at the operational improvements, process alarm reductions and improvement in alarm qualities achieved, and the resulting improvements in operator intervention speeds and increased safety. Migration for Safety Equipment: An Opportunity to Build an Integrated System in Experion at REPSOL, Mario Macias, Repsol Following last year’s HUG presentation, this presentation outlines another big lifecycle project affecting all Repsol’s refineries in Spain.






In 2008, Repsol started to tackle some problems affecting safety-related systems. On the one hand, it needed to comply with various international standards and rules (such as IEC requirements); on the other, a lot of its PLC equipment was close to being obsolete. As a result it undertook an upgrade plan (similar to a life cycle management contract) to migrate all obsolete systems and others that must be replaced for certified systems based on a SIL analysis of the units. The company signed a seven year contract with Honeywell, bringing several benefits: all projects are managed in the scope of one large agreement; flexible scheduling takes into account maintenance shutdown planning; flexibility is enabled with the management of spares from old systems across refineries; a stable HWL services team is in place; and predictable pricing and better discounts are achieved for hardware supplied. This presentation will explain the main items of the contract and experiences from the first projects to be completed. A Project Execution Approach Leveraging Field Auxiliary Rooms for Staatsolie Paramaribo Refinery, Suriname, Maria Chiara Fumi and Domenico Defina, Saipem Integrated control and safety systems (ICSS) MAC project execution today demands methodologies that cut the time and costs of site constructions works as far as possible. Site specific constrains also often require minimization of civil works while installing ICSS equipment in buildings distributed across the site. The use of prefabricated Field Auxiliary Rooms (FAR) helps address such challenges, and Saipem applied this concept for the Staatsolie refinery expansion project. It selected Honeywell as the main automation contractor, including the FAR within the project scope. In this session, Saipem addresses the most common issues and benefits found in applying FAR, discussing how this solution impacts a range of areas: early room dimensioning; cable routing and cable entry size definition; HVAC and pressurization design; third party cabinet management and responsibility; insurance and custom management; field work time; and time spent on effective on-site activities.

The Business Benefits of Alarm Management Applications, Cristian Dumitrescu, OMV Petrom, Petrobrazi Refinery

Honeywell’s Alarm Management application was recently installed in our hydrocarbons processing facility. The refinery complex includes various processes, such as crude distillation, fluid catalytic cracking, naphtha-kerosene-diesel hydro treating, coker and cogeneration. The plants have state-of-the-art Honeywell Distributed Control Systems, and alarming is a major component of the operator interface. Process limits, abnormal events and disturbances are flagged using alarms and events. As a result of the significant number of alarms and the burden on panel operators we implemented an alarm management solution package.






The success of the project can be attributed to an execution approach based the objective of achieving a reduction of the alarms targeting the panel operator. Specifically, the Alarm Management application design was a joint effort between the refinery’s process control staff and Honeywell experts, from the architectural design, content definition, and communications setup up to the final reports layout. The result of this approach was an integrated solution, collecting all process alarm related events in a dedicated database, and providing standardized and ad-hoc alarm reporting facilities. This presentation shows the positive impact of Alarm Management implementation within the refinery applications landscape, the alignment with the organization’s efforts to instate a “safety-first” philosophy, the contribution to improved process disturbance rejection, and the economic benefits.

A Step Ahead Towards Enhanced Operational Readiness in Pulp and Paper Industry, Gerhard Schiefer, Andritz Automation

Andritz Automation enables pulp & paper mills globally to bridge the gap between design, delivery and production in order to achieve operational readiness — quickly, safely, reliably, and ahead of the schedule. We help our customers get the process and automation delivery,start up the plant with full operational readiness and with your own trained staff, and ramp up the production well ahead of expectations. We do this by partnering with Honeywell.

Andritz Automation has implemented a design scheme covering process and AEI (Automation, Electrification, Instrumentation) design into a multi-discipline design database. Globally established, it provides all the data for logic design fed into the simulation and automation platform (the latter being deployed on a Honeywell automation platform).

This paper will explore the Andritz Automation integrated work flow and Honeywell cooperation model, and will describe several successful implementations.

DCS Modernization Objective through Lifecycle Management (LCM) Program, Abderahmane Frih, Sonatrach Since the 1994 installation of Honeywell’s TDC 3000 DCS in Sonatrach’s LNG2 plant, many enhancements and optimizations have been adopted in response to demands for integration of new equipment into the control system, and use of new applications, such as PHD to perform process data archiving and distribution. This led Sonatrach’s management, in collaboration with Honeywell, to consider implementing a lifecycle management (LCM) project at the plant. LCM services provide a complete solution to extend the performance of the TPS system by providing a path to the latest technology. It should be pointed out that since the installation of the TDC 3000 in 1994 the control system has been through many evolutionary phases. These include installation of GUS stations, and implementation of the different release upgrades from TPS R533 in 1999 to R660.3 in 2008, along with other hardware and software solutions, such as the integration of the DOC3000 and PHD systems. LCM is implemented by a service contract that can be spread over 3 to 10 years, during which it will be possible to plan a progressive migration of the old DCS towards Experion.






