Life Cycle Benefits from Design to Operation 27

Life Cycle Benefits from Design to Operation 27 th and 28 th February 2008 Paul Young Automation Improvement Manager Ineos Chlor. Vinyls 1 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Life Cycle Benefits from Design to Operation Introduction Who is Ineos Runcorn Site Automation Strategy Emerson Alliance Partnership Project Genesis Benefits and Risks Summary 2 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Introduction – Paul Young Current Role - Automation Improvement Manager Exploitation of control systems n Plant Reliability and optimisation n Previous Roles Site Instrument Engineer n Plant Manager for Liquid Chlorine Manufacturing Complex n 600, 000 tes Chlorine and 1, 200, 000 tes Caustic per annum – High Hazard Process (Top Tier COMAH Plant) – 120 staff – n Upstream Section Control / Electrical Engineer 10 plants – 3 Engineers, 6 Technical Officers, 20 Tradesmen – 3 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Ineos Manufacturing Locations 68 Manufacturing Sites in 16 Countries Europe Grangemouth Antwerp Runcorn 41 sites Wilhelmshave n Ruhr North America 18 sites Lavéra Köln Asia South Houston Mobile South America 2 sites 27 -Jun-06 4 5 sites Africa 2 sites General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Runcorn Site Automation Strategy began in 1997 between ICI Chlorchemicals and Fisher Rosemount Single Sourcing Agreement Good Discounts Upfront purchase of Delta V licenses to cover site developments onto DCS On-site Asset Manager 5 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Automation Alliance Partnership Regular Alliance Board Meetings Joint Improvement Plans Focus on service, support and technical problems – not contractual issues and sales Site standards Reduction in spares holding, training etc n Prototyping reduced to minimum n Focus on making plants work better – not instrumentation for its own sake 6 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Project Genesis € 300 Million replacement of cellrooms Largely an LSTK project – through Fluor in Holland Make or break for Alliance – Ineos not bought into the concept Competitive bid for Automation (DCS, instrument and valves) Won by Emerson Process Automation 7 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Project Genesis – Technology shifts Majority of plant built to existing site standards Delta V n Hima SIS n 3051, 644, 8800, 8742, DVC 6000 n Technology shifts Instrument comms - Fieldbus versus 4 -20 Hart n Instrument systems - AMS and Portal n Alarm management - Matrikon n Machinery management - Machinery Health Monitor n 8 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Fieldbus – Potential Risks and Benefits RISKS Cost Design competence Segment loading Interoperability of DCS and Instruments Installation / commissioning engineers and technicians competence No commissioning procedures for Fieldbus Loss of segment during operation of plant Spares Affect of magnetic fields and stray currents on Fieldbus becomes obsolete and unsupported (VHS/Betamax or Blu-Ray v HD-DVD) 9 BENEFITS Project Benefits n Fewer Drawings n Reduced commissioning time Operational Benefits n Faster fault finding n Reduction in testing / periodic maintenance Would you risk € 300 Million of your money on it? – Only if you were confident in your partner General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Genesis Instrument Scope 1223 143 1515 Fieldbus instruments Fieldbus segments Hart instruments (Safety Applications and analysers) On / Off signals Over 200 Km’s of instrument cable AMS system linked into SIS Hart loops through an MTL MUX (Multiplexer) Largest fieldbus installation in Ineos (3 x Tiger, 10 x Oxides) Risks, issues and benefits were identified in preparation for the Genesis Project – only possible because of the alliance 10 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Benefits seen on Genesis Reduced instrument drawings n 1000 less instrument loop drawings (35% less) Reduced time to commission the plant control system Record installation time for cabling (1 -2 weeks quicker) n Very small number of connection faults (<0. 5% of loops) n Fieldbus is easier to install (polarity irrelevant on most instruments) – Much faster to check instrument correctly connected than Hart – Loose termination can be picked up by examination of noise on the segment – n Fault finding significantly faster (453 faults to date - @30 mins per fault) Get to root of the problem much faster – Control issues on electrolysers – Magflow noise rejection – n Modifications required to get plant on-line implemented very quickly Valve position mod on cellroom trip – Re-ranging of transmitters running outside design – Benefits worth 2 weeks of production 11 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Benefits seen on Genesis AMS used extensively during shutdown testing Minimised time spent on invasive testing n Changes in shutdown systems retested very quickly without hazardous break-ins n 1 week off shutdown testing program Valve set-up can be done in-situ AMS used to perform valve scan and set-ups without sending the valve away to a workshop n Perceived Valve issues correctly diagnosed with Valve-link n Avoided electrolyser damage due to sizing issues 12 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Risks Managed / Avoided Initial concerns around segment loading largely avoided n n n Concerns had been raised prior to Genesis design of the number of instruments which could be loaded onto a single segment. If got wrong, it can cause instruments to respond slowly and ultimately stop working. Emerson asked to design on Fluor’s behalf as Fluor inexperienced in segment design Realistic limit of 8 instruments per segment implemented (versus max of 12 claimed) Only 4 valves max on a segment (expected more) No loading issues seen to date Finalising instrument locations More critical to finalise early in design to avoid loading issues n Some redesign cost for late changes n 13 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Risks Managed / Avoided Technician Fieldbus skills very limited initially Contract technicians not consistent in there methods for setting up devices and commissioning - have introduced additional problems n Availability of trained resource is still very limited n Stray current from electrolysers caused the loss of digital segments because of earth free installation. n Diagnosis was protracted – magnetic fields believed to be cause Availability of electrolysers – Diagnostic tools and skills on digital networks limited – Emerson support crucial to solution - Jeremy Fern / Steve Harrison and Marshaltown – 14 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Post Project – “A Unique Approach”? Investment by Ineos and Emerson in exploitation of systems My Role : Reliability and Operating Improvement n Duncan Cammack : Extracting the right approaches to issues and resources from Emerson n Target is at least £ 500, 000 of benefit 15 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Operational Benefits Identification of Plant Design / Operational Issues n. Trip diagnostics - ESD and DCS integrated –Compressor trips –Electrolyser trips n. AMS alerts on saturated loops –Ranges incorrect on chlorine interchangers –Evaporator temperature limited at high loads n. Motor current readings brought through to DCS from MCC –Alkaline brine pumps undersized for high loads –EAP circ pumps flow balancing n. Alarm Management –Compressor oil heaters always on –Vibration alarm set too slack All these things were possible because of the integrated nature of the systems used and the availability of data 16 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Operational Benefits Predictive maintenance n Trending of key parameters – n Oil filter problems Vibration monitoring using Machinery Health – Early diagnosis of root cause on brine pumps Optimisation n Investigating multivariate control to stabilize Liquefaction Portal and AMS n 17 Help operators diagnose plant problems faster and more accurately General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Operational Benefits Valve diagnostics Emerson AMS Valvelink used to continuously monitor most critical valves n 7 valves (of 415) identified for overhaul in first major outage based on condition n Poor valve performance improved by control tuning until repairs possible n High travel accumulation highlighted leading to control improvements and reduction in long term valve wear n 18 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Summary Risks of implementation of new technologies largely avoided Commissioning and Operational Benefits have justified Fieldbus and Emerson selection Fieldbus and AMS products are now the site standard for new projects Engineering design learning formalised into our site procedures Training in digital systems for engineers and technicians Exploitation post project is essential to get the most out of the systems 19 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Spare Slides 20 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

