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Ingenious ProRPM overview
- 1. Advanced Softwareand Consulting to the Chemical, Oil & gas and Energy industries Established in 2000, 160+ clients, 4 global offices FastTech50: 6th Fastest growing 2009, INC Magazine 207th Fastest 2009 Software Portfolio ◦ Real time performance monitoring dashboards ◦ Training simulators and e-learning software ◦ Production and economic planning software Consulting Portfolio ◦ Process engineering, simulation & design services ◦ Process Safety Management, Hazop 1
- 2. Performance Operator monitoring Training dashboards ProRPM ProDyn Simulator ProLearn E-learning Economic and learning & ProPlan planning management ProLMS software PRIVATE OR PUBLIC CLOUD DEPLOYMENT 2
- 3. GIS mapping Seismic Interpretation 3D ProDyn: Operator Training mapping Greenhouse Gas Emissions ProLearn: E-learning, SOP’s Reservoir mapping Operations Dashboards OLGA, Petro-SIM, Hysys Equipment Monitoring 3
- 4. Need: Know howyour assets are performing, and how they SHOULD be performing Visualize performance & respond in real-time Reduce energy costs and improve operating efficiency Detect operating problems prior to critical issues Equipment condition & emission monitoring Adapters to multiple data sources like PI, SQL, Excel, OPC and simulation engines 4
- 5. Dashboards Compare actual performance with optimum Improve performance and profits via continuous monitoring Simulation Results Plant information Smart simulation models track Send plant data optimum to data filter performance Data Reconciliation 5
- 6. 5 Steps toPerformance Monitoring 1 Data 1. Data Collection: Data from the plant servers (Historian, SQL Collection server/Excel, DCS) is collected, Key performance indicators 2 (KPI’s) are identified and an objective function is established. Model 2. Model: Build or connect to a simulation model of the asset using commercial modeling & simulation tools 3 3. Dashboards: Based on the model, real data and the KPIs Dashboards 4 4. Monitor: Engineers/operators track, improve and monitor performance parameters. Access via private or public CLOUD Monitor 5. Reports: Reports are sent based on the performance of the 5 asset. Reports are also sent if any critical alarm sets off. Report 6
- 7. ProDyn Training simulator ProLearn e-learning software Need: Critical need to provide standardized and repeatable training to operators, & plant supervisors Knowledge capture & transfer from experts to new hires. CLOUD based & standardized training and learning solutions Avoid safety incidents and production down time Automated exercises & Instructor-less training 7
- 8. A Series B Series C Series D Series A1 Tank Model B1 Basic Controls C1 Crude distillation unit D3 Hydrogen plant A2 Basic Centrifugal Pump B2 Liquid-liquid extraction (cdu) D4 Oil & gas platform A3 Heat Exchanger B3 Fixed bed reactor C2 Amine treating unit D5 Power plant A8 Interacting Controllers B4 Ion exchange C4 Gas concentration unit D7 PRT A11 Flash Tank B5 Distillation unit (goes with FCC unit) D8 Cogen Plant (300 MW) A12 Condenser B6 pH control (academic) C5 Naphtha hydrotreater A13 Reboiler B7 Tanks in series C8 Advanced Distillation A14 Air Cooler B8 Mixing vessel Unit C10 Sour Water Stripper A16 Steam Turbine B9 Steam boiler with 3 Unit A17 Batch Reactor element level control C11 Naphtha Splitter A18 CSTR B10 Reciprocating C13 Product Fractionator A19 Plug Flow Reactor compressor C14 Wet Gas Compressor A20 Fixed Bed Reactor B11 Compressor with anti- surge control C15 TEG Dehydration B13 Reverse Osmosis Unit Unit B14 Basic Unit Operations B15 Instrumentation II B16 Natural Draft Fired Heater B17 pH Control (Industrial) B18 Gas Turbine B19 Three Phase Separator 8
