Oil & Gas Operational Excellence

Not an official UNCTAD record
Oil & Gas

Operational Excellence
8th Africa Oil & Gas Conference
Morocco 2004
Phil Millette
Oil & Gas Industry Consultant
Honeywell Process Solutions
Agenda
Introduction
Oil & Gas industry drivers / challenges
What is Operational Excellence?
Solution components & Customer Examples
Content Owner: Phil Millette

Last Modified: Apr, 2004
Process Solutions
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.

Process Solutions
Honeywells Business Segments
2003 Sales
Specialty
Materials
Aerospace
$3.2B
$8.8B
$7.5B
$3.7B
Automation
and Control Solutions
Total = $23B
Transportation
Systems
Broad
and
Diverse Businesses, Technologies and Products
Process Solutions
Content Owner:
Phil Millette
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

Process Solutions
Examples - Honeywell Oil & Gas Experience

Amoco Trinidad
Kazakhstan
British Petroleum
Offshore Platform
Over
15
Major
Well Field / Fractionation
Well Field
Atlanta Gas Light LNG Plant
North Sea Platforms
Tarim
LNG Plant
British Petroleum
Oil Field Tuha
customer
Oil Field
Marine Terminal
Gas Plant
Petronas
Amoco
Gas Plants
Texaco
Exxon
EPMI/Petronas
Conoco
Platforms
Gas Plants
Chevron
Oil Field
Pemex
Gas Fractionation
Woodside
Petroleum
Corpoven
LNG/Platforms
Gas Fractionation /
Sonatrach
Marine Terminal
India Oil
AGL
LNG Plant
BP
Pipeline
Pipeline
Aramco
Gas Metering
Chevron Escravos
Production Shell
Sasol
Pipeline
DukhanProjects
Oil Field
AGIP
Amerada Hess
Aramco
Ashland
British Gas
British Petroleum
Britoil
Botas
Chevron
Corpoven

Dakota Gasification
Diamond Shamrock
Dome Petroleum
ELF
El Paso Natural Gas
Enron
Enterprise
Exxon/Esso
Kuwait Oil
Mobil
Marathon
Northwest Pipeline
Occidental
Petronas
Phillips
Shell
Statoil
Sun
Texaco
Total
Transok
Woodside
Process Solutions
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
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

Selected FPS
References:
-Hydro Troll Olje /

Norway- Semisub.
-Texaco Captain / UK
FPSO
-Woodside Laminaria /
Australia FPSO
-Esso Jotun / Norway
FPSO
Process Solutions
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
Business
metrics
Best
practices
GAS PLANT
Processing
Improved
Performance
Lower OPEX
OFF-SHORE PLATFORMS
Production
SCADA / DCS & Safety, Security Systems

Field Instrumentation
Process Solutions
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-today

For improved management of
Safety,
Reliability,
Security,
Process & production performance optimisation,
Production management
Process Solutions
Operating Excellence: Achieving Optimal asset

performance
Flexible real-time technology must
support the operational business
processes
Business Management
Advanced
Analysis
tools
Optimization
CMMS
APC
Operator Maintenance
The Future?
In use now!
DCS/ESD
Regulatory
Control
Asset
Diagnostics
Security
Process
Sensors
Approach:
Decision Support
Diagnostic
for Integrated Teams
Remote expert
diagnostic from
support center
Process & Asset

Sensors
onshore & offshore production

Process Solutions
Operating Excellence Challenges

Production Cost reduction / control
Increased top line revenue
Reliability, Uptime!
Reliability, Uptime!
Personnel
Work Practices improvement
Maximize production from existing facilities

Push constraints
Optimize process
Detect Problems, Mitigate Impact
Improve People Effectiveness
Safety Management
Work Practices improvement
Reliability, Uptime! : need to track health and

performance of all plant and automation
assets
Environmental Monitoring / compliance
Learn from Operations

Safety Management
Lifecycle Costs
Plan and Manage Version-up & obsolescence

to capture operational improvements
Integrated Management of automation asset

WITH the plant asset
Focus
Focuson
on more
more production,
production, more
more reliability,
reliability,more
more safety
safety
Process Solutions
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
Process Solutions
Figure from POSC SmartFields meetings:

Loop Characteristics (Shell)
Physical Asset
production
optimization
Data
Plans &
Decisions
cycle time
Physical Asset
Field
Development
Data
Plans &
Decisions
Models
Physical Asset
Models
Data
Plans &
Decisions
production
operations
Reservoir
Surveillance
Models
Data
Plans &
Decisions
Physical Asset
Models
subjectivity
organizational
scale
Focus on short
uncertainty
complexity
term improvement
opportunities,
with exchange to
Enable
Ease of information
givensurveillance
asset
reservoir
function
Process Solutions
Oil & Gas Operations Excellence: Solution

Map
Reservoir
Reservoir
Management
Management
ERP
ERP
Decision
Decision Support
Support
Enterprise
Production
Production Summary
Summary
Enterprise
Enterprise Integration
Integration
Operations
Production
Production
Management
Management
Well
Well Test
Test Manager
Manager
PCC
PCC Rich
Rich Client
Client &
&
Thin
Client
Thin Client
KPI
KPI Manager
Manager
Operations
Operations
Management
Management
Production
Production Event
Event Analyst
Analyst
&
& Shift
Shift Report
Report
Operator
Operator
APC
APC &
& Optimization
Optimization
Effectiveness
Effectiveness
Metering
Intelligent
Metering Report
Report
Intelligent Choke
Choke Cntrl
Cntrl
Production
Production Report
Report
Regulatory
Regulatory
Reporting
Reporting
Asset
Asset Management
Management
Experion, Plantscape
Pipeline
Pipeline Leak
Leak Detection*
Detection*
TPS
Security
Security
Integrated
Integrated Field
Field
Safety
Safety Valve
Valve Scout
Scout
Safety
Safety State
State
Field
Shut
Shut Down
Down Analyzer
Analyzer
All
Allthe
thecomponents
componentsto
toachieve
achieveOperations
OperationsExcellence
Excellence
Process Solutions
Operational Excellence Solutions: People,

Production Control Center (PCC) enables improved decision
Business
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
Safeand
andEfficient
Efficientoperations:
operations:It's
It'slike
likehaving
havingthe
thebest
bestoperator
operatoron
onevery
everyshift
shift
Process Solutions
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

Process Solutions
A Typical Control Room Screen

Proprietary and Confidential
Process Solutions

Map
Reservoir
Reservoir
Management
Management
ERP
ERP
Decision
Decision Support
Support
Enterprise
Production
Production Summary
Summary
Enterprise
Integration
Operations
Production
Production
Management
Management
Well
Well Test
Test Manager
Manager
PCC
PCC Rich
Rich Client
Client &
&
Thin
Client
Thin Client
KPI
KPI Manager
Manager
Operations
Operations
Management
Management
Production
Production Event
Event Analyst
Analyst
&
& Shift
Shift Report
Report
Operator
Operator
APC
APC &
& Optimization
Optimization
Effectiveness
Effectiveness
Metering
Intelligent
Metering Report
Report
Intelligent Choke
Choke Cntrl
Cntrl
Production
Production Report
Report
Regulatory
Regulatory
Reporting
Reporting
Asset
Asset Management
Management
Pipeline
Pipeline Leak
Leak Detection*
Detection*
TPS
Security
Security
Integrated
Integrated Field
Field
Safety
Safety Valve
Valve Scout
Scout
Safety
Safety State
State
Field
Shut
Shut Down
Down Analyzer
Analyzer
All
Allthe
thecomponents
componentsto
toachieve
achieveOperations
Excellence
Process Solutions
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
Reliablemeans
meansmore
moreproduction,
production,lower
lowercost,
cost,more
moresafety
safety
Process Solutions
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
Reliablemeans
meansmore
moreproduction,
production,lower
lowercost,
cost,more
moresafety
safety
Process Solutions
Solution Components
Asset Effectiveness
Early, rich diagnostics per type of equipment
Including partnerships with 3 rd 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

Process Solutions
The Asset Manager PKS responding to faults
Fill out a work order

An action has many
different possibilities
Clicking on the
advised action
can trigger an
action--in this
case a work
order
Send a
page ...
Or an email...
Or run a program
Process Solutions
Asset Manager as the key real-time notification

and work flow platform
Usable on any facility, whatever the automation platform

Notification via all
methods, including
Experion Alarm
interface
Asset Management
Collaborative Control Center
Collaboration
and Impact
Assessment
Documentation,
Information
Field Entry, View
Asset
Manager
PKS
IntelaTrac PKS
Scouts
APC
Scout
Safety
Valve
Scout
Loop
Scout
Turbo
Suite
Profit
Sensor
APC
Apps
Safety
Valves
All
Loops
Rotating
Virtual
Data
Scout
Experion
PKS
OPC
HART
& FF
All
Shutdown
Analyzer
Valves..
The plant is more than the sum of the instruments