This presentation shares the steps to follow for a good and safe migration of the system towards Experion using the LCM philosophy. It also shows the importance and advantages of this migration. The New Central Control Building for Al Hosn, Ahmed Ahmed, Al Hosn Gas, and Piera Scuri, Spaziodesign This presentation describes the design of a state-of-the-art control building at the new Al Hosn Gas plant in U.A.E. Shaped as a dune and covered in silver aluminium shingles, the building is the outcome of close collaboration between Al Hosn high management and Spaziodesign architects. The highly ergonomic and functional design is built around operators’ consoles. Large artificial skylights illuminate the environment, improving operators’ well-being and concentration, even during the night shifts. Ceilings and walls are clad with wooden acoustic panels to improve comfort and communication. The building features extraordinary integration of natural elements such as stones, wooden finishes and vertical gardens lit by natural sunlight with sophisticated technological systems such High Definition audio-visual communication systems, audiovisual systems, automatic switchable glass and computer-controlled lighting systems. Technological, ergonomic and architectural elements have been carefully coordinated to create an efficient and stimulating work environment in the extreme conditions of the Empty Quarter desert. Metering and Station Control 2030 in the Natural Gas Industry, Dr. Klaus Steiner E.ON New Build & Technology The European natural gas industry’s infrastructure today stretches from Russia to Great Britain, from Norway to Spain, and is expected to still be delivering sufficient supply in 250 years. However, while today most of this supply comes from Russia, Great Britain, Norway and the Netherlands, in the near future the gas industry faces seeing a far wider range of sources, increased use of LNG and decreases of low calorific Dutch natural gas. Moreover, use of renewable gases, already being injected into the gas infrastructure for distribution, is expected to increase. Overall, this means a wider variety of gas qualities, with significant consequences for energy accounting, process control, appliances, infrastructure and distribution. This presentation provides an overview on current infrastructure and expected changes, with a particular emphasis on the modifications required by renewables. Examples of biogases and hydrogen injection into the gas network illustrate the impact on fiscal metering, process control, condition monitoring and links to advanced systems such as billing. Production Balance – An Automated System For Refinery Material Balance Reconciliation: Implementation at Petrotel-Lukoil Refinery, Mikael Petukhov, Petrotel-Lukoil This presentation considers the basic principles of material balance construction in a refinery. The main challenges in achieving reliable production performance are shown, and we demonstrate that the production balance system is a powerful tool to improve the reliability of material balance reconciliation. The methods and approaches used are presented, and we will show that production balance is a powerful assistant in identifying incorrectly functioning flow meters.






The session will also describe key features of the production balance implementation at Petrotel-Lukoil refinery, and integration of production balance with other Honeywell applications. Flow Computers and Control Systems – Interface or Integrate? Allan Bryce, BP Since its development in the 1970s, the flow computer has been the cash register of oil and gas measurement systems. Initially they were developed to meet the requirements of stand-alone fiscal metering systems, in a period when customers were prepared to pay high premiums for top of the range equipment. Over time, there has been a drive to both reduce costs and make the associated data available to control systems and beyond. Between 2002 and 2006 Honeywell and Swinton Technology worked together to evaluate whether there was a practical, realistic and cost-effective alternative to traditional flow computer orientated gas and liquid systems. The conclusion was that control systems can perform such a role, and, since then, lifecycle cost benefits and many technological advantages have been identified, including those relating to condition based monitoring and diagnostic tools. This paper briefly covers the conclusion of the evaluation trials, including resultant system uncertainties, and a summary of the benefits realized by customers adopting this approach.

ROUNDTABLES topics Migration Project Experience and External Support, Jose Maria Martin, BP and Mohammed Jazeem, Honeywell This roundtable is intended to give participants the opportunity to take part in a discussion covering various aspects of migration of general interest, including (but not be limited to) project experience, and involvement of external support. We will discuss a number of questions:

• Is Honeywell’s solution for migration helping customers replace outdated hardware effectively? • Does hardware migration require a software migration as well, and what are the value

propositions involved? • What do you expect from a migration, and is Honeywell meeting customers’ requirements? • What are your experiences performing a migration at your site? • Do migrations require a turnaround, and is it safe to do it online? • What are the pros and cons of offline and online migration? • Do you think Honeywell should develop a plan for on-process controller hardware migration? • What is the importance of a risk mitigation plan for performing OPM






What is the Best Way to Design a Control Room? Do we Need to take Steps for and Consider Integration in a Unique Interface for Safety, Control and Fire and Gas Networks? Monica Martinez Iglesias, Repsol, and Erik Kouwenhoven, Honeywell The risk of error is always present when people are asked to work with a machine or complex operating system or within a highly-stressful environment. The nature of accidents causes us to constantly assess the impact of human error on system design and the manner in which equipment improves or degrades man's ability to control a process. This man-machine relationship exists at the consoles, within the information screens, in the entirety of the workstation, and throughout the environment of the control room. This roundtable is intended to give participants the opportunity to take part in a discussion and ask questions about what to take into account when designing a control room:

• Who must manage the project? An engineer, an ergonomist, or someone else? • What are others’ experiences related to this issue? • What is the impact on the process? • What aspects should be considered? • What is the maximum number of stations manageable by the operator? • Which aspects should be taken into account in building a unique interface? • How should the console be distributed? • Should access to the control room be restricted with a special card or similar method?