INEOS History INSPEC Established 1992 to Buy - BP Fine Chemicals - Floated on London Stock Exchange 1994 - 10 Acquisitions in Fine and Speciality Chemicals INEOS Established 1998 to Buy - Oxide Business from Inspec - Inspec taken over later same year INEOS in 2000 - 2005 - Buys, Fluor, Silicas, Chlor from ICI - Buys Phenol from Degussa - Buys EVC, Paraform, Styrenics INEOS in 2005 - $8 Billion in Sales - 8000 People, 46 Sites INEOS in December 2005 - Acquires Innovene from BP for $9 bn 21 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Global Chemical Companies – Estimated Sales 22 9 -Aug-06 General Assembly, Antwerp, 27 -28

Estimated Chemical Sales of Integrated Petrochemical Majors 23 9 -Aug-06 General Assembly, Antwerp, 27

Ineos - Key Performance Indicators Jim Ratcliffe – Inoes CEO and Owner SHE Plant

Ineos and Automation Process control systems are key elements in achieving our KPIs: - Process and personal safety - Reliable, efficient operations leading to greater plant outputs - Fixed Cost Control, including manning levels 25 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Design and Installation Price matching Fieldbus v Hart on field instruments I/O cost higher due to loading issues and redundancy Valve position feedback without additional instruments Flow, temperature and density readings from coriolis meters To enable AMS on SIS loops requires addition of multiplexers DCS cabinets and terminations n Fieldbus cabinet sizes smaller n Less marshalling required and fewer cabinets n Smaller instrument room and fewer cable transits Less cable racking and loading on structure 26 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Commissioning Fieldbus commissioning much faster 10 minutes per loop, versus 30 minutes (@£ 20/loop) n Range differences between field instrument and DCS cannot occur with Fieldbus n Technician Fieldbus skills very limited initially Boultings technicians not consistent in there methods for setting up devices and commissioning - have introduced additional problems n Availability of trained resource is still very limited n 27 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Issues Stray current from electrolysers caused the loss of digital segments because of earth free installation. n Diagnosis was protracted Availability of electrolysers – Diagnostic tools and skills on digital networks limited – n Hart valves did not work either when trialled Unstable flow reading problems from stray currents Magflow meters noise diagnosed using fieldbus n Data only available through Fieldbus identified the solution n 28 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Fieldbus Summary Risks of implementation of Fieldbus on MCP have largely been avoided Review redundancy of Fieldbus I/O and deliver equivalent / better costs for I/O versus Hart Given that we continue to manage the risks, Fieldbus will be adopted on future projects Learning from MCP should be formalised in engineering guidelines Training in digital systems and Fieldbus must be delivered to engineers and technicians across site Any future issues arising on MCP need to be thoroughly investigated and cascaded to the C/E engineering community 29 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

Issues Implementation of modifications identified during commissioning n Re-ranging transmitters Significantly reduced time due to use of AMS – Fieldbus much easier than Hart – n New valve position interlocks for cellroom trip – No additional hardware required as position indication available using fieldbus Process control and operational issues Instrument and valve diagnostic tools essential to quick identification of root causes n Speed of diagnosis helping process teams to understand operational constraints n 30 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation

AMS - Issues Problems with set-up of AMS Technical resource to set-up AMS very limited n Same resource needed to configure sequence code on DCS, therefore AMS issues took a back seat. n Stability of AMS n Several occasions where the AMS system fell over – v 7. 5 not a stable platform Software version of AMS n Does not support most recent instrument release of valve hardware (phasing of release of software version) – Migrated to v 8. 1 standalone to resolve issues Protracted implementation of Portal 31 General Assembly, Antwerp, 27 -28 Feb 08 © 2008 Fieldbus Foundation