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Oil

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Title: Oil


1
Oil Gas Operational Excellence
Not an official UNCTAD record
  • 8th Africa Oil Gas Conference
  • Morocco 2004
  • Phil Millette
  • Oil Gas Industry Consultant
  • Honeywell Process Solutions

2
Agenda
  • Introduction
  • Oil Gas industry drivers / challenges
  • What is Operational Excellence?
  • Solution components Customer Examples

3
Company Overview
  • 108,000 employees in nearly 100 countries
  • A Fortune 100 company 23 billion sales in year
    2003
  • One of 30 select companies represented by the Dow
    Jones Industrial Average
  • On Money magazines list of 75 Best Benefits
    companies for the third consecutive year
    December 2003
  • Winner of the Technology and Business Vision
    Award from Start magazine and Microsoft, and the
    Control Engineering Editors 2003 Choice Award,
    for Honeywells Experion PKS system, an
    integrated solution that boosts manufacturing
    capacity and cost effectiveness.

4
Honeywells Business Segments
2003 Sales
Total 23B
Broad and Diverse Businesses, Technologies and
Products
5
Automation and Control Solutions
  • Businesses
  • Honeywell Fire Solutions
  • Honeywell Sensing Control
  • Now also including Honeywell Sensotec
  • Honeywell Environmental Combustion Control
  • Honeywell Building Solutions
  • Honeywell Process Solutions
  • Products
  • Controls for heating, cooling, ventilation, air
    conditioning, humidification, industrial process
    automation, video surveillance, people and asset
    tracking and access control equipment
  • Security/fire alarm and industrial safety
    systems, home automation systems
  • Advanced software applications for home/building
    control and industrial optimization
  • Sensors, switches, control systems and
    instruments for measuring pressure, air flow,
    temperature, electrical current and more
  • Drinking water solutions
  • Combustion control solutions
  • Commitment to service
  • Global Presence
  • 40,000 employees in 100 countries
  • Headquarters Minneapolis, Minnesota
  • Sales --- 7.5 billion in 2003

6
Evolution of Honeywell Automation Technology
Safety Manager PKS
FSC
_at_ssetMax
Asset Manager PKS
Consistent Evolution for Customer Investment
Protection
7
Experion PKS Process Knowledge System
Honeywells Process Knowledge System expands the
role of an automation platform to address all of
a companys critical business objectives.
Experion PKS combines best-in-class technologies
of existing Honeywell systems and emerging new
technologies to provide customers with an
enterprise-wide automation solution.
8
Solutions for the whole Oil Gas Supply Chain
Exploration
Upstream Processing
Production
Markets Customers
Transportation
Storage
Onshore Oil
Offshore Oil Gas
Gas Processing LNG Liquefaction
LNG Regasification and Storage
Gas Pipelines
Drilling
Power Generation
Natural Gas Distribution
Gas Plants
Gas Terminals
Gas Pipelines
LNG Carriers
Chemicals
Offshore Production Platforms
Petrochemicals
Oil Gas Pipelines
Oil Gas Plants
Oil Terminals
FPSO
Refining
Deep Water
Oil Tankers
Oil and Gas Pipelines
Oil and Gas Separation Treatment / Processing
Offshore Gas
Oil and Gas Separation / Processing / Storage
Drilling
9
Examples - Honeywell Oil Gas Experience
Amoco Trinidad Offshore Platform LNG Plant
Kazakhstan Well Field / Fractionation
British Petroleum Well Field
Over 15 Major North Sea Platforms
Atlanta Gas Light LNG Plant
Tarim Oil Field
Tuha Oil Field
British Petroleum Marine Terminal
customer Gas Plant
Petronas Gas Plants
Amoco Texaco Exxon Conoco Gas Plants
EPMI/Petronas Platforms
Chevron Oil Field
Pemex Gas Fractionation
Woodside Petroleum LNG/Platforms
Corpoven Gas Fractionation / Marine Terminal
Sonatrach LNG Plant
India Oil Pipeline
AGL Pipeline
BP Gas Metering
Aramco Production Projects
Chevron Escravos
Shell Pipeline
Sasol
Dukhan Oil Field
AGIP Amerada Hess Aramco Ashland British Gas
Dakota Gasification Diamond Shamrock Dome
Petroleum ELF El Paso Natural Gas
British Petroleum Britoil Botas Chevron Corpoven
Enron Enterprise Exxon/Esso Kuwait
Oil Mobil Marathon
Statoil Sun Texaco Total Transok Woodside
  • Northwest Pipeline
  • Occidental
  • Petronas
  • Phillips
  • Shell

