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Digitalization assuring your plant achieves its full potential Larson

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digital applications and capabilities needed to achieve operational excellence: applications and capabilities that derive their value from knowledge of how the plant has operated in the past combined with its current and future potential; and an actionable optimum path to achieving and sustaining that potential.

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Digitalization assuring your plant achieves its full potential Larson

  1. 1. 1 Digitalization: Assuring Your Plant Achieves Its Full Potential Mel Larson LARTC 2019 1 - 4 October 2019 | Cartagena, Colombia
  2. 2. KBC BELIEVES IN A WORLD OF: 2 No safety incidents No unplanned outages Rigorous adherence to operating plans Nimble response to market changes and plan disturbances A culture of profitability A motivated and informed workforce Proprietary Information © 2018 KBC Advanced Technologies plc. All rights reserved.
  3. 3. 3Proprietary Information 3 Digitalization... A key strategy for the pursuit of operational excellence The scalable application of the digital technologies, and alignment of the organizational capabilities that we believe an energy or chemical process operation should have and master with digital information at the core in order to achieve excellence.
  4. 4. 4Proprietary Information Context– Competitioncontinues
  5. 5. Proprietary Information Africa 73,000 BPD 0.7% Context- RefinerySizeandAvgYearlyAddition North America 150 KBPD 2.2% FSU 130,000 BPD (-1.5%) Middle East 162 KBPD 1.0% Europe 137 KBPD 1.0% Asia 189 KBPD 2.6% Latin America 91 KBPD 1.0% Asia has largest absolute regional CDU capacity and has grown fastest since 1996 Bubble size approximates average regional CDU capacity Data: Oil & Gas Journal 10
  6. 6. Proprietary Information © 2018 KBC Advanced Technologies plc. All rights reserved. Operations Management Automation Production Management Business Management LossesDue to Uncertainty Reduced Remaining Competitive Requires Change Digitally wise decision-making cycle compressed DecisionValue SECONDS Ago MINUTES Ago HOURS Ago MONTHS Ago SECONDS Ahead MINUTES Ahead HOURS Ahead DAYS Ahead MONTHS Ahead DAYS Ago NOW Decision-Making Time Horizon Decision Impact Time Horizon Proprietary Information © 2018 KBC Advanced Technologies plc. All rights reserved.
  7. 7. Shift Supervisor Unit Supervisor Operations / Maintenance Managers Plant Manager Key elements top to bottom… Data acquisition is transparent Data analytics open to all Procedures in place to take action Driven to profit safely and reliably Operations / Maintenance
  8. 8. 8Proprietary Information Managed performance Specificcharacteristicsset apart leadersandlaggards Strategic Intent Operational Design Management Focus Required Enablers Supporting Infrastructure Targeted Outcomes Risk Minimization Reliable Profitability Quality / LEAN Production Maximize Asset Value Focus on basics VULNERABLE Business process Process integration STRUCTURED Performance optimization DISCIPLINED Business Growth INNOVATIVE Stability Productivity Operational effectiveness Continuous improvement Agility Built baseline Developed bench strength Sustained endurance Capability resilience Capability generation Orphaned tools Point solutions ERP Automated workflow Artificial intelligence Loss minimization Positive cash flow Repeatable results Predictable results Sustained value creation OpX 1.0 OpX 2.0 OpX 3.0 OpX 4.0 ACCEPTING Bottom 25% Top 1% Increasing Maturity Upstream Oil Exploration PetroChem Industry Refining
  9. 9. 9Proprietary Information ProcessSimulationhelpstheareasthat prevent a plantachievingit full potential Unit Upset Troubleshoot Identifies sub-optimal performance Improves plans and targets Actual Plan Set by LP Petro-SIM Simulation
  10. 10. 10Proprietary Information Plantsunderstand thevalueof rigorous simulation Most simulators are not an up to date representation of the plant or do not connect to historian for their “As-Is” data 10Proprietary Information
