A safety system can improve plant productivity and profitability by ensuring 100% availability and avoiding unnecessary shutdowns. A new safety system called HIMax is introduced that claims to deliver non-stop availability through online hardware and software changes without plant shutdowns. This allows for cost savings through reduced lifecycle costs and improved uptime. By choosing the right safety system that maximizes availability, a plant can improve its return on assets and overall productivity.

1. 1
 Can we compromise SAFETY to drive Productivity ?
CASE STUDY : Safety. Productivity. Profitability.
 Can operators have the best of both worlds – to reduce Risk and
increase Profitability ?
Alvin CJ Chin – Sales Director
HIMA Paul Hildebrandt GmbH + Co KG

2. 2
Safety is Paramount
- Your Business is committed to Safety
April 2010,
Deepwater Horizon Macondo Blowout
Jul 1988 , Piper Alpha –
North Sea Aug 2009 , Montara WHP & Rig Fire
27 Jul 2005 , Mumbai High North

3. 3
Profitability is equally important !
- Your business depends on productivity
 The cost of safety is tied directly to the profits of a company.
If it is an unsafe company - almost certainly pay out more in
Occupational Safety and Health Administration (OSHA) fines, lawsuits
and attorney's fees and also for increased insurance premiums than
needed.
 All of these payments directly affect the bottom line.
 Owners / Operators constantly balancing between increase
profitability i.e. driving up plant productivity and yet not compromising
safety !
 Today , every safety case must drive profitability.

4. 4
 Initial process design
 Selection of reliable equipment
 Implementation of the most efficient maintenance routines
What drives plant productivity and profitability?

5. 5
 Market demands & price level
 Constant plant uptime
 Controlling operating costs
 Efficient operations
What drives plant productivity and profitability?

6. 6
How can a safety system
improve your plant
productivity?

7. 7
An “ideal” safety system must never be the cause of a
shutdown – for ANY reason.
FPSO Owners / Operators
become accustomed to
unnecessary shutdowns
as a result of
 Spurious trips
 Periodic proof tests
 Hardware and software upgrades
 Common cause failures

8. 8
 Save $$$ - only buy what is needed
-> system must be scalable
 Save $$$ - reduce lifecycle costs
- > operating Nonstop
 Save engineering $$$
- > using a flexible, intuitive and easy
adaptable platform
Already, FPSO Owner‟s expects suppliers to consider
Capital Cost and Operational Expense. Why?

9. 9
What‟s needed NOW and in the future?
A safety system that will deliver
100% availability and never
affects plant uptime.

10. 10
A safety system that will help you
to generate more revenue.
What‟s needed NOW and in the future?

11. 11
What‟s needed?
A safety system which supports a
business case to reduce
PURCHASE COST ( CAPEX )
and
OPERATIONAL EXPENSES
(OPEX )

12. 12
HIMA understands what is needed in the Future
Introducing HIMax:
The first safety system that improves
productivity and profit.

13. 13
Improve business
performance

14. 14
Why HIMax ? – Save you $$$$
 Availability - 100% system availability for the life cycle of your
project
 Flexibility - 100% on-line hardware, software and operating
system changes -> nonstop …no need to shutdown the plant
anymore !
 Performance – Unrivaled performances with the latest state of the
art technology

15. 1515
The XMR® difference
XMR®:
Moving beyond TMR fault tolerance
and functionality

16. 16
Never need to turn system off – for the life of the
plant
100% system and plant availability through:
Availability – HIMax stays on NON STOP
What is the financial impact of
an unwanted plant shutdown?
 Perform mandatory On-line proof testing.
 Allows user to carry out ANY Modification ONLINE when
plant is in operation :
- Operating System Upgrades
- Add or delete of ANY parts of User Program
- Add or delete of Communication Protocols
- Add or delete of CPU Modules
- Add or delete of IO modules
- Add or delete entire hardware, racks and cabinets
 No-single-point-of-failure architecture design.

17. 17
The XMR advantage
 Always SIL 3 – no restrictions even in “simplex” configuration
 Scalable availability with more levels of fault tolerance than any other architecture
 CPU and I/O support 4-3-2-1 operation without “degraded” safety or time limits
 Spurious trips eliminated
 Highest availability – even with very long MTTR

18. 1818
Engineered for flexibility and productivity
MODULARITY ARCHITECTURE BENEFITSMODE OF OPERATION
XMR®
X = 1
SIL = 3
Single inputs
Single outputs
Single CPU
Safety architecture for process
facilities which do not need
redundancy.
Most widely used safety architecture
providing absolute safety and
availability.
X = 2
SIL = 3
Dual inputs
Dual outputs
Dual CPU
Traditional architecture (TMR) which
can provide similar safety and
availability characteristics as X=2. For
customers who „require‟ TMR
technology.
X = 3
SIL = 3
Triple inputs
Triple outputs
Triple CPU
Application that provides maximum
common-cause hardware protection
and maximum availability.
X = 4
SIL = 3
Quadruple inputs
Quadruple outputs
Quadruple CPU

19. 19
connect red system bus
NONSTOP advantage – plant upgrade
Main steam boiler
(running)
New AUX boiler
(remote I/O)
DOWNLOAD
CHANGE
FATPRIOR
TOINSTALL