10
Oil Gas - Offshore production References
  • Honeywell controls offshore platforms and FPS in
    all worldwide regions
  • North Sea (UK and Norway)
  • Middle East
  • Australia
  • Southwest Asia

Selected FPS References -Hydro Troll Olje /
Norway- Semisub. -Texaco Captain / UK
FPSO -Woodside Laminaria / Australia FPSO -Esso
Jotun / Norway FPSO
  • West Africa
  • Gulf of Mexico
  • Caribbean
  • Recent EMEA Offshore Projects
  • Shell Shearwater, North Sea
  • Mobil Galahad, North Sea
  • Amerada Hess Scott, North Sea
  • Shell Brent, North Sea
  • Chevron Escravos, Nigeria
  • Chevron Robertkiri, Nigeria
  • Statoil Kvitebjorn, Norway
  • Esso Ringhorne, Norway
  • Veba Hanze 2, The Netherlands
  • ExxonMobil Skene/UK
  • BP Clair UK / FEED
  • Dong Naturgas Torup, Denmark

11
Honeywell Oil Gas Installations
  • 1 Offshore w/ 100 Platform and FPSO Projects
  • Norsk-Hydro Troll, Texaco Captain, Chevron Alba,
    Esso Jotun, ConocoPhillips Bacton, BP GOM, Shell
    Expro, ConocoPhillips
  • 1 Onshore w/ 77 Projects
  • Tazhong IV, Chevron Kutubu, Amoco Pine Creek,
    BP Badami, Tengiz Chevroil, Karachaganak, Exxon
    Chad, Aramco
  • 1 in Gas Processing w/ 94 Gas Plants / LNG Jobs
  • Shell Brunei, ARAMCO Safaniya, Adco,
    ConocoPhillips Bacton, Phoenix Park, Exxon King
    Ranch
  • 1 in Transportation w/ 65 Pipeline, 75 Terminal
    Projects
  • ConocoPhillips Blue Ridge, Duke Energy - gas
    transmission
  • BP Forties, CNPC - crude oil, Shell / Petronas -
    refined products
  • Sonatrach LNG Export terminal, Aramco Crude Oil
    Terminal, Petronas Melaka truck terminal

12
Honeywell Integrated Oil Gas Solutions
Operational Excellence Solutions
Asset Management Security Solutions
Oil Gas Process Production Management
Solutions
Transportation
PRODUCTION TERMINAL
ONSHORE GAS/OIL FIELDS
Improved Performance Lower OPEX
Business metrics Best practices
GAS PLANT
Processing
OFF-SHORE PLATFORMS
Production
SCADA / DCS Safety, Security Systems
Field Instrumentation
13
Oil Gas Operational Excellence
  • Performing at best-possible state
  • People
  • Assets
  • Process
  • Business
  • With the equipment, assets, production
    configuration we have today
  • From minute-to-minute, hour-to-hour, day-to-day
  • For improved management of
  • Safety,
  • Reliability,
  • Security,
  • Process production performance optimisation,
  • Production management

14
Industry Drivers Operational Performance
  • Looking to produce reliably, consistently,
    optimally
  • But managing support costs
  • And lowering engineering costs
  • Using more consistent approaches across assets,
    supportive tools
  • But wanting increased visibility of processing
    facilities/ asset capability, reliability
  • More data collection, interpretation and
    communication
  • More rigorous analysis and follow up, optimise
    the operations
  • Looking to replicate use of best practices
  • Accumulate and manage knowledge on new operations
  • Maximizing production given short term equipment
    capability
  • Lowering lifting costs
  • Developing and bringing online additional similar
    facilities based on the knowledge gained
  • Safety
  • Security

