PPT Template - Invensysiom.invensys.com/EN/userGroupsPresentationsDallas2013/SimSci/SS... · Agenda • Why Invensys Software cares about Advanced Measurement Solutions (AMS) –

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SS OPTMZ-05Part 1Advanced Measurement Solutions

Joe Fillion - overviewRobert Hegger - AIT solution setDavid Seiver – Valero VGBOPCase StudySteve Newland – Phillips 66, ABSCase Study

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© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

Joe Fillion - overviewRobert Hegger - AIT solution setDavid Seiver – Valero VGBOPCase StudySteve Newland – Phillips 66, ABSCase Study

© Invensys 00/00/00 Invensys proprietary & confidentialSlide 2

Agenda

• Why Invensys Software cares about Advanced Measurement Solutions(AMS) – If you cannot measure it, you cannot control it

• ACA – HF, water and ASO measurements for an HF Alky unit

• Announcing a Partnership with Applied Instrument Technologies (AIT)

– Key inputs to the Software Stack with a full line of process analyticalinstrumentation

– GC, FTIR/FT-NIR/NIR, Mass Spec and Raman technologies

• Case Study: VGBOP – Valero Gas Blending Optimization Platform

• Announcing the ABS, next in the line of AMS

• Case Study: Ammonium BiSulfide at Phillips 66

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• Why Invensys Software cares about Advanced Measurement Solutions(AMS) – If you cannot measure it, you cannot control it

• ACA – HF, water and ASO measurements for an HF Alky unit

• Announcing a Partnership with Applied Instrument Technologies (AIT)

– Key inputs to the Software Stack with a full line of process analyticalinstrumentation

– GC, FTIR/FT-NIR/NIR, Mass Spec and Raman technologies

• Case Study: VGBOP – Valero Gas Blending Optimization Platform

• Announcing the ABS, next in the line of AMS

• Case Study: Ammonium BiSulfide at Phillips 66

Why Advanced Measurement Solutions?If you cannot measure it, you cannot control it

• Off-sites, Advanced Process Control, ROMeo, Yield Accounting--allneed measurements from the field in order to work or to work better

– More Accurate, faster and more appropriate measurements

– We have sold these solutions and some do not work because of the on-linemeasurements supplied by others, do not work. Take control of thesolution.

• Clients are demanding one complete solution:

– No finger pointing, one point of contact, contract, etc.

• Higher value generated having the correct measurements from thecorrect streams, in a closed system in real time.

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• Off-sites, Advanced Process Control, ROMeo, Yield Accounting--allneed measurements from the field in order to work or to work better

– More Accurate, faster and more appropriate measurements

– We have sold these solutions and some do not work because of the on-linemeasurements supplied by others, do not work. Take control of thesolution.

• Clients are demanding one complete solution:

– No finger pointing, one point of contact, contract, etc.

• Higher value generated having the correct measurements from thecorrect streams, in a closed system in real time.

Product Blending

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Crude Blending, CDU Feed & Rundown

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Summary:Advanced Measurement SolutionsWhat: The selection, integration, and implementation ofappropriate measurement technologies

Why: Enable real-time optimization and/or advanced control ofprocesses and blending operations through online measurementof key stream properties

How: Evaluate stream measurement requirements asdetermined by process optimization objectives, then configurean appropriate measurement solution

Where: Principally the refining industry• Off-sites (crude feed and finished blended products)• Unit optimization (CDU, FCC, alkylation unit and reformer units)• Petrochem: ethylene cracker feed analysis

Go Simple where ever possible – High Reliability, Low Maintenance andlow life cycle costs

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What: The selection, integration, and implementation ofappropriate measurement technologies

Why: Enable real-time optimization and/or advanced control ofprocesses and blending operations through online measurementof key stream properties

How: Evaluate stream measurement requirements asdetermined by process optimization objectives, then configurean appropriate measurement solution

Where: Principally the refining industry• Off-sites (crude feed and finished blended products)• Unit optimization (CDU, FCC, alkylation unit and reformer units)• Petrochem: ethylene cracker feed analysis

Go Simple where ever possible – High Reliability, Low Maintenance andlow life cycle costs

Total Performance Solutions•Performance CDU:

•APC & Romeo Real Time Optimization•FTIR/NIR for Crude and product stream analysis

•Performance FCC:•APC & Romeo Real Time Optimization•FTIR/NIR for Feed and product stream analysis

•Performance Blending:•Blend Optimization Supervisory System (BOSS)•FTIR/NIR for finished product stream analysis and Crude Oil

