Plant Management
■ HSE – Can I-MAC help me ensure process safety, physical security, and port security? What about abnormal situation management?
■ Plant Management – Can you deliver my project safely, under budget, ahead of schedule, with a flawless start- up, ensuring safety, reliability, and efficiency in lifecycle operations?
Integrated approach Reducing risk in completing complex greenfield and brownfield expansion projects, small projects, and migrations demands co-operation and aligned objectives between prime contractors, subcontractors, EPCs, and other suppliers. I-MAC begins with integrating and aligning the approach with the customers ‘big picture’ business objectives. This team approach, implemented early in front-end engineering development (FEED), is essential for resolving interface and scope issues to maximize results and minimize integration risks. Through each project phase, Honeywell promotes a consultative approach to deliver on project and lifecycle priorities. A single point of accountability and contact for the entire facility automation scope can reduce communication failures, as well as risk, cost, and schedule management. It also provides for seamless integration between the parties involved.
reduces scope growth and project cost contingencies. There is rigorous and continuous identification, quantification and mitigation of project risks across the entire project systems, software and field instruments from project inception through commissioning.
Operational readiness Operational readiness incorporates ensuring employees have all the training, data and processes needed to safely operate the plant from day one. One opportunity is to develop dynamic simulators and
operator training system simulation (OTS) systems well ahead of typical schedules, which will in turn drive a faster startup, help avoid mishaps in operations, and help owner/operators achieve a faster ramp-up to full production capacity, as well as maintain a more reliable operation. Steady state and dynamic simulation models can be
collaboratively developed using models, tailored specifically for the processes being constructed. After plant design, these can be used to examine process unit design improvements and explore new operating regimes. Operating training simulators can be preconfigured so that
operators are trained ahead of plant start-up. Best in class graphics are interchangeable and only need to be built once for both simulation and OTS systems ensuring operational staff are familiar with the automation system prior to startup. Early OTS development also allows operating and start- up procedures to be developed and validated against a live model. Once validated, these procedures can be hard-coded into the automation system ensuring traceability and accountability. DCS base configuration can be tested and control loops pre-tuned against the training simulator to validate control strategies well in advance of plant start-up and reduce commission time. Profit optimisation models, developed in the OTS training
simulator, can be used to get an early start into advanced process control implementation. During plant start-up, the process units can be stabilised and brought up to full capacity faster than by conventional means. The ability to connect the process model to process data
and to the process controller allows a rigorous plant model to be used as an online optimiser, making it robust and fast to execute.
Fig. 3. Mobile workforce tools provide an easy way to automate operator and maintenance rounds around the refinery.
The owner/operator’s vision begins to be translated into outcomes and expectations very early in the project phase. Through concept and demand studies, the initial scope is defined with high level business requirements, a technology map and excepted outcomes. The next phase introduces workshops with all stakeholders in a discovery process to create a master automation plan, a system architecture and a deployment schedule. Business and domain consulting drives the next front end
engineering design phase to create a final scope and firm proposal before beginning execution and establishing ongoing lifecycle support. A detailed project execution plan that incorporates stakeholder workshops prior to the detailed engineering phase
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www.engineerlive.com Another important aspect to the I-MAC concept is a
strategic approach to applying wireless-enabled technology to help reduce time and cost of construction and commissioning. Mobile workforce tools (Fig. 3), for instance, provide an
easy way to automate operator and maintenance rounds around the refinery. Asset location technology can be used in both construction and in lifecycle operations to track the location of key assets during construction. This can drive construction efficiency of 4-7 days on large projects and can also reduce shrinkage of key equipment on site by an estimated 50-75 per cent. Additionally, wireless tablet-PC technology help during commissioning and with operator interaction, once again providing refiners the opportunity to re-think their commissioning and operations work processes. It helps drive significant cost and schedule benefits by helping to develop
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