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Advances in Digital Automation within Refining Tim Olsen Emerson Process Management

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Speaker <ul><li>Tim Olsen </li></ul><ul><ul><li>Emerson Process Management </li></ul></ul><ul><li>Emerson, 1998 – Present </li></ul><ul><li>Performance Consultant </li></ul><ul><li>UOP, 1990 – 1998 </li></ul><ul><li>Technical Advisor on Refinery Unit Startups </li></ul>

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The Digital Refinery <ul><li>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” </li></ul><ul><li>Background: Advances in Computing </li></ul><ul><li>Examples: Advances in Automation within Refining </li></ul>

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Typical Process Computer’s Performance 50% per year increase! Compounded for 40 years!

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Computer Advances Cray 2 Supercomputer 1 Gigaflop 1985 - $23 million Ref Wired , February 22, 2008 , by Rob Beschizza Cray CX1: 4 Terraflops $25,000 Available on Amazon.com Ref: Wired; September 16, 2008; by Brian Chen

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Memory 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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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 - Wireless 200% per year compound increase!

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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.

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Implications of Computing Trends <ul><li>Low cost computing / communications replaces higher cost “other” </li></ul><ul><li>“ Distance Doesn’t Matter” - Physical location of individuals irrelevant with regard to communication and information availability – virtual organizations </li></ul><ul><li>Computational limits are receding </li></ul><ul><li>Everything that can be digitized will be digitized </li></ul><ul><li>No “practical limits” on data / information storage </li></ul>

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What does this mean for the Refining Industry? The Growth of The Smart Refinery through Digital Automation

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Older Automation Field Networks – Analog 4-20 ma 4-20 mA Only 1 value is transmitted Only one direction

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But Computers and Communication and Calculations have migrated to the Field Devices… 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_SUM ACK_OPTION, WRITE_PRI, WRITE_ALM ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PV OUT, 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_LIM 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_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 Field Networks Require To Support

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Control Rooms have also Modernized Site Wide Control Room Coordinated Multiple Loop Digital Control Computer Screen Interface Each Unit had a separate Control Room Single Loop Analog Control Panel Board Interface Photo Ref: Emerson Process Management Photo Ref: Emerson Process Management

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

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Advances in Digital Automation in Refining <ul><li>Predictive Diagnostics </li></ul><ul><li>Key Performance Indicators (KPI) </li></ul><ul><li>Advanced Process Control (APC) </li></ul><ul><li>Wireless Health Monitoring </li></ul><ul><li>Single Site Engineering Support / Control Room </li></ul>Sample Examples

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Predictive Diagnostics and Analytics Condition Detection BEFORE it becomes a problem in the Plant! Photo Ref: Emerson Process Management

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Future Trends – Predictive Analytics - How do we avoid this? Photo Ref: Emerson Process Management

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Smart cars monitor tire pressure Tire icon indicates low pressure Car advises driver of abnormal situation made possible via new technologies Photo Ref: Emerson Process Management

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

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Hydrocracker Quench Control Valve <ul><li>Low instrument air pressure to quench valve actuator – poor response to control </li></ul><ul><li>Maintenance and Operator alerted </li></ul><ul><li>Potential exothermic reaction runaway avoided </li></ul><ul><li>No emergency depressuring / shutdown required </li></ul><ul><li>No safety incident </li></ul>ALERT

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Labor Savings – Predictive Analytics <ul><li>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. </li></ul><ul><li>Manpower savings 1.6 hours per instrument per year with root cause analysis </li></ul><ul><ul><li>1,000 instruments </li></ul></ul><ul><ul><li>1,600 hours savings </li></ul></ul>

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Smart Turnaround Case <ul><li>Three-year study with Gulf Coast Refiner to reduce maintenance spending utilizing predictive instrument and valve diagnostics </li></ul><ul><li>Average maintenance savings $100,000 USD per year </li></ul><ul><li>Unexpected benefit of ~$1 million USD per year operations with better process control and plant availability </li></ul>Fix only what needs maintenance, nothing more

