Conoco Denver Refinery Implements Six Sigma Loop

Optimization Process Using Honeywell Loop Scout,

Saving 500k$/year

Scott Gallagher, Conoco

Randy Miller, Lane Desborough, and Peter Jofriet, Honeywell
Abstract A joint Six Sigma project was undertaken between
Conoco and Honeywell to optimize control loop maintenance at the
Denver Refinery. A Six Sigma DMAIC (Define, Measure, Analyze,
Improve, Control) work process for control loop monitoring and
maintenance was developed, implemented, and validated. Loop
Scout was used to collect performance data on all of the control
loops. This data was then analyzed and the focus was narrowed
to an economically significant, poor-performing subset of the
control loops. From this opportunity list, specific cause (e.g. valve
stiction) and effects (e.g. common oscillations) were identified,
and prioritized resolution actions were performed. A work process
was delivered that initiates and sustains optimization of Conocos
loop repair resources. Based on a validated cost/benefit analysis,
the process was then rolled-out to four refineries.

INDUSTRY SOLUTIONS FOR A CHANGING WORLD USERS GROUP 2002

 CONTROL LOOP MANAGEMENT
SOLUTION
Scott Gallagher, Conoco
Lane Desborough and Randy Miller, Honeywell
 OUTLINE

Maintenance Objectives
Why Loop Scout was chosen
Loop Scout Service
Six Sigma and Loop Scout (DMAIC)
Benefits
 MAINTENANCE OBJECTIVES

Reliability Maturity Continuum

Source: Strategic Asset Management Inc.

Reliability-Centered Maintenance
(RCM)
Reliability %

Predictive Maintenance

Preventative Maintenance

Reactive Maintenance

Maintenance expense $$
CONOCOS MAINTENANCE PRACTICES
Moving to RCM will drive maintenance savings

100%
90%
Conoco control loop maintenance range
80%
70% industry average for all maintenance

60% Target
50%
40%
30%
20%
10%
0%
reactive preventative predictive
 MAINTENANCE OBJECTIVES
TO REALIZE RCM

Performance/Criticality vs. Fixed Interval based

Applicable plant wide corporately
Automated
Provides actionable maintenance
recommendations
Sustainable/Measurable benefits realized
Creates a work process that drives and
maintains optimal loop maintenance (RCM)
WHY LOOP SCOUT WAS CHOSEN

Other Options Considered

Non-Intrusive Closed Loop Analysis
All Control Loops Included
Easily implemented on TDC3000 GUS
or APPNode
 LOOP SCOUT SERVICE
User defined prioritization
Loop Type
Unit
Valve Stiction
Loop Scout Performance
Hyperlink Criticality
to other Criticality weighted performance
loops at same One click sorting KPI
frequency

Overview
Report

Detail
Report

Common
Oscillations
Analysis

Data Collector
Scheduled
GUS/APP/OPC
30 min setup
Smart sampling
Scout Express Loop Scout
Server
Client
6 SIGMA AND LOOP SCOUT

D (Define)
M (Measure)
short project
A (Analyze)
I (Improve)

C (Control) Annual Loop

Scout service
 DEFINE / MEASURE
Steps
1. PERFORMANCE 2. IMPACT 3. ECONOMICS

642 Control Loops

17%
17% 14%
14% 153 High Impact Loops
2% 5%
7% 21%
4%
4% 7%
16%
16%
High

14%
14%

28%
30%
Low
10%
10%
25%
25%

excellent acceptable fair poor openloop inactive saturated

 ANALYZE
Steps
1. IDENTIFY 2. PRIORITIZE
Tag Eng Units Loop Type Sample Performance Impact Priority Valve Oscillation CPI COV PV Mean OP Mean Collection Date
Time Stiction Period
FC1 BPD flow 1 poor High 14 5 1m 38s 0.099885 0 27100.44 76.68 12-Oct-2001 17:38:17
QC855 PERCENT other 30 poor High 14 N/A 17m 38s 0.051999 0.01 30.14 40.65 17-Oct-2001 03:49:12
FC254 BPD flow 1 poor High 14 99 2m 23s 0.006458 0.02 3987.82 50.89 12-Oct-2001 17:25:21
FC277 BPD flow 1 poor High 14 11 0m 11s 0.14447 0 2949.83 69.61 12-Oct-2001 17:25:21
FC214 BPD flow 1 poor High 14 5 0m 48s 0.089248 0 6249.95 74.14 12-Oct-2001 22:00:07
TC216 DEG F temperature 30 poor High 14 N/A 33m 38s 0.11185 0 713.57 17.12 17-Oct-2001 03:49:12
FC103 BPD flow 1 poor High 14 18 0m 57s 0.088726 0 18000.5 72.03 12-Oct-2001 18:53:07
FC108 BPD flow 1 poor High 14 0 0m 10s 0.10089 0

r i t y
11192.71 46.73 12-Oct-2001 18:53:07

o
FFC170 BPD flow 1 fair High 12 0 3m 42s 0.040617 0.01 824.35 16.36 12-Oct-2001 17:25:21

