Operations Reliability & Sustainability

Operation excellence is under pressure in recent times. There is a need to identify the perfect solution at the right time to provide greater value than ever. It is also essential to focus on O&M procedures to deliver results at a lower cost, increase reliability and improve profit margins.

8.30am

Registration

Welcome Address by Chairman

9.30am

Industry Address

IEC 62591 (WirelessHART) the International Standard for Wireless in Process Applications

WirelessHART (IEC 62591) is the only international standard for wireless sensor networks. This session will explain how WirelessHART was designed specifically to meet the needs of users in the process industries. It will cover how WirelessHART carries on a tradition of multi-vendor interoperability which started with the HART Communication Protocol (4-20mA + HART digital) which has been used and trusted by users and manufacturers alike for more than two decades.The session will explain the underlying technology which has made WirelessHART the leading wireless solution for process applications because by providing the highest degree of interoperability; including the ability to easily integrate devices from different suppliers and use common configuration tools and technician skills.

The presentation will also cover aspects like secure commissioning, low cost and risk of installation, as well as coexistence with other wireless technologies

Jonas Berge, Director, PlantWeb Consulting

10.00am

Organising OPEX savings to ensure ROI

Customers in emerging regions are increasingly facing challenges around lowering the operating expenses without sacrificing the required operations and maintenance to run these plants efficiently. One area where customers look towards when developing strategies to lower OPEX is plant wide automation strategies that have touch points to process variables, critical rotation equipment, and electrical devices. Traditionally these areas have been viewed as separate islands of information and customers need to look at how to develop solutions that are cross-functional.  This will remain a significant impact area in developing and realizing OPEX saving strategies.

GE is committed to leveraging its wide product and system portfolio in developing such solutions that add tangible value to customers.

Devender Singh, Regional Marketing Manager, GE Energy

10.30am

Tea break

11.00am

New Application Possibilities in Chemicals, Petroleum/Energy, Waste & Water Industry Using High Resolution Continuum Source (HR-CS) AAS

HR-CS AAS allows fast sequential multi element analysis, operational simplicity, robustness, speed and flexibility. The HR-CS AAS system of Analytik Jena, named contrAA has a xenon short-arc lamp as a continuum source with optimal intensity over the entire wavelength range relevant for AAS. The evaluation of molecular absorption bands, allowing the analysis of additional elements, is a further innovation.  The high-resolution echelle spectrometer allows an optimum line separation.

Aside from the intensity of the analysis line, the entire spectral vicinity is recorded on the CCD array detector simultaneously. Using a high number of reference pixels in combination with fully automated correction routines a unique simultaneous background correction is possible. The lecture will describe interesting applications demonstrating new information content for the user especially in the field of chemicals, petroleum/energy, waste and water industry. Furthermore, the use of direct solid sampling technique will be shown as a unique possibility

Burcu Ozmen, Product Specialist Optical Spectroscopy, Analytik Jena AG

11.30am

Improving lifecycle costs of plants by reducing energy consumption

• Ensuring better energy management with energy analysis modeling and new  technologies
• Understanding power consumption – Outage management and lifecycle
  How to reach net-zero energy consumption in the long run?

Norman BM Lee, Managing Director, Actsys Process Management Consultants Pte Ltd

12.00pm

The Success Story of Korea Southern Power Co, LTD Remote Monitoring & Diagnostic Center

• Case study of KOPSO and its ability to meet Korea’s power demand
• How it manages 3 power plants with 16 gas turbines, 16 steam turbines & boilers and a huge number of BOP assets
• GE System 1 as the existing State-Of-Art condition monitoring system and how automated diagnostics system was added on
• How KOPSO’s RM&D center has emerged as best-in-class with advanced condition monitoring processes and technologies?
• Testimonies of RM&D center for delivering high level of value with improved machine reliability
   

Kim Mun Seok, Expert, Technology Support Center, Korea Southern Power Company

12.30pm

Lunch break & visit exhibition

Opening Address by Chairman

Dil Devaser, Consultant, Power

Process Automation

Process engineering improves the performance of a plant, increase productivity which in return reduces maintenance and operation costs. Industries have to leverage on the advances in technology and increase ROI. 

