ASSET INTEGRITY & OPERATIONAL EXCELLENCE EVENT

5TH TO 7TH OCT 2020

INCREASING THE RELIABILITY & AVAILABILITY OF

ASSETS WITH ASSET PERFORMANCE
MANAGEMENT(APM)
PS Moorthy
General Manager, Technical Services
OQ DS Refinery & Petrochemicals

5th October 2020

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OQ Overview
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Portfolio – 54 investments

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OQ Portfolio

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OQ, a true global Company

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 Asset Performance Management (APM)

APM enables customers to gain an

understanding of the status of their
assets and business opportunities that
will provide the
‘quickest & sustained financial return,
reliably’.

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 What is operational excellence?
Operational excellence framework
APM Leverages
Throug
on the power of
hput Revenue
Digitization
Max levers
Quality
uptime
Ops
Impact
excel-
levers
lence
People
Yield producti
vity Cost
Energy levers
efficien
cy

Technology, people competency,

Enablers
processes/ SOPs

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This is not new – the industry has been working on this for years
 Limits of traditional monitoring methods
“To reduce lost production and maintenance costs,
timely data correlation and analysis is key to
“All of these systems proactively fixing process and equipment related
generate a lot of data making issues” – Petrochem customer
it practically impossible for
site engineers to gather,
Condition Condition ERP /
correlate and analyse data to Monitoring Monitoring Work DCS Historians
predict and prevent System #1 System #2 Orders

equipment failures”
Refining Customer

• PRODUCTION, ASSET & MAINTENANCE SYSTEMS ARE SILOED

• UNABLE TO TURN DATA INTO ACTION IN A TIMELY MANNER
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APM DRIVES IMPROVEMENT

Essential to drive continuous improvement and operational excellence
• Define asset and process related KPI’s (Customers embed there site knowledge)
• Measure asset and process KPI’s continuously from unified plant data and embedded Digital
Twins
• Analyze problems thoroughly from analytics outcomes and with built-in data science tools
• Improve all asset and process related plant productivity metrics for recurring profitability gains

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Asset Performance Management

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 OQ APM Road Map
OQ has developed an operation excellence roadmap; Improving Sohar RFCC
reliability is the most urgent step

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APM REVEALS & MONITIZES

Honeywell Forge APM reveals and monetizes opportunities for:
• Maximized throughput – increased productivity from assets and process
• Reduced energy usage – greater efficiency from machinery and process
• Increased uptime – maximized machinery utilization
• Resolve hidden constraints – greater operational flexibility

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 Connected Plant Solution (CPS)
Salient Features
 24X7 monitoring of process and
critical asset condition.
 Early event detection by use of UOP
fault models
 Alert Engineers and proactively
troubleshoot issues those leading to
drop in Yield/Conversion/Efficiency

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 Process Reliability Advisor (PRA)
https://cps.accessuop.com/webapp
SCOPE
 R&R (U2000)
 Main Fractionator (U2100)
 Gas Concentration (U2200)
 Propylene Recovery (U2700)
 Critical Exchanger Fouling
 MAB, WGC, HPC – Process aspects

CURRENT STATUS
 Development Phase complete.
 Review of limits, recommendations
with UOP nearing completion
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 Asset Performance Monitor (APM)
SCOPE
 Condition Monitoring of MAB, WGC
and HPC
 Condition monitoring of respective
Turbines and Motors
 Furnace F-2002 available

CURRENT STATUS
 Ready for deployment.
 Advance Pattern Recognition (APR)
for Cat Coolers failure initiated,
development will continue during
contract period
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 Control Performance Analytics (CPA)
SCOPE
 APC Monitoring – RFCC & PRU
 Economic evaluation of Lost
opportunity

CURRENT STATUS
 Ready for deployment.
 PI Tags for Dynamic product price to
be incorporated for realistic dollar
value lost calculations

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APM What This Could Do?

APM observed outcomes:
• Break-through improvements drive fast recovery of APM investment (avg. break-even <1 year)
• Recurring annual savings of $2-3 MM in small and $7-30 MM in larger deployments
• Over 100 installations and over 50,000 assets monitored globally
• Continual delivery of new operational intelligence and process improvement opportunities
• Recognition of universal improvements for replication across multiple sites

Customer Value
Increased Increased
Increased Asset Reduced
Operating Safety
Utilization Maintenance
Efficiency

• Predict failure, reduce • Reduce preventative • Energy monitoring • Minimize risks by ensuring
unplanned downtime & maintenance expense reveals hidden loss normal and stable
minimize equipment • Analytics estimate time sources to show operations
secondary damage to extended period to opportunity to reduce • Eliminate production
energy costs stops for safety Care
• Increase process overhaul system Share Dare
throughput verification
 Benefit of Honeywell CPS for OQ

Could Potentially Increase margin by $3-5m/ year!

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Typical Industry Savings with APM

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 Asset Performance Management Takeaways…

APM is ‘Powerful’ Tool, leveraging on ‘Digitization’.

 Data is ‘Power’, only if we maximize the usage!

Data Mining & Big Data can bring value here and now!

Every business is unique! Understand the value drivers & priorities!

Move away from “On-Demand” reactive to “On Purpose” proactive.

Partner with Licensor to drive towards maximizing margins in a reliable and

sustained manner!!!

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Thank You….

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