15
Operating Excellence Achieving Optimal asset
performance
Flexible real-time technology must support the
operational business processes
Business Management
Advanced Analysis tools
Optimization
CMMS
Approach Decision Support Diagnostic for
Integrated Teams
APC
Operator
Maintenance
Asset Diagnostics
DCS/ESD Regulatory Control
The Future? In use now!
Remote expert diagnostic from support center
Security
Process Sensors
Process Asset Sensors
onshore offshore production
16
Operating Excellence Challenges
Focus on more production, more reliability, more
safety
17
Honeywells approach
  • Honeywell looks at all Oil Gas operational
    Business Processes
  • Provide solutions that are focused on enabling
    the day-to-day, hour-by-hour decisions
  • Including closed loop response capability where
    appropriate and possible
  • Minute-by-minute events activities
  • Not focused on the drilling business processes
  • Not focused on detailed reservoir/petrophysic
    part of oil gas asset management
  • Knowledge of
  • Automation safety
  • Process
  • Advanced Control
  • Asset Management
  • Production Management
  • Security
  • IT / Integration Expertise

18
Figure from POSC SmartFields meetings Loop
Characteristics (Shell)
cycle time
Field Development
production optimization
Reservoir Surveillance
production operations
subjectivity uncertainty complexity
Enable Ease of information exchange to reservoir
surveillance function
organizational scale
19
Oil Gas Operations Excellence Solution Map
Reservoir Management
ERP
Decision Support
Enterprise
Production Summary
Enterprise Integration
Operations
PCC Rich Client Thin Client
Production Management
Well Test Manager
KPI Manager
Production Report
Operations Management
Regulatory Reporting
Production Event Analyst Shift Report
APC Optimization
Asset Management
Operator Effectiveness
Experion, Plantscape TPS
Pipeline Leak Detection
Intelligent Choke Cntrl
Metering Report
Security
Integrated Field
Safety Valve Scout
Safety State
Field
Shut Down Analyzer
All the components to achieve Operations
Excellence
20
Operational Excellence Solutions People, Business
  • Production Control Center (PCC) enables improved
    decision making Improved visibility of
    facilities
  • Installations on Statoil Kvitebjorn, Norsk Hydro
    Troll B, BP Ula, BP Valhall, ChevronTexaco Alba,
    Talisman Gyda
  • Consistent management work practices
  • Helps operators, managers focus on the real
    issues find / focus on bottlenecks to improve
    production and manage important safety issues
  • Single environment to manage all operations work
    related tasks
  • Assign causes for production deferments
  • Includes safety valve scout, shutdown analyzer,
    production event analyzer, Well test Manager
  • Integrates production, process, safety, asset and
    work flow information together
  • Designed for Collaborative work, improving work
    practices, such as reducing routine work load
  • Matches the vision of major oil companies
  • Is the overall framework enabling new value to be
    captured from even existing historians
  • Use from any web page

Safe and Efficient operations It's like having
the best operator on every shift
21
Operational Excellence Solutions People, Business
  • Available functions / applications/ reports with
    PCC
  • Production Overview advanced form of report and
    display
  • Production Reporting
  • Well Test Manager
  • Production Balance
  • Production Allocation
  • Metering Reports
  • Lab, chemicals, Emissions tracking
  • Operations Monitoring KPI - Manager
  • Flexible Shift Reporting system
  • Production Event Analyst
  • Weather Information
  • Load Stabilisation
  • With a partner
  • Pipeline Management, including multiphase
  • With Fantoft as pipeline management partner