2.00pm

Developing robust and flexible O&M procedures to integrate with innovation in technology sustainability to avoid shutdown and failures

The performance and reliability of a distribution services is dependent on Operations and Maintenance practices of the plants. In a power Utility, interruption following plant failure grossly affects the reliability index with losses to the consumers. This problem can be tackled with stringent operation and maintenance practices.
 
CESC limited, a century old company engaged in power generation and distribution of electricity realized that to be a front runner in power business, reliability in power supply should be the primary focus area and developed stringent asset management norms starting from plant selection, procurement, erection, commissioning and maintenance practices along with asset creation, handing over and taking over principles. CESC developed in-house software for asset management considering the best practices of utilities and the OEM, identified Standard Operating Procedures (SOP)s for critical plants and maintenance regime. The software also seamlessly integrated with outage management software (OMS) for restoration and spare management.

CESC shifted from age old time based maintenance to condition based maintenance and root cause analysis to remove of the primary causes of failure and adopted the 1st time right policy for asset creation.  CM tools like PI, Tan delta, Furan analysis PDC analysis, DGA FRA and IR thermography, PD, Dynamic Contact resistance are applied for Transformers, Circuit Breakers, LCM for Lightening arrestor and PD Monitoring for HT Cables, Capacitors.
 
CESC’s effort to make high capacitiy ring network with RMUs, SOPs and latest technical practices and has improved the average interruption duration from 3 hrs to 1.5 hrs following any network outage.
 
CESC sought technical support from the Singapore Power and two years consultancy services of SPGS from 2008-2010 has greatly helped CESC to overcome the shortcomings and 2.5 million CESC consumers are happy today to get a much reliable supply.

Sankar Mukhopadhyay, Senior Manager (Training), CESC Ltd

2.30pm

Effective Mixing Techniques

• The Various Styles Of Mixing Based On The Materials Involved
• The Results Desired
• Common Problems Faced
• The Choice Of The Right Instruments 
• Important Factors To Determine Before Deciding On Instruments
• Particle Size Reduction
• Heating As An Aid
• Grinding As A Pre-Requirement To Wet Disperse

Fabian Especkerman, Senior Regional Sales Manager, South East Asia, IKA

3.00pm

Plant Safety

Achieving robust plant safety and operations require many effective strategic elements to be included in the planning and design process, and organizations often find this a great challenge.

What and where should organizations focus on and what are the core features and approaches? How do we utilize and effectively incorporate emerging new technology to produce and implement safety in process, automation and instrumentation? This conference will cover many grounds in the various critical areas.

Opening Address

Kwong Kok Chan, President, ICS

9.30am

Keynote Address

Safety Instrumented Systems

For all types of business, the risk for potential operating accountability exists. The Process Safety Standards provides guidance for realistic assessment and gainful reduction of these risks - critical to protecting the safety of personnel (employees and the public), asset, business continuation (including exposure to legal and regulatory compliance) and reducing environmental damage.

Risk tolerance and risk acceptance principles will be discussed with particular reference to Process Safety Standards and Safety Life Cycle concepts.

However, to achieve functional safety more management, know-how and planning than the regulatory requirements of original code are necessary. Procedural safeguarding measures being applied to prevent accidents will be discussed.

Stanley Joseph, Business Development Manager (Process Safety), Industry Automation and Drive Technologies, Siemens Pte Ltd

10.00am

Active Monitoring of Flow Line Heating Systems

Over the past 12 years, DEH has emerged as the primary alternative to Chemical Injection for prevention of Hydrate and Wax formation in subsea flow lines. During, or after a production stop, a current is injected into the flowline, heating the process fluids to maintain a temperature at which hydrates and waxy solids cannot form, allowing production to start with a minimum of effort.

This reduces the reliance on chemicals which has economic benefits to projects, is environmentally responsible and reduces risks involved in chemical transport and storage.

