Advances In Digital Automation Within Refining

Advances in Digital Automation within Refining

Advances in Digital Automation within Refining

Tim Olsen

Emerson Process Management

SpeakerSpeaker

Tim Olsen

Emerson Process Management

Emerson, 1998 – Present

• Performance Consultant

UOP, 1990 – 1998

• Technical Advisor on Refinery Unit Startups

The Digital RefineryThe Digital Refinery

The continuing evolution in digital computing and communication capabilities and the application of these technologies have led to fundamental differences in the way processing plants operate and will continue to change the way they operate in the future. We can characterize these changes as “The Digital Refinery”

Background: Advances in Computing

Examples: Advances in Automation within Refining

Typical Process Computer’s PerformanceTypical Process Computer’s Performance

50% per year increase! Compounded for 40 years!

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P C - S in g leC o re

P C - M u ltip leC o re s

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Computer AdvancesComputer Advances

Cray 2 Supercomputer 1 Gigaflop1985 - $23 millionRef Wired , February 22, 2008 , by Rob Beschizza

Cray CX1: 4 Terraflops

$25,000

Available on Amazon.comRef: Wired; September 16, 2008; by Brian Chen

Memory CostMemory Cost

70% per year increase! Compounded for 40 years (RAM); 25 years (Disk) !

100 gigabytes – Basic Demographic information on every human on earth!

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D ata R e f: R . K u rz w e il; T h e S in g u lar ity is N ear ; Vik in g , 2005, p .75 , 76

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IP Network Communication – Wired (Max - Bandwidth x Distance (wo amp))IP Network Communication – Wired (Max - Bandwidth x Distance (wo amp))

Any information will be available anywhere! Bandwidth will substitute for local memory!

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Network Communication - WirelessNetwork Communication - Wireless

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Ref: R. Kurzweil; The Singularity is Near ; Viking, 2005, p.77

200% per year compound increase!

The Exception - Software Productivity Growth The Exception - Software Productivity Growth

Only 4% per year increase from 1970 to 2000; less thereafter! Salary increases similar! No net cost reduction.

Software is dominant cost in system development/ implementation!

However, software has much longer life than hardware.

Implications of Computing TrendsImplications of Computing Trends

Low cost computing / communications replaces higher cost “other”

“Distance Doesn’t Matter” - Physical location of individuals irrelevant with regard to communication and information availability – virtual organizations

Computational limits are receding

Everything that can be digitized will be digitized

No “practical limits” on data / information storage

What does this mean for the Refining Industry?

What does this mean for the Refining Industry?

The Growth of The Smart Refinery through Digital Automation

Older Automation Field Networks – Analog 4-20 maOlder Automation Field Networks – Analog 4-20 ma

4-20mA

Only 1 value is transmittedOnly one direction

ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, RS_STATE, TEST_RW, DD_RESOURCE, , MANUFAC_ID, DEV_TYPE, DEV_REV, DD_REV, GRANT_DENY, HARD_TYPES, RESTART,

FEATURES, FEATURE_SEL, CYCLE_TYPE, CYCLE_SEL, MIN_CYCLE_T, MEMORY_SIZE, NV_CYCLE_T, FREE_SPACE, FREE_TIME, SHED_RCAS, SHED_ROUT, FAIL_SAFE, SET_FSAFE, CLR_FSAFE, MAX_NOTIFY,

LIM_NOTIFY, CONFIRM_TIME, WRITE_LOCK, UPDATE_EVT, BLOCK_ALM, ALARM_SUMACK_OPTION, WRITE_PRI, WRITE_ALM

ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PVOUT, SIMULATE, XD_SCALE, OUT_SCALE, GRANT_DENY, IO_OPTS, STATUS_OPTS, CHANNEL, L_TYPE, LOW_CUT, PV_FTIME, FIELD_VAL, UPDATE_EVT, BLOCK_ALM,

ALARM_SUM, ACK_OPTION, ALARM_HYS, HI_HI_PRI, HI_HI_LIM, HI_PRI, HI_LIM, LO_PRI, LO_LIM, LO_LO_PRI, LO_LO_LIM, HI_HI_ALM, HI_ALM, LO_ALM, LO_LO_ALM

ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PV, SP, OUT, PV_SCALE, OUT_SCALE, GRANT_DENY, CONTROL_OPTS, STATUS_OPTS, IN, PV_FTIME,