•Performance HF:•APC & Romeo Real Time Optimization•ACA.HF for catalyst and HCA.HF for Hydrocarbon streams

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•Performance CDU:•APC & Romeo Real Time Optimization•FTIR/NIR for Crude and product stream analysis

•Performance FCC:•APC & Romeo Real Time Optimization•FTIR/NIR for Feed and product stream analysis

•Performance Blending:•Blend Optimization Supervisory System (BOSS)•FTIR/NIR for finished product stream analysis and Crude Oil

•Performance HF:•APC & Romeo Real Time Optimization•ACA.HF for catalyst and HCA.HF for Hydrocarbon streams

© Invensys 10/23/2013Invensys proprietary & confidential8

ACA update:• Measures HF, Water and ASO in an HF Alky unit on-line

• Value Proposition:

• Safely operate at optimum HF and Water levels while avoidingAcid Run Away

• Optimize I-O ratio and minimize unit corrosion

• Reduce HF Regeneration costs.

• Beta in 2009 – 2010; Launched in 2011.

• Current Acceptance

• Gained 25% Market Share in the US from an order bookperspective

• Product Break through of the year and a finalist for theKirkpatrick Award

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• Measures HF, Water and ASO in an HF Alky unit on-line

• Value Proposition:

• Safely operate at optimum HF and Water levels while avoidingAcid Run Away

• Optimize I-O ratio and minimize unit corrosion

• Reduce HF Regeneration costs.

• Beta in 2009 – 2010; Launched in 2011.

• Current Acceptance

• Gained 25% Market Share in the US from an order bookperspective

• Product Break through of the year and a finalist for theKirkpatrick Award

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Announcing: AIT and InvensysPartnership• AIT will allow Invensys to supply turn key projects (software and on-

line measurements) for refining and chemical solutions.

• Technologies include GCs, FTIR/FT-NIR, NIR, Mass Spec and more.They are very strong in the refining and chemical markets

• Global Support Structure

• Robert Hegger, SVP, Applied Instrument Technologies

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• AIT will allow Invensys to supply turn key projects (software and on-line measurements) for refining and chemical solutions.

• Technologies include GCs, FTIR/FT-NIR, NIR, Mass Spec and more.They are very strong in the refining and chemical markets

• Global Support Structure

• Robert Hegger, SVP, Applied Instrument Technologies

Process Analytical Solutions forRefining Applications

Presented by Robert C. HeggerVice PresidentApplied Instrument Technologies16, October 2013

AIT

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© Invensys 23 October 2013Invensys proprietary & confidential12

Presented by Robert C. HeggerVice PresidentApplied Instrument Technologies16, October 2013

AIT

AITTechnology Portfolio

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Analysis Points for FTIR/NIR & GCAIT

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Analysis Points for FTIR/NIR & GC

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AITCustomer Base

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US FTIR/NIR Refinery Projects Executed AIT

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Global FTIR/NIR Refinery Projects ExecutedAIT

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Gasoline/Diesel Blending AIT

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PIONIR MVP• Database of gasoline, diesel & component stream models

• Plug ‘n play – predict out of the box

• Localize models specific to your refinery units & process

• Seamless calibration transfers to ANY other PIONIR unit

Process Development and RefineryLaboratory Analyzers AIT

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PIONIR MVP• Database of gasoline, diesel & component stream models

• Plug ‘n play – predict out of the box

• Localize models specific to your refinery units & process

• Seamless calibration transfers to ANY other PIONIR unit

Analect Diamond20 RefinIR• Ability to build predictive models

– Crude oil to final blends – up to 125°C• Seamless calibration transfer to on-line system

• Automated sampling

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RackmountPIONIR MVPGeneral purpose areaCost effective solutions

SCS & Probe Final blend component stream

Fiber Optic Link

On-line Fiber Optic based NIRAnalyzers

AIT

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Fiber Optic Link

PIONIR XTCHazardous Area

SCS & Probe

SCS & Probe

SCS & Probe

Multiple blend headers and/ormultiple component streams

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HydrocarbonSmartSystemHazardous area

Cell2

Cell1

Crude, intermediates orfinal products

On-line FTIR/FT-NIR Analyzers AIT

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Multiple blends and/or components using streams switching

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Wash and Validation System

• ASTM D6122 compliant

•Two, 36 liter tanks for wash andvalidation solvent

•Typical 3-6 month supply.

•Level indicators and switches.Generates warning on low level

Wash and Validation per ASTMprotocols

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Wash and Validation System

• ASTM D6122 compliant

•Two, 36 liter tanks for wash andvalidation solvent

•Typical 3-6 month supply.