DEH power cables can lie idle for months or even years between operations, therefore, prior to applying power, it is advisable to verify the integrity of the system. The Wärtsilä DEH protection system performs integrity tests continuously, and alarms any failure, allowing operators to be aware of system availability at all times. This system was recently installed in the Tyrihans oil field in the harsh environment of the North Sea and has been field proven for almost 2 years. The methodology is safe, fast and reliable at detecting electrical faults in the subsea heating cables over the entire length of the pipeline.

Ingebjorg Lien, Specialist Engineer, Electrical Systems, Wartsila Norway A. S.

10.30am

Tea break

Balancing Safety with Profitability - Can Operators have the Best of Both Worlds to Reduce Risk and Increase Profitability?

Do we compromise safety to increase profitability? Can operators have the best of both worlds to reduce risk and increase profitability?

In most of today’s world, one would be thinking of 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 only 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 shut down. It has its “hands around the neck” of the plant management; it has ultimate ‘control” over the production process as it ties into the heart of the plant operation in view of its overriding safety functions.

So a wrongly chosen SIS may in fact causes more headaches if it often causes spurious trips, require regular mandatory system modifications, upgrades, repair, proof testing activities which inevitably require an SIS to shut down - which usually means a plant shutdown too.

This presentation outlines questions to consider for the Operators and Owners of plants to make the right choice in choosing a SIS that will help their plant to improve profitability and safety. Will today’s advances in technology and techniques produce such SIS solution?

Alvin Chin, Sales Director, HIMA S.E.A. SDN BHD

Panel Discussion: Plant Safety – how much is enough?

• Hear from operators on measures taken to ensure plant safety
• Risk levels vs. cost considerations – a balancing act
• Challenges faced, and the impact of increasingly stringent regulations

12.00pm

Lunch break & visit exhibition

Opening Address by Conference Chairman

Ho Weng Kuan, Associate Professor, NUS

2.00pm

Process Safety Management

Process  Safety Management   is  a collection of  Management  Systems  and   Implementations with the  purpose of  controlling  the  risk  of  accidents  and  focus on preventing the  accidents originating  from process hazards.  Controlling the risk is  primarily  about  reducing  risk of  human  error. The organisation has to address  various  Human  Factor Categories to  minimise   accidents.

CESC  Ltd  has  a  tradition  of up  keeping and maintaining  its  assets which are  rendering services   safely  for a long time ,  due  to application of   good safety management  techniques.  Accident rates  are   low  in  this  company   as  compared  to other  Utilities  in  India  due to excellent Safety Management Culture.

CESC  Ltd  got associated through SPGS , few years back , with Singapore Power , the best Distribution Company in the world , for  further improvement  in  safe  and  sound  work  culture.  Amalgamating  their  practices  in our   work  culture  yielded  reliability and quality.

Asit Kumar Bhattacharyy, Sr Deputy Manager ( HR), CESC Ltd

2.30pm

Making Intelligent Devices Easy to Use

When devices from multiple vendors were first integrated using bus technologies there were difficulties accessing all device features and there were difficulties to make full use of the features that could be accessed. Many plants were not able to use the device management software part of their asset management solutions to its full potential. A new concept was required to achieve even greater results with digital bus technologies. The new innovative solution to the problem was enhancements to an old technology that has been an unnoticed part of leading digital bus technologies for over fifteen years.

This international standard, called EDDL (IEC 61804-3), with enhancements, makes bus technologies more compatible with the competencies of maintenance technicians. EDDL makes intelligent devices easy to use in exactly the same way the World Wide Web made the Internet so easy that anyone could use it. Systems based on EDDL with enhancements now make maintaining intelligent devices very much easier for technicians and enable digital bus technologies to be fully utilized to derive greater result for the plant and there are no other means to achieve the same result.

Jonas Berge, Director, PlantWeb Consulting, Emerson Process Management

3.00pm

3.10pm

End of Day 2 Plant Processes and Safety Conference 2011