Driving Process Optimization with Asset Performance Management

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OverviewSub-optimal process configurations and operating conditions can result in off-spec or inconsistent products, excessive energy costs, unintended losses and unplanned shutdowns and all have a significant impact on plant economics. Forward leaning operators are changing the way they think about process optimization. They are integrating asset performance with process simulation to increase safety, efficiency and production. Fusing these together in the Cloud enables continuous interrogation of process data against the model, and the ability to predict and quantify operational decisions in near-real time. This integration is a game changer, providing connectivity between operations, assets, people and business, and allowing for true end-to-end optimization. It empowers organizations to maximize asset value by strengthening decision confidence to improve facility performance and drive organizational excellence.

APMAPM is a suite of software and service solutions designed to help optimize asset performance. The output from APM can be used to increase reliability and availability while optimizing maintenance costs, mitigating operational risks, and reducing total cost of ownership (TCO). The suite connects disparate data sources using advanced analytics to turn data into actionable insights while fostering collaboration and knowledge-management across the organization. The benefits of APM are vast: its hierarchical architecture means it works at the enterprise level across plant, sub-systems and equipment.

Built on a cloud-based platform, APM gives organizations the flexibility to develop new analytics and applications, and it’s versatile enough to meet changing needs. Asset management is a continual, evolving process: operational conditions and demands will change over time; equipment will age and require replacement; upgrades and improvements will be implemented; and pressure to reduce costs will always be present. Dynamic performance management and a continuous loop of improvement are essential which APM delivers.

Driving Process Optimization with Asset Performance Management

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Process Simulation Leveraging Advanced AnalyticsBy integrating BHGE’s AI Factory™ software with KBC’s process simulation technology, Petro-SIM™, the solution delivers continuous process management. Operating data taken directly from the plant is monitored in real-time and reconciled against the simulation model which becomes the digital twin of the asset. Discrepancies between the operating data and the digital twin are analyzed, reviewed and evaluated against the guidelines for plant operations. Operators are immediately presented with recommendations relating to production and operations improvements that balance maintenance and reliability management constraints.

Combining predictive analytics, equipment and process data with a given simulation model improves operational efficiency, speed, and decision making. Operators reduce time spent on optimizing production from several months to days. The business outcomes allow operators to debottleneck their plants’ process and equipment to achieve maximum production.

Continuous process management can help you:

INCREASE RELIABILITY AND PRODUCTION

The convergence of process, maintenance, and operations results in increased production, and significantly reduced operating costs by lowering energy consumption and carbon footprint, reducing flare emissions, and lowering maintenance costs.

ENHANCE OPERATIONAL EFFICIENCY

Continuous process management delivers a single, unified view with predictive analytics of oil and gas equipment, operations and process data to break down data silos, improve operational efficiency and speed up decision-making. This ultimately reduces the time and effort required by personnel to analyze operations and ensures that every decision regarding equipment and processes is made with the efficiency, safety, and operation of the entire plant and organization in mind.

REDUCE LIFECYCLE COSTS

Continuous process management can be used to review, analyze and set best practice guidelines for plant operations, all of which contribute to a reduction in lifecycle costs. Users can ask for production advice or improvements, with the knowledge that the solution will find the optimal recommendation that balances both production and reliability management constraints.

ELIMINATE BOTTLENECKS AND INCREASE REVENUE

The joint solution provides customers with the capability to quickly identify and eliminate bottlenecks in facilities, processes and equipment to achieve optimal production.

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Process Models

OFFSHOREMaximizing compressor uptime on an offshore platform

By using continuous process management, the Process Engineer is able to quickly identify and remedy a vibration problem without having to shut down the compressor, which could have potentially resulted in a production deferment and lost revenue.

LNG PLANTForecasting reliability and availability of an AGRU

The solution provides facility operators with a better understanding of AGRU performance and reliability by identifying primary and secondary KPIs that are critical to operation. By using built-in predictive analytics to monitor and analyze the KPIs, the operators can forecast unit reliability and availability, which allows for optimization of amine use regeneration schedules. This ultimately leads to reduced energy consumption, lower OPEX, and increased throughput.

DOWNSTREAM

Predicting fouling of wet gas compressor in a fluid catalytic cracking unit

The solution uses all the available data to detect degradation before the symptoms become apparent to the operators or maintenance teams. It makes a probabilistic assessment of the compressor fouling and the impact on efficiency. The solution also uses the process simulation to calculate the effect of the compressor efficiency loss and propose operating adjustments to both mitigate the loss of efficiency and determine when to schedule the compressor cleaning.

Optimizing heat exchanger maintenance schedules in preheat trains

The solution provides refinery operators with the capability to predict future fouling in preheat trains several months in advance, enabling them to reduce energy consumption and avoid throughput-limiting conditions before they occur. In addition, the solution provides insight on how to optimize heat exchanger cleaning schedules so that return on investment (ROI) can be maximized.

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Why BHGE?Our process optimization solution separates itself from other digital solutions on the marketplace in that it utilizes overarching layers of functionality (including Artificial Intelligence and Machine Learning) built on top of traditional IT and OT technologies. Leveraging the data generated by these tools, and utilizing the power and flexibility of cloud computing, you can forecast plant behavior and output days and even weeks in advance.

GEA33963 10/2018

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In the case of large and complex organizations, continuous process management ensures that this information is not segregated at the plant level but is made available across the enterprise, allowing separate facilities to share best practices and know-how so that organization-wide optimization can be achieved. BHGE is working with customers to develop the value proposition to solve their challenges, starting small, using agile development, but with enterprise-wide end goal.