Electric Corporation Continuous value creation for customers Define potential improvement areas Perform safe and stable operations Design and deploy solutions Maintain value creation cycle Identify Create & Implement Operate Sustain & Improve Business & Domain Knowledge in Process Industry OT-IT Solutions in Industrial Automation Best-in-class automation technology Leading simulation technology Strategic consulting + + 4 Co-Pilot Profit-driven Operation
Electric Corporation An expert always by the client’s side 6 Client has hands on the controls KBC as a 2nd pair of expert eyes Just as the co-pilot of an aircraft is there to assist the pilot with additional knowledge and to step in and help at times of intense activity, KBC’s Co-Pilot is there to remotely support an asset with expertise and insight supplementing the asset’s own capabilities and resources, thus assuring that it achieves its full potential.
Electric Corporation Unit performance assurance Co-Pilot 7 AP Plant Cloud Data Center Historian PIMS -Login -Home Historian PIMS DCS/MES Performance dashboard on the browser KBC/Yokogawa Data as a Service • Web*Technician –secure mirroring of unit data • Petro-SIM, SIM Reactor Suite –rigorous simulation of unit operation • LP unit sub-models –coordination of planning models and simulator • UMT –data validation and reconciliation for auto-fit of model to plant data Expert Services • IT networking and security set-up and monitoring • Web-based dashboard design and configuration • Model building and calibration • Process analysis and insight • Practical recommendations • Value and action tracking -Unit performance This window displays three different types of gross unit revenue, showing the actual measured value, the potential value simulated by the process simulator, and the planned value as calculated by the LP unit sub-model. -Unit overview -Product yield trend
Electric Corporation Case study at Coker unit -Issues 8 Units fail to attain full value due to 3 factors Upsets, which reduce availability, throughput or yield Sub-optimum operation - below target or plan Sub-optimum plan/targets which is often a ‘hidden’ loss as no-one sees the missing potential Co-Pilot repeatedly assures performance in 3 ways Faster response to/recovery from upsets Identify impending issues and resolve them before operation becomes constrained – remaining on plan Identifies improvements and improves plans and targets to realise more value Plan/Target Actual upset Sub-optimum Improved Target Plan/Target Without Co-Pilot With Co-Pilot Unit Performance Without Co-Pilot Unit Performance With Co-Pilot 1 2 3 Value $$ Value $$
Electric Corporation Case study at Coker unit –Faster response to upsets 9 See Issues Sooner Dashboards and Alerts cut through mass of data to identify areas of value loss KPIs clearly linked to value and tasks Reduce Analysis Time Automatically up to date calibrated simulations and mass balance provided to customer engineers via co-pilot system to aid diagnosis No Waiting for Engineers to Arrive KBCs global network provides insight and analysis before the site engineer gets into the plant Broad and Deep Expertise Available Advice from leading experts to supplement internal expertise to diagnose the problem faster and recommend solutions proven elsewhere Faster Resolution See Issues Sooner Mass Balance & Simulation Ready to go Support From Other Time Zones Expert Diagnosis & Solutions Case Study: Middle East Coker Fractionator • Limitations in overhead cooling compromised separation efficiency • Recommendations to modify pumparound duties reduced HCGO/HHCGO overlap from 120 F to 40 F • Generated benefits of approx. $3m per year Reducing off-plan time Cokerのmain fractionator のトップのガスをH/Eで冷まして液にして出す クーリングの制約から、処理量増やせないか圧力下げられない（キレをよくでき ない） Heavy Coker Gas OilかHeavy Heavy Coker Gas Oilが入っているのをポン プアラウンドを増やすことで温度下げている
Electric Corporation Service offerings 10 Technical Building Blocks Technology forms the foundation for Co-Pilot Services: • Web*Technician • Cloud Data Hosting • Simulation Models • Daedalus Dashboard Reactive Service: Model Performance Assurance Ensure input data is correct, model is calibrated and outputs are sensible. Interpretation and assessment by the client. Proactive Service: Monthly Assess performance vs business goals and track profits delivered. Identify and elaborate strategy changes and improvement projects. Proactive Service: Weekly Assess performance vs plan and evaluate unit plan accuracy and lost opportunity – issues and trends requiring engineer investigation or maintenance planning. Proactive Service: Daily Assess operational performance vs plan and constraints – short term actionable recommendations.
Electric Corporation Automation Co-Pilot (to be released) 11 AP Plant Cloud Data Center Historian PIMS -Process alarm -Sensor -Control valve -Manual intervention -Graphic -MOC (DCS parameters) -Advanced Process Control -PID Control -SIS/ESD -Online Analyzer Historian PIMS DCS/SIS Performance dashboard on the browser KBC/Yokogawa Data as a Service • Web*Technician –secure mirroring of unit data • CEA, Exaquantum/ARA • MDpro • AMADAS Expert Services • Sensor maintenance/update • Analyzer maintenance/update • PID parameter tuning • APC capability transfer • APC model update • SIS capability transfer • SIS update • Alarm system design • Alarm rationalization • Procedure automation • Ergonomic graphic design Specifications are subject to change without notice
Electric Corporation Customers’ challenges for more profitable operation 13 Conflicting KPIs can create waste $5-15M per year more profit in Operations! C-Suite KPIs are not connected DCS Big Data is not fully utilized Experience and competency are declining What if KPIs could be structured systematically to unify all the employees’ capabilities and motivate them?
Electric Corporation SPIs based on domain knowledge and DCS big data 14 Drill down on SPI issues related to Engineering or Operations Contribute to management SPIs Synaptic Performance Indicators (SPIs) unify vertical organizations 93 Daily SPI 357 Hourly SPI Production cost Margin Energy cost Maintenance cost Yield or Quality Optimizer performance Energy consumption Availability ESD triggers Incidents Production Profit Reliability Energy Safety Control performance Process performance Furnace efficiency Asset performance Critical alarm 377 Real-time SPI Operations Management Engineering 12 Daily SPI 32 Hourly SPI 77 Real-time SPI Refinery Ethylene Profit-driven Operation on DCS Co-Pilot on cloud Co-Pilot on cloud Specifications are subject to change without notice
Electric Corporation Seamless operation using synaptic dashboard 15 Shift-basis Karaoke-type Dashboard SPI Dashboard with Expert Advice • Operators understand the pattern of own operation • Operators can be motivated to better operation • Operators drill down on reasons of low score • Managers analyze the balance of different objectives • Managers identify improvement opportunities • Senior Operators can take agile action based on alert and expert advice • Managers can avail benefits of benchmarking, root cause analysis and expert consulting for continuous SPI improvement Energy -Hot Crude Preheat Inlet Temperature (1) Operator to check the process conditions of the preflash drum or prefrac, if applicable (2) Ensure that exchanger bypasses are adjusted appropriately. Also, if multiple trains ensure flow is properly balanced (3) Discuss with shift supervisor and, if necessary,escalate to Process Engineer Specifications are subject to change without notice
Electric Corporation Continuous value creation for customers Define potential improvement areas Perform safe and stable operations Design and deploy solutions Maintain value creation cycle Identify Create & Implement Operate Sustain & Improve Business & Domain Knowledge in Process Industry OT-IT Solutions in Industrial Automation Best-in-class automation technology Leading simulation technology Strategic consulting + + 16 Co-Pilot Profit-driven Operation
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