22
A Typical Control Room Screen
Proprietary and Confidential
23
Oil Gas Operations Excellence Solution Map
Reservoir Management
ERP
Decision Support
Enterprise
Production Summary
Enterprise Integration
Operations
PCC Rich Client Thin Client
Production Management
Well Test Manager
KPI Manager
Production Report
Operations Management
Regulatory Reporting
Production Event Analyst Shift Report
APC Optimization
Asset Management
Operator Effectiveness
Experion, Plantscape TPS
Pipeline Leak Detection
Intelligent Choke Cntrl
Metering Report
Security
Integrated Field
Safety Valve Scout
Safety State
Field
Shut Down Analyzer
All the components to achieve Operations
Excellence
24
Operational Excellence Solutions Assets
  • Asset Management Solutions enables path to Best
    Practice AND lowest cost reliable Oil Gas
    Operations
  • Overall
  • Improvements due to 3-5 increase in production
    reliability increase in throughput
  • In some markets, savings in cost 1M-2M due to
    staff effectiveness reduction in maintenance
    cost
  • Large installation on Pemex Cantarell
  • Lower deferred production from fewer trips and
    unplanned shutdowns
  • Lower maintenance cost through better real time
    follow up of equipment performance
  • Transmitters, valves, process equipment,
    exchangers, vessels, pumps etc
  • All plant assets can be tracked by Asset Manager
  • Catch Abnormal Situations early!
  • Alarm Configuration management, Early Even
    Detection

Reliable means more production, lower cost, more
safety
25
Operational Excellence Solutions Assets
  • (2) Asset Management Solutions enables path to
    Best Practice AND lowest cost reliable Oil Gas
    Operations
  • Through TurboSuite Better follow-up of
    turbo-machinery performance due to advanced
    real-time performance tracking
  • Lower cost of work order generation automatic
    links to ERP systems
  • Safety Valve Scout Shutdown Analyzer Lower
    cost of safety system tests obtain business
    value from analyzing actual shutdown / safety
    system performance.
  • Opportunity to foster joint work teams
    maintenance and operations
  • Alert Manager Better engineering and management
    response due to quicker notification of alerts
    issues and potential problems, using automatic
    email, SMS etc messaging.

Reliable means more production, lower cost, more
safety
26
Solution Components
  • Asset Effectiveness
  • Early, rich diagnostics per type of equipment
  • Including partnerships with 3rd party equipment
    suppliers
  • Diagnostic knowledge with the equipment itself
  • Automate work processes
  • Wireless field work support
  • Calibration support
  • Compressor / rotating equipment monitoring
  • Control Loop monitoring
  • Links to CMMS, documentation
  • Safety Management Reporting
  • Checking Shutdown systems
  • Safety Valve monitoring
  • Safe management of the Alarm system
  • Remote Management
  • Example Solutions
  • Web-framework for oil gas operations and
    production management

27
The Asset Manager PKS responding to faults
Fill out a work order
An action has many different possibilities
Send a page ...
Clicking on the advised action can trigger an
action--in this case a work order
Or an email...
Or run a program
28
Asset Manager as the key real-time notification
and work flow platform
Usable on any facility, whatever the automation
platform
Notification
via all
Collaboration
methods, including
Documentation,
and Impact
Experion Alarm
Information
Assessment
interface
Field Entry, View
Asset Manager
Asset Management
Collaborative Control Center
IntelaTrac PKS
PKS
Scouts
Safety
Loop
Turbo
Profit
Data
HART
Shutdown
APC Scout
Valve
Scout
Suite
Sensor
Scout
FF
Analyzer
Scout
APC Apps
Safety
All
Experion
OPC
Rotating
All
Virtual
Valves
Loops
Valves..
PKS
The plant is more than the sum of the instruments
29
Automating Safety Management Reporting
  • For offshore installations safety is crucial
  • Safety Equipment like Safety Valves must be
    monitored
  • Safety Systems like ESD / PSD, Fire protection
    systems etc. have to be regularly controlled
  • The Regulatory Agencies (government) requires
    regularly reports
  • Safety Management Reporting is time consuming for
    offshore personnel
  • Integrated with Asset Manager PKS, open
    software-enabled Safety Management can
  • Standardized Work-processes
  • Continuously Monitored Real-time
  • Remotely Managed

Enables More Effectiveness of Offshore Staff
30
Shut Down Analyzer
  • Analyze events after a ESD / PSD
  • Compare the events with the Cause Effects
    Matrix
  • Report the result of the comparison
  • Web based HMI
  • Benefits
  • Early detection of ESD / PSD failure
  • Simplify safety reporting