20. 20
connect red system bus
NONSTOP advantage – SIS upgrade on-line
Original ESD
(2008 – V3.3)
Plant expansion
2012 - V4.5
UpgradeOSto
V4.5online
FATPRIOR
TOINSTALL
New functionality
New functionality

21. 21
NONSTOP advantage
 Typical plant experiences several days lost production over its lifetime due to
unplanned downtime to maintain SIS
 HIMax gives you that production, revenue and PROFIT back

22. 22
A system that future-proofs your initial investment:
 Fully on-line expandable.
 Buy only what is required at the start of the
project – CAPEX savings.
 Expand your system as your plant or project
grows
 Replace modules, software and OS on-line.
Flexibility - unrestricted on-line changes
What is the financial benefit
from the ability to make
unlimited on-line changes?

23. 23
Unrivaled system performance
10 ms 50 ms 100 ms Cycle Time
(Scan Time)
50
1000
2000
I/O points

24. 24
High performance & high capacity
 Single controller set supports 16 base plates and up to 200
modules
 Max I/O per controller set is ~ 12,000 points
 Up to 256 controller sets can be networked into a single
safeethernet network
 Power PC microprocessors in every module
 Direct processing of I/O onboard I/O module
 Unlimited floating point & other complex calculations
 Application complexity almost no effect on scan times
 Parallel processing & Multitasking in single controller
 Power to apply model predictive control principles to safety

25. 25
 Emergency Shutdown Systems (ESD)
 Burner Management Systems (BMS)
 Fire & Gas Systems (F&G)
 Turbo machinery Control (TMC)
 High Integrity Pressure Protection Systems (HIPPS)
HIMax – for all process safety & critical control
applications

26. 26
HIMax References

27. 27
HIMax installations
Evonik Degussa
 Torch control
 Chemical Plant
Ineos, Cologne
 Centralising CCR
 Refinery, Special Chemicals, Plastics
Ineos, Wihelmshaven
 Ship loader
 Refinery, Plastics
Vinnolit, Gendorf (Infraserv)
 Compressor control
 Chemicals, Chlorine

28. 28
HIMax installations
MiRO, Karlsruhe
 Burner Management
 Refinery, Petrochemical
OMV, Burghausen
 Water Jet Cutting
 Refinery, Petrochemical
Shell, Hamburg & Sarnia Canada
 Wastewater Utility
 Refinery, Petrochemical
ExxonMobil
 HIPPS, ExxonMobil Baytown
 ESD , Fawley Refinery
 Boiler, Antwerp

29. 29
HIMax installations
Angola LNG
 HIPPS
Bayer MaterialScience, China
 TDI, TDA, DNT/SAC Plants

30. 30
HIMax installations
Yara, Brunsbüttel
 Ammonia-Plant
 Fertiliser
Holborn, Hamburg
 Oven and SPC-Plant
 Refinery, PE-Plant
Mauell, Velbert
 Burner Management
 Power-Station, New Plant

31. 31
HIMax Project In-progress
Inpex /TOTAL Icthys Browse, Australia
 LNG Development
 Onshore and Offshore
Koniambo , Australia
 Nickel Steel Plant
TOTAL E&P Congo
 Onshore Platform

32. 32
Conclusion

33. 33
Choosing the right Safety Instrumented System (SIS )
 A SIS that drives plant profitability
 A SIS that have maximum availability to the plant critical
systems
 A SIS that improves lifecycle costs
 A SIS that achieve maximum safety (SIL3) to protect plant,
people and environment
 A SIS that keeps OPEX costs to a minimum yet only shutdown
on real process demand –i.e. does not shutdown for any other
reasons, including SIS lifecycle activities
Key factors to consider :

34. 34
How to get what you want ?
 Think long term
 Do not be short sighted - cutting costs by implementing the minimum
requirement to satisfy regulatory requirements saving initial costs of project
simply by delegating the most critical decision that drives plant safety and
profitability to either a third party contractor such as EPC or MAC ( Main
Automation Contractor) that have short term interest in the entire life cycle of the
plant
 It is vital to note that the SIS has final control over whether the plant runs or
shutdown. It has ultimate control over production process as it ties into the heart
of plant operation in view of its overriding safety functions.
 Be in control of specifying the right SIS

35. 35
Return on Assets
 Commonly – Finance team looks at ROI ( Return on Investment )
 ROI – Ineffective tool for evaluating ; does not take into account
the consequences of a sudden breakdown, process trips or
failures.
 ROA – Return on Assets is a better measure.
 ROA defined as ROA = Operating Income / Total assets
 The higher the ROA , the more efficient the plant is using its
“assets” -> A Safety System that operates NONSTOP certainly
will be contributing to a positive ROA.

36. 36
Conclusion
 The power is in your operator/ owner hands
 If you want a high-end made car ( eg. BMW ), but only specify
something with 4 wheels and engine and then pass to a
middleman to source it, don’t complain when a second hand 3rd
world made car appears on your driveway !
 You need to take control , test drive and specify what you want
.
 Review each asset – how does interruptions affect plant
operations and hence profit ?