•Level indicators and switches.Generates warning on low level

In-Line

• Fiber optics to direct insertionprobe

Extractive

• Extract representative sampleand transport it toanalyzer/sample system

Sampling

Fiber Opticsto Analyzer

In-situ or Extractive Sampling?

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In-Line

• Fiber optics to direct insertionprobe

Extractive

• Extract representative sampleand transport it toanalyzer/sample system

SamplePlumbed to

System

Select Samples from Stored Retains1 week

Install Lab Analyzer, Run retains4 weeks ARO

Continue to run routine line samples whileprocess system being fabricated & installed

16-36 weeks

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Continue to run routine line samples whileprocess system being fabricated & installed

16-36 weeks

Develop Models based on sample data collected1-2 weeks

Install Models on-line, monitor performance,update based on line samples

SulfurAnalyzer

RVPAnalyzer

AIT HSS FTIRAnalyzer

TriconexControls

AIT

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SampleRecovery

Fast LoopSCS

ASTMValidationTanksSample

Chiller Valero Gasoline BlendingOptimization Program

Wood River, IL• PIONIR NIR x 2 on Gasoline and Diesel• PIONIR NIR in the lab• Analect HSS FTIR (4 Stream) on Benzene

Reduction Unit• Analect RefinIR FTIR in the lab

Wilmington (LAR)• PIONIR NIR x 2 on Gasoline

Blending• PIONIR NIR in the lab

Phillips 66 References AIT

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Wood River, IL• PIONIR NIR x 2 on Gasoline and Diesel• PIONIR NIR in the lab• Analect HSS FTIR (4 Stream) on Benzene

Reduction Unit• Analect RefinIR FTIR in the lab

Bayway NJ Refinery• PIONIR 1024 on Gasoline

Blending

Analysis Points for FTIR/NIR & GC

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Description ApplicationAnalect HSS FTIR/NIR Analyzer Only•Fast Loop/Sample System•ASTM Validation•Models•Commissioning

Gasoline, Diesel, Components

Redundant Analect HSS FTIR/NIRAnalyzers Only•Fast Loop/Sample System/Recovery•ASTM Validation•Models•Commissioning


Multiple Blend Headers

Redundant Analysis

AITIndicative Pricing for Refinery Analyzers

Analect HSS FTIR/NIR w/Shelter•Engineering/system Integration•Fast Loop/Sample System/Recovery•ASTM Validation•Models•Commissioning


Single Blend Header

“VGBOP” Design Redundant FTIR/NIRw/Shelter•Engineering/system Integration•Fast Loop/Sample System/Recovery•RVP Analyzer•Sulfur analyzer•ASTM Validation


Multiple Blend Headers

Redundancy

Optimized Gasoline Blending –A Standardized Approach

Presented by David S. SeiverDirector of Blending APCTechnologyValero Energy16 October, 2013

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Presented by David S. SeiverDirector of Blending APCTechnologyValero Energy16 October, 2013

Valero’s Standardized Approach toOptimized Gasoline Blending

• The Analytical Package (VGBOP)– Key Gasoline Properties must be accurately measured on-line and standardized

systems & procedures in place to actively calibrate them to the primary labmeasurements that certify the blend

– Three (3) key analyzers can perform the job. Valero’s standards are:

• Redundant AIT Analect HSS On-Line FTIRs for measurement of Knock Engine, D86,FIA, and Densitometer lab measurements

• Redundant Grabner On-Line RVP/TVL analyzers for RVP and TVL

• XOS On-Line MWD XRF On-line analyzer for measurement of ppm-level Sulfur

• The Optimization Package– Valero has standardized on Invensys’ BOSS Optimizer & AMADAS QA/QC

• BOSS is full-featured, superior to competition, well integrated to other oilmovements applications, and meets all our blending needs

• AMADAS ensures that BOSS consistently delivers benefits over the long-term

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• The Analytical Package (VGBOP)– Key Gasoline Properties must be accurately measured on-line and standardized

systems & procedures in place to actively calibrate them to the primary labmeasurements that certify the blend

– Three (3) key analyzers can perform the job. Valero’s standards are:

• Redundant AIT Analect HSS On-Line FTIRs for measurement of Knock Engine, D86,FIA, and Densitometer lab measurements

• Redundant Grabner On-Line RVP/TVL analyzers for RVP and TVL

• XOS On-Line MWD XRF On-line analyzer for measurement of ppm-level Sulfur

• The Optimization Package– Valero has standardized on Invensys’ BOSS Optimizer & AMADAS QA/QC

• BOSS is full-featured, superior to competition, well integrated to other oilmovements applications, and meets all our blending needs

• AMADAS ensures that BOSS consistently delivers benefits over the long-term

What is VGBOP?•• VValero GGasoline BBlending OOptimization PPlatform

– A Standardized analytical approach to gasoline blending optimization.