- 9. PL-A1 Pumps SAFETY MODULES PL-A2 Heat Exchangers PL-E1 Ergonomics PL-E2 Tool Safety PL-A5 Reactors PL-E3 Slips, Trips, and Falls PL-A6 Compressors PL-E4 Respiratory Protection PL-A7 Furnaces PL-E5 Reporting Hazards PL-A8 Process Variables PL-E6 LOTO PL-E7 Lifting Techniques PL-A9 P&ID Trainer PL-E8 Hearing Protection PL-AA Controls PL-E9 Hazard Communication PL-AB Instrumentation Troubleshooting PL-E10 Hand Protection PL-AC Advanced Control Schemes PL-E11 Fork Lift Safety PL-AD Distributed Control Systems (DCS) PL-E12 Foot Protection PL-E13 First Aid and Bloodborne Pathogens PL-AE Boilers PL-E14 Fire Prevention PL-AF Valves PL-E15 Eye Protection PL-AH Vibration Monitoring PL-E16 Confined Space Entry PL-AI Hydraulics PL-E17 Accident and Spill Procedures PL-E18 Safety Psychology Systems (Intermediate) PL-E19 Safety Work Rules PL-B2 Ion Exchange PL-E20 PSA Guidance PL-B3 Distillation PL-E21 Chemical Hygiene Plan I PL-B4 pH Control PL-E22 Chemical Hygiene Plan II PL-E23 EHS Policy PL-B8 Reverse Osmosis PL-E24 Basic Electrical Safety PL-B9 Unit Operations PL-E25 Emergency Action Procedures Refinery Processes (Advanced) PL-E26 File Storage PL-C1 Crude Distillation Unit PL-E27 Forklift Safety PL-C4 Naphtha Hydrotreater PL-E28 Machine Guarding PL-E29 Office Safety PL-C7 Fluidized Catalytic Cracking PL-E30 Personal Protective Equipment PL-C9 Hydrogen Plant PL-E31 Public Relations I Complex Processes (Advanced 4) PL-E32 Public Relations II PL-CB Production Platform unit PL-E33 Radiation Safety PL-E34 Railcar Safety PL-CD BioDiesel Plants PL-E35 Respiratory Protection 9
- 10. Process simulation, design,basic engineering Process Safety Management Technology & M&A Advisory services Six Sigma, Gap analysis, Management of Change Select References: Gas Oil Separation plant, Desalter, fired heater simulation and optimization—Khafji Joint Operations, Saudi Arabia Diesel hydrotreater optimization and safety Study – Valero Energy Basic Design package, Delayed Coker and FCC—CB&I Lummus Process engineering, simulation, safety: Continental Carbon, Siemens Process safety and reliability studies: BASF, Lion Copolymer M&A/Technology Advisory services: Haverhill, Mexichem, Goradia 10
- 11. Business Intelligence:Profitability, production, EHS Operational Intelligence: Performance of asset, equipment, Yields, Energy Management, Emissions etc Training & Learning: Real time access to SOP’s, training simulators and e-learning library for on- the-go learning Analytics: Simulation and modeling engines, KPI calculations, equipment performance templates: feedback to Business level 11
- 12. 1. Pemex 18. Saudi Aramco 35. Yanbu Industrial 2. Khafji Joint 19. Siemens 36. Lupin Pharma Operations 20. Emerson 37. Dishman Pharma 3. Valero Energy 21. Jubail Industrial System 38. Jubilant Pharma 4. Reliance 22. National Oil well Varco 39. India Glycols 5. PETRONAS 23. Alkyl Amines 40. PT Asahimas 6. Haverhill Chemicals 24. Gujarat Fluoro 41. Lemigas 7. Lion Copolymer 25. Mexichem 42. Pertamina 8. BASF 26. Indian Oil 43. Institute of Technology 9. Formosa 27. Gas Authority of India 44. Praj Industries 10. Continental Carbon 28. National Thermal Power 45. Houston Community College 11. CB&I Lummus Corp 46. Asian Paints 12. KBR 29. TATA 47. Kuraray Asia 13. Shaw 30. Aker Solutions 48. Emery Oleochemicals 14. Glenmount Global 31. Jacobs Engineering 49. Sulzer 15. Mustang 32. Alfa Laval 50. Saudi Polytechnic 16. Cepu Indonesia 33. Kuwait Institute 17. Baton Rouge College 34. Kuwait University 12