31
Safety Valve Scout
  • Analyze all events related to safety valves
  • Reports for all valves
  • not been operated
  • failed during operation
  • long travel time
  • Connection to Alert Manager is planned
  • Output from Valve verification becomes a symptom
    for each valve in Alert Manager
  • Alert Manager fills inn notification / work order

32
Well Test Manager - Sample Displays
Well Testing - test and flow details,
flow/pressure curve, test times
33
Oil Gas Operations Excellence Solution Map
Reservoir Management
ERP
Decision Support
Enterprise
Production Summary
Enterprise Integration
Operations
PCC Rich Client Thin Client
Production Management
Well Test Manager
KPI Manager
Production Report
Operations Management
Regulatory Reporting
Production Event Analyst Shift Report
APC Optimization
Asset Management
Operator Effectiveness
Experion, Plantscape TPS
Pipeline Leak Detection
Intelligent Choke Cntrl
Metering Report
Security
Integrated Field
Safety Valve Scout
Safety State
Field
Shut Down Analyzer
All the components to achieve Operations
Excellence
34
Operational Excellence Solutions Process
  • APC (Advanced Process Control) and Optimization
    technologies boost Production, providing a direct
    Revenue Increase
  • Honeywells APC and Optimization have repeatedly
    been used to increase Production and Reduce Cash
    Costs.
  • Can increase production by 2 to 10 depending on
    current conditions
  • Intelligent Choke controller
  • Flexible control able to smooth impact of slugs
    by manipulating choke valves.
  • Reduces trips due to smoother resulting level
    control in high pressure separator.
  • Documented cases on Shell platforms
  • Multivariable control Profit Controller
  • Mature technology
  • Proven in oil gas, onshore and offshore
    applications
  • In one recent case, increase was 6000 bbl/d.
  • Also documented cases on BP Ula platform,
    Woodside
  • Optimisation Gas Lift and field wide
  • Coordinating multiple controllers for optimal
    performance
  • Enhanced optimisation by modeling from sand face
    to surface, through gathering network and gas
    lift. with partner EPS.

APC provides proven value in oil gas!
35
Field Optimization Network
Manifold
iDO Well, Pipe Network, Facilities
Well Choke Valve
Field Pump
Profit Optimizer
Gathering Compressor
Profit Controllers
UNIFORMANCE
SCADA
Oil
Gas
Facilities
36
Integrated Field-Wide optimisation Closing the
loop with Multivariable Control
PVO OBJECTIVE FUNCTION PRODUCT VALUES, ENERGY
COSTS
Profit Optimizer MV Control coord
Profit Controllers (RMPCT)
MULTIPLE CHOKES MV CONTROL
SEPARATOR 1 MV CONTROL
SEPARATOR 2 MV CONTROL
GAS LOOP MV CONTROL
Wells, Separators
37
Additional areas covered by Honeywell
  • Operator Training simulators
  • High fidelity
  • Platforms, gas plants etc, as well as LNG
  • Shell, BP as major customers
  • Business integration
  • Large project capability
  • Experience at Nodco, Statoil, others
  • Integration to SAP via Business Hiway
  • Implementation of SAP via partner
  • Experience at Sasol
  • Implementation of Maximo Maintenance system
  • Improved Production Site, Plant platform
    security
  • Honeywell security solutions include perimeter
    protection, Honeywell cctv cameras, Access
    control, Personnel on Board
  • Implement and link in 3rd party marine or other
    harsh service cameras
  • Central Management capability country wide
  • DVM Digital Video Manager
  • TemaLine Access Control
  • Integrated, unique real-time monitoring platform
    EBI.
  • Including Caspian Pipeline consortium, Shell,
    Spanish nuclear plants, Dubai airport, Sydney
    Olympics

38
Oil Gas Operational Excellence conclusions
  • Its achievable now
  • Technologies exist to support integration of
    safety, reliability, process and business
    management as well as security of facilities
  • Benefits are real in increased production,
    reduced lifting costs, improved reliability and
    safety
  • Does not require a capital project to get started
  • Is not dependent on the underlying automation
    platform
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