– An integrated package/shelter system with several key sub-systems:• Analyzers

• Redundant AIT Analect HSS On-Line FTIRs; Redundant Grabner On-Line RVP/TVLanalyzers; XOS On-Line MWD XRF On-line analyzer

• Manual Sample Collection System (MSCS)

• Valero custom designed solution from Welker to purge, chill, and automatically fillmanual sample bottles for intra-blend routine header sampling

• Sample Conditioning System (SCS)

• Valero custom designed solution from Xenon to filter and condition all sample cominginto the VGBOP shelter before delivery to analyzers, MSCS, etc.

• Sample Recovery System (SRS)

• High availability proprietary system from Xenon to recover the VGBOP process streams

• Welker Sample Compositor for on-line certification of certain blends/sites & future

• Invensys Triconex TriGP for single data connection to DCS

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•• VValero GGasoline BBlending OOptimization PPlatform– A Standardized analytical approach to gasoline blending optimization.

– An integrated package/shelter system with several key sub-systems:• Analyzers

• Redundant AIT Analect HSS On-Line FTIRs; Redundant Grabner On-Line RVP/TVLanalyzers; XOS On-Line MWD XRF On-line analyzer

• Manual Sample Collection System (MSCS)

• Valero custom designed solution from Welker to purge, chill, and automatically fillmanual sample bottles for intra-blend routine header sampling

• Sample Conditioning System (SCS)

• Valero custom designed solution from Xenon to filter and condition all sample cominginto the VGBOP shelter before delivery to analyzers, MSCS, etc.

• Sample Recovery System (SRS)

• High availability proprietary system from Xenon to recover the VGBOP process streams

• Welker Sample Compositor for on-line certification of certain blends/sites & future

• Invensys Triconex TriGP for single data connection to DCS

Redundant On-Line Analect HSS FTIRAnalyzers installed at a Valero Refinery

• Measures multiple propertieslike RON, MON, D86, Olefins,Benzene, Aromatics, Density(API)

• Redundancy adds to uptime,aids in troubleshooting, and byaveraging results of the twoon-line we match the labprimary methods better

• Model Transference issuescommon in Raman technologynot a problem with FTIR

• Quick response < 3 minutesfor all properties modeled

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• Measures multiple propertieslike RON, MON, D86, Olefins,Benzene, Aromatics, Density(API)

• Redundancy adds to uptime,aids in troubleshooting, and byaveraging results of the twoon-line we match the labprimary methods better

• Model Transference issuescommon in Raman technologynot a problem with FTIR

• Quick response < 3 minutesfor all properties modeled

LabLab Analyzer + SpectraQ Software CollectCalibration

Spectra

CalculateCalibration

Model

Spectra into SpectraQuant to create model

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Calibrating the FTIRs

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Invensys proprietary & confidential3434

CalculateCalibration

Model

SpectraRTS collects Spectra and applies modelsto onon--lineline FTIR(s) to produce values

RON = 97.2MON = 88.1…

Use Models tocalculate on-lineproperty values

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AIT Integrated Software SuiteGasoline Property Performance by FTIR

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Oxygenated Gasoline OptimizationInferring BOB (CBOB,RBOB) Properties

USE NEAT Blend Spectra (NIR or RAMAN) to develop models to predictBLENDED PropertiesBLENDED Properties

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Redundant On-Line Grabner RVP/TVLAnalyzers installed at a Valero Refinery

• Same technology asused in our labs(MiniVap)

• Measures both RVPand TVL in sameinstrument

• Redundancy adds touptime, aids introubleshooting, andby averaging results ofthe two on-line wematch the lab better

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• Same technology asused in our labs(MiniVap)

• Measures both RVPand TVL in sameinstrument

• Redundancy adds touptime, aids introubleshooting, andby averaging results ofthe two on-line wematch the lab better

On-Line XOS MWD XRF Sulfur Analyzer• Same technology as used

in our labs (SINDIE)

• Measures Sulfurconcentrations as low as0.6 ppm

• Low Power source (75wx-ray) vs. hydrocarbonexposure to high (1000+degC) temperatures byother analyzers