Pri
PC164 PSIG pressure 5 fair High 12 N/A none 0.027833 0.01 101.47 34.38 13-Oct-2001 07:48:39
2. Determine loop performance
=
PC188 PSIG pressure 5 fair High 12 N/A none 0.008953 0.01 46.71 103.38 13-Oct-2001 07:48:39
FC341 BPD flow 1 fair High 12 2

a c t1m 1s 0.20956 0.01 4250.8 62.24 12-Oct-2001 17:38:17

p
FC343 BPD flow 1 fair High 12 99 1m 6s 0.21085 0 370 65.56 12-Oct-2001 17:38:17

xIm
FC355 BPD flow 1 fair High 12 9 1m 16s 0.1746 0.01 9202.48 65.57 12-Oct-2001 17:38:17
FC879 BPD flow 1 fair High 12 5 0m 58s 0.23782 0 8838.42 50.4 12-Oct-2001 22:00:07
FC311
FC207
BPD
BPD
flow
flow
1
1
fair
fair
High

n
High
c e 12
12
61
2
2m 46s
5m 21s
0.0080326
0.0012036
0.02
0.01
449.48
1066.21
25.78
25.85
12-Oct-2001 17:25:21
12-Oct-2001 22:00:07
FC218 BPD flow 1

r m
fair
a
High 12 18 7m 53s 0.051407 0 6072.36 69.16 12-Oct-2001 22:00:07

o
FC235 BPD flow 1 fair High 12 1 3m 53s 0.008435 0 1600.73 13.66 12-Oct-2001 23:27:58

f
Per
FC259 BPD flow 1 fair High 12 37 8m 21s 0.16762 0 5551.18 51.08 12-Oct-2001 23:27:58
FC262 BPD flow 1 fair High 12 8 19m 3s 0.08104 0 299.82 41.01 12-Oct-2001 23:27:58
FC263 BPD flow 1 fair High 12 5 2m 36s 0.063231 0.01 124.75 66.33 12-Oct-2001 23:27:58
FC320 BPD flow 1 fair High 12 0 8m 22s 0.010693 0 8525.33 62.98 12-Oct-2001 23:27:58
FC333 LBS/HR flow 1 fair High 12 5 2m 9s 0.18975 0 2997.49 42.05 13-Oct-2001 00:55:11
PC209 PSIG pressure 5 fair High 12 N/A 11m 19s 0.11113 0.01 12.77 41.69 13-Oct-2001 09:24:27
PC216 PSIG pressure 5 fair High 12 N/A 33m 36s 0.0043141 0.07 6.83 57.85 13-Oct-2001 09:24:27
PC323 PSIG pressure 5 fair High 12 N/A 32m 46s 0.020402 0.01 11.4 54.56 13-Oct-2001 09:24:27
PC344 PSIG pressure 5 fair High 12 N/A 16m 11s 0.092836 0.01 6.93 49.47 13-Oct-2001 09:24:27
TC369 DEG F temperature 30 fair High 12 N/A 39m 13s 0.13628 0 724.28 28.12 17-Oct-2001 03:49:12
FC116 BPD flow 1 fair High 12 2 6m 57s 0.0086326 0.04 628.74 22.04 12-Oct-2001 18:53:07
FC143 BPD flow 1 fair High 12 5 1m 42s 0.017242 0 5801.32 53.94 12-Oct-2001 20:20:54
FC115 BPD flow 1 fair High 12 0 6m 0s 0.033713 0 6697.12 85.12 12-Oct-2001 20:20:54
FC158 BPD flow 1 fair High 12 21 0m 53s 0.12221 0 10728.43 49.57 12-Oct-2001 21:49:09
FC500 GPM flow 1 fair High 12 74 5m 48s 0.029216 0.01 34.85 65.27 12-Oct-2001 21:49:09
 IMPROVE
Steps
1. REPAIR 2. VALIDATE 3. VALUE

Work Package - The 33 Minute Problem

Opportunity: TC1 is high critical, performance is only fair

Failure: TC1 is oscillating at 33 minutes
Failure Effect: Five other loops are oscillating at 33 min.
Investigation: All six are related loops within the process
Diagnosis: PC1 valve stiction probability of 95%
1. Place PC1 in manual
2. Size/Repair PC1
Work Package: Install positioners, Re-tune
Validate: As-left analysis using Loop Scout
Benefit: 300+% return on repair investment
 CONTROL
Steps
1. AUTOMATION 2. TRAINING 3. CRITICALITY 4. WORK PROCESS

Implement
Implement Assess
Assess Criticality
Criticality Using
Using
Criticality-
Criticality- Ranking Method
Ranking Method
based
based
Schedule
Schedule
Assess
Assess
Performance,
Performance, Sort
Sort and
and Develop
Develop and
and Use
Use Loop
Loop Scout
Scout
Collect
Collect Data
Data Stiction,
Stiction, Common
Common Prioritize
Prioritize based
based Execute
Execute to Assess
to Assess
using
using RTDC
RTDC Oscillations,
Oscillations, on
on Performance
Performance Work
Work Repair
Repair
Tuning
Tuning Changes
Changes and
and Criticality
Criticality Packages
Packages Effectiveness
Effectiveness
using
using Loop
Loop Scout
Scout

Reactive
Reactive
Legend
Legend Maintenance
Maintenance
Track
Track Benefits
Benefits
using
using Six
Six
Work
Work Orders
Orders Sigma
Sigma Methods
Methods
One-time
One-time Human
Human from
from Ops
Ops Investigate
Investigate
Activity
Activity and
and Repair
Repair Valve
Valve

Recurring
Recurring Human
Human Set
Set Benefits
Benefits
Activity Tune
Tune Controller
Controller Targets
Activity Targets and
and
Expectations
Expectations
Automatic
Automatic Repair
Repair // Replacement
Replacement
Activity
Activity Measurement
Measurement Device
Device
 BENEFITS

Optimization
Control Variation Reduction, Push
Constraints
APC Uptime
Higher Yields, Throughput, $$

Maintenance
Work Prioritization - Just in Time
Maintenance
High Frequency, Passive Diagnostics
Performance History
 SUMMARY

On the path to Reliability Centered

Maintenance
Six Sigma accelerated the pace
Loop Scout was key for DMAIC