BYPASS, CAS_IN, SP_RATE_DN, SP_RATE_UP, SP_HI_LIM, SP_LO_LIMST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PV

SP, OUT, PV_SCALE, OUT_SCALE, GRANT_DENY, CONTROL_OPTS, STATUS_OPTS, INPV_FTIME, BYPASS, CAS_IN, SP_RATE_DN, SP_RATE_UP, SP_HI_LIM, SP_LO_LIM, GAIN

RESET, BAL_TIME, RATE, BKCAL_IN, OUT_HI_LIM, OUT_LO_LIM, BKCAL_HYS, BKCAL_OUT, RCAS_IN, ROUT_IN, SHED_OPT, RCAS_OUT, ROUT_OUT, TRK_SCALE,

TRK_IN_D, TRK_VAL, FF_VAL, FF_SCALE, FF_GAIN, UPDATE_EVT, BLOCK_ALM, ALARM_SUM, ACK_OPTION, ALARM_HYS, HI_HI_PRI, HI_HI_LIM, HI_PRI, HI_LIM, LO_PRI,

LO_LIM, LO_LO_PRI, LO_LO_LIM, DV_HI_PRI, DV_HI_LIM, DV_LO_PRI, DV_LO_LIM, HI_HI_ALM, HI_ALM, LO_ALM, LO_LO_ALM, DV_HI_ALM. DV_LO_ALM

Digital FieldNetworks Require

To Support

Digital FieldNetworks Require

To Support

But Computers and Communication and Calculations have migrated to the Field Devices…But Computers and Communication and Calculations have migrated to the Field Devices…

Site Wide Control Room

Coordinated Multiple Loop Digital Control

Computer Screen Interface

Control Rooms have also ModernizedControl Rooms have also Modernized

Each Unit had a separate Control Room

Single Loop Analog Control

Panel Board Interface

Photo Ref: Emerson Process Management

Photo Ref: Emerson Process Management

Ref: A. Chatha; “Current Business Drivers and Trends;” ARC 2009 Orlando Conference; February, 2009

Advances in Digital Automation in RefiningAdvances in Digital Automation in Refining

Predictive Diagnostics Key Performance Indicators (KPI) Advanced Process Control (APC) Wireless Health Monitoring Single Site Engineering Support /

Control Room

Sample Examples

Predictive Diagnostics and AnalyticsPredictive Diagnostics and Analytics

Condition Detection BEFORE it becomes a problem in the Plant!

Photo Ref: Emerson Process Management

Future Trends – Predictive Analytics - How do we avoid this?Future Trends – Predictive Analytics - How do we avoid this?

Photo Ref: Emerson Process Management

Smart cars monitor tire

pressure

Smart cars monitor tire

pressure

Tire icon indicates low pressure

Tire icon indicates low pressure

Car advises driver of abnormal situation made possible via new technologiesCar advises driver of abnormal situation made possible via new technologies

Photo Ref: Emerson Process Management

Two requirements: - Sensing technology- Presentation to user at the right time

Two requirements: - Sensing technology- Presentation to user at the right time

Hydrocracker Quench Control ValveHydrocracker Quench Control Valve

Low instrument air pressure to quench valve actuator – poor response to control

Maintenance and Operator alerted

Potential exothermic reaction runaway avoided

No emergency depressuring / shutdown required

No safety incident

FC

TI

Feed

FC

H 2Recycle

FC

TC

AI

TI

TI

TI

TI

Effluent

TI

FC

FC

FC

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TC

TC

H 2 Quench

H 2

ALERT

Labor Savings – Predictive AnalyticsLabor Savings – Predictive Analytics

Studies have shown that more than 60% of a typical instrument technician’s trips to the field result in either no action or a minor configuration adjustment that could be done from their office with smart instruments.

Manpower savings 1.6 hours per instrument per year with root cause analysis– 1,000 instruments

– 1,600 hours savings

RoutineCheck

NoProblem

FailedInstrument

PluggedLines

ZeroOff

CalibrationShift

4%6%6%

20%

28%

35%

0RoutineCheck

NoProblem

FailedInstrument

PluggedLines

ZeroOff

CalibrationShift

4%6%6%

20%

28%

35%

0

Smart Turnaround CaseSmart Turnaround Case

Three-year study with Gulf Coast Refiner to reduce maintenance spending utilizing predictive instrument and valve diagnostics

Average maintenance savings $100,000 USD per year

Unexpected benefit of ~$1 million USD per year operations with better process control and plant availability

Fix only what needs maintenance, nothing more

System Modernization CaseSystem Modernization Case

“Poor reliability and frequent shutdowns were undermining the refinery's efforts to serve the market effectively.”