Process Solutions

Map
Reservoir
Reservoir
Management
Management
ERP
ERP
Decision
Decision Support
Support
Enterprise
Production
Production Summary
Summary
Enterprise
Integration
Operations
Production
Production
Management
Management
Well
Well Test
Test Manager
Manager
PCC
PCC Rich
Rich Client
Client &
&
Thin
Client
Thin Client
KPI
KPI Manager
Manager
Operations
Operations
Management
Management
Production
Production Event
Event Analyst
Analyst
&
& Shift
Shift Report
Report
Operator
Operator
APC
APC &
& Optimization
Optimization
Effectiveness
Effectiveness
Metering
Intelligent
Metering Report
Report
Intelligent Choke
Choke Cntrl
Cntrl
Production
Production Report
Report
Regulatory
Regulatory
Reporting
Reporting
Asset
Asset Management
Management
Pipeline
Pipeline Leak
Leak Detection*
Detection*
TPS
Security
Security
Integrated
Integrated Field
Field
Safety
Safety Valve
Valve Scout
Scout
Safety
Safety State
State
Field
Shut
Shut Down
Down Analyzer
Analyzer
All
Allthe
thecomponents
componentsto
toachieve
achieveOperations
Excellence
Process Solutions
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,
throughAPC
gathering network
and gas lift. in
with&partner
EPS.
APCprovides
providesproven
provenvalue
value inoil
oil &gas!
gas!

Process Solutions
Field Optimization Network

iDO
iDO
Well, Pipe Network, Facilities
Well, Pipe Network, Facilities
Profit
ProfitOptimizer
Optimizer
Manifold
Well Choke Valve
Field Pump
Gathering Compressor
Profit
ProfitControllers
Controllers
UNIFORMANCE
UNIFORMANCE
SCADA
SCADA
Oil
Gas
Facilities
Process Solutions
Integrated Field-Wide optimisation:

Closing the loop with Multivariable Control
i-DO
AIM
i-DO
i-DO
Production
Server
Production
Data
Planning
Managemen
GAIN
SUSTAIN
PVO OBJECTIVE
FUNCTION
t
{PRODUCT VALUES, ENERGY COSTS}Production
Targets
Profit Bridge
Network
Model
and
Optimizer
Well Perf
Curves
Economic
Parameters
Reservoir
Models
Tests
Well
Models
Pres,
GOR, BS&W
Review,
Approval
Pres, kh,
Skin
Transient
Pressure
Analysis
LAN/WAN/Internet/Intr
Profit Optimizer anet

MV Control coord
SEPARATOR 1
MV CONTROL
i-DO
SEPARATOR
2
GAS LOOP
Client
MV CONTROL
MV CONTROL
Engineer
PCs
MULTIPLE
CHOKES
MV CONTROL
Profit Controllers
(RMPCT)
Wells, Separators
Process Solutions
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

Process Solutions
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

Process Solutions

Oil & Gas Operational Excellence

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Not an official UNCTAD record

Oil & Gas

Content Owner: Phil Millette

108,000 employees in nearly 100 countries

On Money magazines list of 75 Best Benefits companies for

Winner of the Technology and Business Vision Award from

Start magazine and Microsoft, and the Control Engineering

Content Owner: Phil Millette

Honeywells Business Segments

Automation and Control Solutions

Honeywell Fire Solutions

Now also including Honeywell Sensotec

Honeywell Environmental Combustion & Control

Controls for heating, cooling, ventilation, air conditioning,

humidification, industrial process automation, video surveillance,

40,000+ employees in 100 countries

Content Owner: Phil Millette

Examples - Honeywell Oil & Gas Experience

Content Owner: Phil Millette

Oil &Gas - Offshore production References

Recent EMEA Offshore Projects

Content Owner: Phil Millette

-Hydro Troll Olje /

Honeywell Integrated Oil & Gas Solutions

ONSHORE GAS/OIL FIELDS

SCADA / DCS & Safety, Security Systems