www.circortech.com 1 Complete, Modular, Ready Today Discussions of Modular Sample System Implementation in S. California Refineries
Www.circortech.com Complete, Modular, Ready Today 1 Discussions of Modular Sample System Implementation in S. California Refineries.
Dec 19, 2015
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www.circortech.com
1
Complete, Modular, Ready Today
Discussions of Modular Sample System
Implementation in S. California Refineries
www.circortech.com
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Complete, Modular, Ready Today
Current integration schemes with “GEN 1” systems
PROCESSANALYZER
MODBUSPROCESS
ANALYTICAL DATA
SAMPLE SYSTEM
VENT
TO FLARE
IS EVERYTHING OK?
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Complete, Modular, Ready Today
Current “GEN 1.5” IntegrationCurrent “GEN 1.5” Integration
PROCESSANALYZER
PLC TEMP CONTROL
SENSOR DAQ
MODBUS
PROCESS ANALYTICAL
DATA
SAMPLE SYSTEM I/O
PURGE CONTROL
PROCESS IN
PROCESS BYPASS
SAMPLE SYSTEM
NO COMMUNICATIONBETWEEN ANALYZERAND SAMPLE SYSTEM
CONTROLLER
SAMPLE SYSTEM
RETURN
FLOW CONTROLALARMS
AND SWITCHING
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Complete, Modular, Ready Today
CommentsComments
There is a current inability to integration the sample system using multi-drop, plug and play digital-bus technology due to a lack of IS, digital-bus components in the modular, low-flow footprint
There have been no documented, IS-certified GEN2 systems installed to date
End users and OEM alike can still benefit from IMSS integration of analyzer to sample system or PLC to sample system thru conventional IS certified analog instruments
Automation, closed-loop control, remote alarm and monitoring, and some diagnostic functions can be performed today which will still bring performance and cost of ownership benefits to the end user.
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End User Benefits TodayEnd User Benefits Today
ITEM # CATEGORY DESCRIPTION 1 New Component
Technology Component designs for IMSS implementation have been advancing. More reliable and better performing components have resulted in less maintenance and better quality analysis runs.
2 System Maintenance 75-95% time reduction for component change outs and seal replacement.
3 Reduced Size Has allowed for more component redundancy in less space, such as redundant filters for automatic change over after fouling.
4 Intelligent control PLC and electronic component implementation in sample systems has resulted in less unplanned maintenance as well as frequency of hands on involvement at each system; which results in less technician time needed and a probability reduction of damage to the analyzer and even process itself.
5 Reduced volume, surface area
This has equated to shorter lag times and more analysis runs in a given time.
6 Reduced Analyzer Downtime
Downtime due to sample systems is estimated at ~10% of total downtime. This has been reduced to no documented downtime, due to sample system failures, over past 3 years. This equates to more effective use of emission credits on CEM’s applications (due to Missing Data Incidents) and less technician time needed.
7 Enhanced surface properties
The use of surface treatments in certain MSS applications has greatly improved sample analysis stability, especially with SO2 and H2S analysis.
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CEM COO CommentsCEM COO Comments
Sample system downtime on CEM applications results in Missing Data Incidents
Have to either trade emission credits or pay fines if tonnage of emissions are over budget
There is a high probability that CEM analyzers will go down because of a sample system/ component issues or leak
VALUE TO END USER
EMISSION CREDIT
TRADING VALUE OR
FINE
CEM ANALYZER DOWNTIME DUE TO
SAMPLE SYSTEM
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Complete, Modular, Ready Today
Hard COO DataHard COO Data
A traditional tube and fitting blending system was replaced with a modular type system
Traditional System required 16 hours to rebuild 8 valves every 6 months
8 valves per system Parts to Rebuild = $150 / valve (highly conservative) Technician Rate was $50/hour New modular type of valves has been in service for over two
years with no rebuilds needed 2 YEAR SAVINGS = (16 * 4 * $50) + ($150 * 4 * 8) = $8000 COST SAVINGS PER VALVE/ YEAR = ($8000 ÷ 8 ÷ 2) = $500 TIME SAVINGS PER VALVE/YEAR = 32 HOURS
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“Greenfield Extrapolation”
“Greenfield Extrapolation”
Take these numbers and assume a 10 year valve cycle life (1M cycles, 5min analysis cycle time) and a refinery scale implementation (1000 valves)
TOTAL SAVINGS = (1000 * $500 * 10) = $5M TOTAL TIME SAVINGS = (32 * 10) = 3200 MAN-
HOURS
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The Future Modular in S. Cal. RefineriesThe Future Modular in S. Cal. RefineriesMODULAR PORTION OFSAMPLE SYSTEM
CLOSED LOOP BYPASS CONTROL
SAMPLE BOMB FOR LABORATORY
ANALYSIS
ONLINE MASS, DENSITY, FLOW,
TEMP OF SAMPLE CONDITION
TO/ FROMANALYZER
FROM PROCESS
BYPASS
AUTOMATIC FOULEDFILTER BYPASSPRESSURE AND MASS FLOW MONITORING
NOT SHOWN:
PLC control and monitoring
Calibration standard and self-validation sample cylinders
Temp control of system and sample lines
Sample Pumps
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The Future of IMSS in S. Cal. Refineries
The Future of IMSS in S. Cal. Refineries
Currently Implemented systems have the following capability Both Modular and High Flow Tube and Fitting Interconnect Technology Online Density and Mass Flow Measurement Differential Pressure Monitoring of Filters with Redundancy and Auto
Switch Over Flow Control of Bypass, Analyzer, and Calibration Flows In Situ Validation and Calibration using Certified Standards Both Discreet Analog 4-20mA and Digital Outputs to the Analyzer
Control Room Complete Closed Loop or Open Loop Control of all Flow Controllers,
Control Valves, Stream Select Valves, Heater Controls, and Sample Pumps
One of the major refiners has mentioned that modular will become a standard for all new sample systems due to field proven performance enhancements and lower overall COO
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Complete, Modular, Ready Today
ConclusionConclusion Proper design and component selection is paramount in
obtaining desired performance from Modular Performance benefits have been proven at the refineries
engaged in this study for Gen 1 and 1.5 type Modular implementation
Hard performance and COO data is scarce because this new data is considered proprietary; primarily due to the unique process and performance advantages that Modular Sample Systems are bringing
It will not be feasible to utilize modular in 100% of all applications; hence a hybrid modular / fitting approach and hybrid analog / digital approach will need to be adopted
End-users do not need to wait for a true digital bus implementation to benefit from IMSS systems today.
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