Automation System Upgrade on Gulf Coast Hydrocracker

Results showed sustained 50% reduction in reliability risk

Estimated Savings, $1-2 Million per year

Key Performance Indicators, KPIKey Performance Indicators, KPI

Quickly at a glance, understand issues with the refinery.

Poor performance does not go undetected.

Energy use per barrel processed is tracked and trended.

Predictor for poor heater operation or effects of heat exchanger fouling.

Detect losses with heat and weight balancing

KPI Dashboard CaseKPI Dashboard Case

“After the installation of data reconciliation software and a KPI dashboard display, the model showed an incorrect process unit lineup. A recycle line was open that should have been closed. After closing the recycle we were able to increase hydrotreater throughput by 8 percent. This resulted in an energy savings of $400,000 per year and a product profit increase of $500,000 per year, for a total benefit of $900,000 USD per year.”

Planning Manager

Refinery, North America

Abnormal Operation does not go Undetected

Advanced Process Control, APCAdvanced Process Control, APC

Embedded APC within Modern Automation Systems– Better measurements and tighter control valve resolution

– Easy and Faster Startup

– Easy for Board Operators to understand, thus stays “ON”

– Easy to Maintain and Change as Needed

IMPROVED PROFITBY CHANGING

TARGET

REDUCEDVARIABILITY

POOR CONTROL

$PROFIT

SPECIFICATION LIMITSafety Margin

APC Case, Complex Distillation ColumnAPC Case, Complex Distillation Column

2 weeks configuring and commissioning

1 week proof testing

Average overehead product loss reduced by ~22%

Impurities in bottoms were maintained within specifications.

Steam usage reduced ~7%

Estimated value over $700,000 USD per year

Bottoms Main Product

Feed 1

TC

TI

Feed 2

At constant OH rate, this temp sets the energy balance (R/F).

Internal Reflux

Lt EndsImpurities

This flow sets the material balance

(D/F)

Complicated OH

condenser system

LC

Pump Health Monitoring Current Pump Health Monitoring Current PracticePracticePump Health Monitoring Current Pump Health Monitoring Current PracticePractice Preventive pump maintenance

programs pull pumps whether the pump needs maintenance or not increasing pump maintenance cost

API RP 52 (auxiliary pump seal flush system) improves safety but does not include monitoring for undetected failures

Auxiliary pump seal flush system alarms not implemented– Insufficient spare wiring in the field

Typical Pump Seal Assembly•What: Unpressurized buffer fluid circulation

through reservoir

•Why: Backup seal

•Where: High vapor pressure fluids, emissions

Pump Health Monitoring CasePump Health Monitoring CasePump Health Monitoring CasePump Health Monitoring Case

NA Refiner Wireless Field Instruments on Pumps

Secure, robust Smart Wireless gateway

Benefits

– Health monitoring enables prompt detection of abnormal pump vibration

– Wireless sensor network implementation saved 75% of the cost over wired alternative

Multi-Site Control Center / Remote SupportMulti-Site Control Center / Remote Support

Control CenterEngineering

CenterPlant 1

Plant 2Plant 3

Photo Ref: Emerson Process Management

But…. Has it Mattered?But…. Has it Mattered?

US Oil Refining Industry Employee ProductivityUS Oil Refining Industry Employee Productivity

Employee Productivity Up 300%, Even With:- Increased Complexity - More Crudes/ Product Grades

- Increased Regulatory Requirements

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Ref: Crude Run: US DOE EIA: http://tonto.eia.doe.gov/dnav/pet/hist/mttrius2a.htmEmployment: US DOL BLS; http://www.bls.gov/oes/

Refining Safety ImpactRefining Safety Impact

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Ref: US DOL BLS http://www.bls.gov/iif/oshsum.htm

ConclusionsConclusions

The continuing evolution in digital computing and communication capabilities and the application of these technologies have led to fundamental differences in the way plants operate and will continue to change the way they operate in the future.

Operate Smarter, More EfficientlyOperate Smarter, More Efficiently

Diagnose and Alert problems prior to failure or safety incident

Opportunity to act on information to prevent failure or safety incident

Identify root cause of problem prior to going into the field Quickly see KPI Dashboards to detect abnormal

operation

Questions?Questions?

1. Questions? Comments – contact [email protected]

2. More material on subject:

www.SmartRefinery.com