OXOCHIMIE OXOCHIMIE at OSI conference 1999 OXOCHIMIE Lavera - France François GERMAIN Plant manager From yield optimization to manufacturing cost control

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Oxochimie

Bienvenue en Provence

Lavera en Provence

Lavera site

OXOCHIMIE OXOCHIMIE at OSI conference 1999 BPA CHEMICALS ELF ATOCHEM PEOPLE 43 Bn$ TURNOVER PEOPLE 14 Bn$ TURNOVER 50 % OXOCHIMIE 100 PEOPLE 100 M$ TURNOVER OXOCHIMIE

OXOCHIMIE OXOCHIMIE at OSI conference 1999 What are we doing? n We are making basic chemicals n Production de Tonnes/year of OXO-alcohols n Applications for plasticisers, paints, inks, solvents… n 5th world producer of Oxo-alcohols

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Summary 1. Before PI 2. A fast track project 3. Rapids benefits of PI 4. Reports 5. Data reconciliation + demo 6. Link to manufacturing costs

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Before PI RE-KEYING OF DATA PRINTOUTS LABORATORY REPORTS TELEPHONE CALLS HUMAN ERROR Time consuming to consolidate reports When?

OXOCHIMIE OXOCHIMIE at OSI conference 1999 The PI project n Initiated by Elf group n Limitation with DCS historical (ABB MOD 300) n Motivated team for installing the PI system n Fast project n Immediate results

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Project planning n Dec 96:Project definition n Jan 97:Project kickoff n Feb 97: Hardware purchase n March 97:PI start up n Avril 97: User training n June 97: Laboratory transfer on PI n Feb 98: Automatic daily reports n March 98: Manufacturing costs

OXOCHIMIE OXOCHIMIE at OSI conference 1999 PI implementation n DCS: ABB MOD 300 n Alpha server 1000A 5 / VMS 7.1 n PI2 license 5000 tags (3800 used) n existing PC network (W95)

OXOCHIMIE OXOCHIMIE at OSI conference 1999 What they say about PI (1) Console operator « It is a great advantage of PI above DCS historical, Process Book gives facilities to configure appropriate scales, time ranges, tags… » Shift supervisor « When you are back on the plant after a shift break, we do identifie previous modifications. With 2 or 3 clicks we get the right information… »

OXOCHIMIE OXOCHIMIE at OSI conference 1999 What they say about PI (2) Day foreman « The system is user friendly » Lab supervisor « By mixing lab data and process, we do understand the quality variations » Logistic engineer « With PI and associated tools, we really get the right data. Time consuming is divided by 3 »

OXOCHIMIE OXOCHIMIE at OSI conference 1999 What they say about PI (3) PI administrator « The PI system gave me hard days at start up, but It is a pleasure to see people happy with it » Site general Manager «PI is the good tool, we will install it on the other plants »

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Rapid benefits 4 4 After training phase, Process book was largely used for trouble shooting mainly 4 4 Every incident is investigated with PI 4 4 Increased reliability 4 4 Daily optimization 4 4 Obtain returns

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Plant reliability %

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Daily reporting n Manufacturing report show yield variations and performance n Laboratory reports include process data n PI Data link + PI Perf equation usage n Replacement of our rekeyed report by automatic PI reports

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Morning manufacturing report

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Morning laboratory report

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Other reports n Monthly manufacturing report: Totaliser tags: integration of daily rates n Identification and reconstruction of plant model (unit by unit): mass balance n Maintenance report: usage rate of equipments

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Corporate application tools used n X / Y add-in in Procbook for correlation study n Comparison of laboratory analysis versus on line analyzer n Temperature profile analysis for tubular reactors n SQC reports from laboratory (Excel 97)

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Data reconciliation è Complexity of numerous units and links è What is Datrec? è Demo

Complexity of units products links

OXOCHIMIE OXOCHIMIE at OSI conference 1999 What is Datrec n Reconciliate data n Detect faulty measurement device n Compute daily/monthly material balance for the whole plant from raw materials to finished products n Developed by Elf research center (Solaize) n Distributed by Honeywell and Technip

OXOCHIMIE OXOCHIMIE at OSI conference 1999 General characteristics n Treat any redundancy equation: - Linear (mass balance) - Non linear (energy balance, constituent balance) n Estimate the missing measurements n Power of maths in user friendly interface n PI Interface (through PI API) : - instantaneous - average - integration

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Results with Datrec n Gets accurate coherent and reliable data to generate yield and mass balance n Improves data quality, feed back of faulty values n Feeds sound data for manufacturing costs calculation

OXOCHIMIE OXOCHIMIE at OSI conference 1999 PI / Datrec / Cost system PI DATREC Daily balance Production report Monthly balance Plant VCS COSTS PC Data

OXOCHIMIE OXOCHIMIE at OSI conference 1999 DATREC DEMO

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Manufacturing cost project Objectives: n Calculate the variable costs of productions based on market prices. n Generate quantity repartition by product for each shareholder

OXOCHIMIE OXOCHIMIE at OSI conference 1999 VCS OXO PRINCIPLES Ü PI: collect technical data + mass balance + analysis of deviations Ü DATREC: reconciliate data Ü PC: chemicals consumption and prices Ü VCS: Variable Cost system. feed stock balance (production / stocks / sales). consumption by product - cost calculation of each product - product cost for each shareholder - variance reports

OXOCHIMIE OXOCHIMIE at OSI conference 1999 Questions ?