• Low viscosity processstreams and finishedproduct blending

– Diesel

– Gasoline

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• Same technology as usedin our labs (SINDIE)

• Measures Sulfurconcentrations as low as0.6 ppm

• Low Power source (75wx-ray) vs. hydrocarbonexposure to high (1000+degC) temperatures byother analyzers

• Low viscosity processstreams and finishedproduct blending

– Diesel

– Gasoline

On-Line Blend Optimization System

MultiMulti--BlendBlend

PlanningPlanning

MultiMulti--BlendBlend

PlanningPlanning

BlendBlendRatioRatio

ControlControl

BlendBlendRatioRatio

ControlControl

BlendBlendQualityQualityControlControl

BlendBlendQualityQualityControlControl

Invensys BOSSInvensys BOSS

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FTIRs & GrabnersFTIRs & Grabners

Welker CompositorWelker Compositor

XOSXOS

SCSSCS

BOSS BBlend OOptimization & SSupervision SSystem

• Integrated with inventory (TIS) andmovement (OMM) modules

• Minimizes quality giveaway & recipedeviation, subject to:– component pump and line capacities– component tank inventories/ullages– header & final tank/batch specifications– integrated tank/batch on-spec point

• Blend model predictions biased usingonline analyzer & feedback

• Extensive analyzer validation

• Expert operator guidance in the eventof infeasibility

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© Invensys 10/23/2013Invensys proprietary & confidential40 © InvensysInvensys proprietary & confidential

• Integrated with inventory (TIS) andmovement (OMM) modules

• Minimizes quality giveaway & recipedeviation, subject to:– component pump and line capacities– component tank inventories/ullages– header & final tank/batch specifications– integrated tank/batch on-spec point

• Blend model predictions biased usingonline analyzer & feedback

• Extensive analyzer validation

• Expert operator guidance in the eventof infeasibility

BOSS Header “Spot Sample” Feedback

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Laboratory analyses usedLaboratory analyses usedto bias online analyzersto bias online analyzerswith significant deviationswith significant deviations

Results, Conclusions, & Future DirectionStatus of Valero Sites in this Program

• Benicia, CA: Optimized prior to the current program but has beenusing the AIT Analect HSS FTIR for many years with no significantissues

• Texas City, TX: Non-VGBOP site with BOSS optimizer running sinceSummer-2011. Upgrading analyzers with VGBOP standardsubsystems later this year

• Houston, TX: Partial-VGBOP project. First VGBOP shelter deployed inearly-2013. Currently running in optimized mode

• McKee, TX: Partial-VGBOP project. Three Blend Header system withredundant AIT Analect HSS FTIRs and redundant Grabners.Scheduled to be running in optimized mode later this year

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Status of Valero Sites in this Program

• Benicia, CA: Optimized prior to the current program but has beenusing the AIT Analect HSS FTIR for many years with no significantissues

• Texas City, TX: Non-VGBOP site with BOSS optimizer running sinceSummer-2011. Upgrading analyzers with VGBOP standardsubsystems later this year

• Houston, TX: Partial-VGBOP project. First VGBOP shelter deployed inearly-2013. Currently running in optimized mode

• McKee, TX: Partial-VGBOP project. Three Blend Header system withredundant AIT Analect HSS FTIRs and redundant Grabners.Scheduled to be running in optimized mode later this year

Results, Conclusions, & Future DirectionStatus of Valero Sites in this Program (Continued)

Corpus Christi, TX: Full-VGBOP project (sans on-line sulfuranalyzers) scheduled to be running in optimized mode in late 2013

Pembroke, Wales: Full-VGBOP project (sans on-line sulfuranalyzers & re-using existing site shelter) scheduled to be running inoptimized mode in late 2013

Memphis, TN: Full-VGBOP project – dual blend header systemscheduled to be running in optimized mode in 2014

Several other Valero sites tentatively scheduled to be completed in 2015+

Projects completed and running in optimized mode havegenerated millions of dollars in documented savings for thecompany so far

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Status of Valero Sites in this Program (Continued)

Corpus Christi, TX: Full-VGBOP project (sans on-line sulfuranalyzers) scheduled to be running in optimized mode in late 2013

Pembroke, Wales: Full-VGBOP project (sans on-line sulfuranalyzers & re-using existing site shelter) scheduled to be running inoptimized mode in late 2013

Memphis, TN: Full-VGBOP project – dual blend header systemscheduled to be running in optimized mode in 2014

Several other Valero sites tentatively scheduled to be completed in 2015+

Projects completed and running in optimized mode havegenerated millions of dollars in documented savings for thecompany so far

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