  11. 11. 11Proprietary InformationProprietary Information Plant staff often don’t have the time nor priority to use simulation tools The world is not perfect, so time is necessary to reconcile simulations versus actual versus planning Reporting and “fixing” often multiple person task and never easy Time is better spent on actionable items 11Proprietary Information
  12. 12. 2 Proprietary Information  Aligns with and drives business data model  Sophisticated analytics  Only create one DIGITAL TWIN Slightly different representations of the same thing When one changes, so should the other HISTORIAN DATA AND PROCESS SIMULATOR KBChaveintegrated Petro-SIMandOSIsoftPI 1
  13. 13. 13Proprietary InformationProprietary Information A Digital Twin goes beyond traditional simulation Traditional Simulation Particular operating case A snapshot in time Ad-hoc basis to answer a question Owned and used by isolated groups Specific tools for different silos Digital Twin Full range of asset operation Full history and future Automated to business workflows Centralized single version of the truth, used by everyone Single integrated twin of process, utilities and heat exchange systems
  14. 14. 14Proprietary Information 14 Co-Pilot: Fusion of digital excellence and human excellence
  15. 15. CaseStudy: DCUat Established USGulf Coast Refiner 15Proprietary Information Co-Pilot Opportunities identified: $8million in 6 months Alwaysavailablerationalizedandcorrected unitmaterialbalance. Connectivityofyieldaccounting,unit performance,productionplanningand processgroupsandtechnology Advancedanalyticshelpedincreaseuptime ofkeyprocessequipment
  16. 16. 16Proprietary Information Securely Monitors RecommendationsReal-time Reporting CollaborationPortal
  17. 17. 17Proprietary Information BasisisinData-as-a-Service(DaaS): Makingrealtimesingleversionaccurate datacollaboration possibleallowingcorrectdecisionstobemadefaster. Aggregates, rolls up and analyzes in a flexible centralized Data Source Real time connectivity for your data sources Visualized and presented in line with engineering expectations to whoever needs to see the data Proprietary Information 17 Powered by The Cloud
  18. 18. Proprietary Information © 2018 KBC Advanced Technologies plc. All rights reserved. • Collaborative and smart • Digital twin… with teeth • Automated (almost everything) • Safety through transparency - No ‘black box technology’ 18 • Outcome-orientation • Holistic in scope • Fusion of technology and expertise • Responsive and adaptive – Leading edge, not bleeding edge KBC’s Digitalization philosophy Being ‘digitally wise’ Proprietary Information © 2018 KBC Adv
  19. 19. Proprietary Information Becomingthedigitallywise February 7, 2020 19 OperationalExcellenceBusinessConstruct Innovative Vulnerable Orphaned Tools Accepting Point Solutions Structured ERP Disciplined Automated Workflow Fragmented Structured Integrated Services Consolidated Services Seen as a Utility Manual Automated OT/IT Converge Inconsistent Manually Verified Data Backed Open Loop Closed Loops Digital Components Data Collection Decision Support Infrastructure (IT Backbone) User Capability Technology Organization Hero’s Reactive Process / Preventative Proactive Discontinuity of Data Flow Enterprise Configuration Front to Back Integration Industrial Internet of Things Industry 4.0 Predictive Operations model transition point Artificial Intelligence Non-User Tech Savvy Gamers Developers Hackers Suggestive Predictive Business Process Risk Minimization Reliable Profitability Quality / LEAN Production Maximize Asset Value Business Growth Strategic Intent
  20. 20. 20Proprietary Information Digital Twin is just one part of the Digitalization journey SITUATIONAL AWARENESS VALUE SUSTAINMENT READINESS DECISION MAKING OPERATIONAL EXECUTION
  21. 21. 21Proprietary InformationProprietary Information Mel.Larson@kbc.global www.kbc.global Mel Larson Excellence is never an accident. It is always the result of high intention, sincere effort, and intelligent execution; it represents the wise choice of many alternatives - choice, not chance, determines your destiny. Thank you

digital applications and capabilities needed to achieve operational excellence: applications and capabilities that derive their value from knowledge of how the plant has operated in the past combined with its current and future potential; and an actionable optimum path to achieving and sustaining that potential.

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