Alarm Management: Is There Low Hanging Fruit? Luc de Wilde, TOTAL and Tony Alexander, Honeywell Alarm management has been a hot topic for years. Ever since the introduction of DCS, operators have struggled with high numbers of alarms, which can result in incidents or even serious accidents. Everyone in the industry agrees they need to solve the “alarm problem”, and books and guidelines on the subject explain what the problem is and what we have to do to solve it. However, the “ideal” approach takes time and, moreover, requires resources – a lot of resources. So is there an easier way to tackle the problem? Is there a more pragmatic approach? We frequently hear questions from sites:

• Can’t we just do a bad actor approach? If we rationalize the 20 worst actors each month, isn’t that enough to bring alarm rates down?

• Is it really necessary to do a rationalization exercise of the complete alarm database? Can’t we just rationalize the high priority alarms?

• Can we apply alarm masking immediately, without going through a lengthy rationalization exercise?

• Can’t we just buy alarm management tools, install them and see what comes out of them?






• Can’t we just outsource the rationalization exercise, as we don’t have the resources to do it ourselves?

These questions lead into a “minimal” approach that may give some quick wins, but will not result in a reliable, sustainable alarm management system. There is low hanging fruit, but just picking it is not sufficient, and will in the end not deliver the improvement sought. Taking into account limited resources, then, how can we tackle the alarm problem in the most efficient way? And what does the ASM consortium say about it?






Documentation and Management of Change: What is the Right Way? Suneel Appan, British Sugar and Rodney Tjon, Honeywell Effective Management of Change (MOC) is a key loss prevention tool for any company seeking to avoid future losses resulting from today’s changes. The MOC process collects relevant data within a process plant, gives it context, and presents the information to personnel where and when they need it. In a typical industrial operation, however, approval procedures for major re-work do not always address specific changes within the automation layer. Most current MOC systems also tend to be either paper-based, or an electronic version of the paper-based system, and utilized in conjunction with a work order. These methodologies can result in changes being filed away and forgotten after the change has been implemented. This presentation examines the issues and challenges and details a better approach for an effective MOC process. Life Cycle Management of the Control System? Jose Maria Martin, BP and Rodney Tjon, Honeywell Typically, the expected life of equipment in an industrial installation is several decades. The technological improvements and control evolution increases continuously the requirements to the digital control system, in terms of number of signals, data communication, links, etc., which requires today continuous changes of hardware and software. For the users experience and perspective, this suppose for the control system a path of continuous movement on it, with full changing technologies, more or less, every 10 years in advanced control, and 20 years in controllers. This situation is unique, because the technological changes on mechanical and electricity industrials installations and equipment are slower than in instrumentation, automation and control. This require learning of technologies, training for design, maintenance and operations engineers, and, sometimes, a lot of creativity to be able to fit the new technologies on the existing installations, not always designed with the future in mind. And also require for the people involved on it a lot of work to follow the technological evolutions and take the proper decision for the technological movement. Most of these changes should be done with installations in full production status, and critical activities (to be done on TAR) should be planned years before, with limited information to take decisions. Also other issues related to the evolution are: spare parts management, firmware of devices, compatibility, obsolescence, software evolution, etc. This roundtable is intended to give participants the opportunity to take part in a discussion covering these and other aspects of the automation system Lifecycle; share experiences and understood what are the ways to manage this.






Maintenance Services, William Horner, SABIC and Jesus Vallejo, Honeywell A common challenge of modern automation infrastructure is how to adapt methodologies to provide an efficient support for Open Systems, against a backdrop of scarce resources and changing skills.

• How to effectively integrate support for automation platforms L1 through L4? • How can we deal with the constant technological churn of operating system evolution, software

applications and their associated platforms, in a synchronized manner that covers all automation levels?

• How does one ensure the most efficient and appropriate support that addresses all layers of the automation infrastructure, whilst maintaining optimum levels of reliability and performance?

Join us for our roundtable, an open discussion debate to see if we together can discover our mutual challenges and how we manage these. Cyber Security: Where do we draw the line? Paul Stewart, Marathon, Ahmed Haddou, Sonatrach, Mike Baldi and Frans van der Scheer, Honeywell Cyber security is increasingly important in the design, operation and maintenance of process control networks. The online world faces constant dangers, with hundreds of new worms and viruses attacking the world's computer systems each month. In the process control and automation industries, keen to provide end users with more information, tighter integration of the process and business networks provides entry points for hackers. These risks must be mitigated. A large number of commercial products and strategies protect against targeted cyber intrusions. With organisations typically facing financial constraints and resource limitations, however, a number of competing factors must be considered when developing a cyber security strategy. This roundtable session will discuss where we draw the line with cyber security. See the latest Honeywell Users Group Information: Honeywell Users Group (EMEA)




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Documents

Knowledge - Honeywell Process presentation highlights the total economic benefits to the KPPC Aromatics Complex of the APC application, showing a final predicted payback period of