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System Modernization Case <ul><li>“ Poor reliability and frequent shutdowns were undermining the refinery's efforts to serve the market effectively.” </li></ul><ul><li>Automation System Upgrade on Gulf Coast Hydrocracker </li></ul><ul><li>Results showed sustained 50% reduction in reliability risk </li></ul><ul><li>Estimated Savings, $1-2 Million per year </li></ul>

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Key Performance Indicators, KPI <ul><li>Quickly at a glance, understand issues with the refinery. </li></ul><ul><li>Poor performance does not go undetected. </li></ul><ul><li>Energy use per barrel processed is tracked and trended. </li></ul><ul><li>Predictor for poor heater operation or effects of heat exchanger fouling. </li></ul><ul><li>Detect losses with heat and weight balancing </li></ul>

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KPI 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

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Advanced Process Control, APC <ul><li>Embedded APC within Modern Automation Systems </li></ul><ul><ul><li>Better measurements and tighter control valve resolution </li></ul></ul><ul><ul><li>Easy and Faster Startup </li></ul></ul><ul><ul><li>Easy for Board Operators to understand, thus stays “ON” </li></ul></ul><ul><ul><li>Easy to Maintain and Change as Needed </li></ul></ul>IMPROVED PROFIT BY CHANGING TARGET REDUCED VARIABILITY POOR CONTROL $ PROFIT SPECIFICATION LIMIT Safety Margin

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APC Case, Complex Distillation Column <ul><li>2 weeks configuring and commissioning </li></ul><ul><li>1 week proof testing </li></ul><ul><li>Average overehead product loss reduced by ~22% </li></ul><ul><li>Impurities in bottoms were maintained within specifications. </li></ul><ul><li>Steam usage reduced ~7% </li></ul><ul><li>Estimated value over $700,000 USD per year </li></ul>Bottoms Main Product Feed 1 TC TI Feed 2 At constant OH rate, this temp sets the energy balance (R/F). Internal Reflux Lt Ends Impurities This flow sets the material balance (D/F) Complicated OH condenser system LC

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Pump Health Monitoring Current Practice <ul><li>Preventive pump maintenance programs pull pumps whether the pump needs maintenance or not increasing pump maintenance cost </li></ul><ul><li>API RP 52 (auxiliary pump seal flush system) improves safety but does not include monitoring for undetected failures </li></ul><ul><li>Auxiliary pump seal flush system alarms not implemented </li></ul><ul><ul><li>Insufficient spare wiring in the field </li></ul></ul><ul><li>Typical Pump Seal Assembly </li></ul><ul><li>What: Unpressurized buffer fluid circulation through reservoir </li></ul><ul><li>Why: Backup seal </li></ul><ul><li>Where: High vapor pressure fluids, emissions </li></ul>

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Pump Health Monitoring Case <ul><li>NA Refiner </li></ul><ul><li>Wireless Field Instruments on Pumps </li></ul><ul><li>Secure, robust Smart Wireless gateway </li></ul><ul><li>Benefits </li></ul><ul><ul><li>Health monitoring enables prompt detection of abnormal pump vibration </li></ul></ul><ul><ul><li>Wireless sensor network implementation saved 75% of the cost over wired alternative </li></ul></ul>

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Multi-Site Control Center / Remote Support Control Center Engineering Center Plant 1 Plant 2 Plant 3 Photo Ref: Emerson Process Management

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But…. Has it Mattered?

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US Oil Refining Industry Employee Productivity Employee Productivity Up 300%, Even With: - Increased Complexity - More Crudes/ Product Grades - Increased Regulatory Requirements Crude Run Employment Ref: Crude Run: US DOE EIA: http://tonto.eia.doe.gov/dnav/pet/hist/mttrius2a.htm Employment: US DOL BLS; http://www.bls.gov/oes/

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Refining Safety Impact

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Conclusions <ul><li>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. </li></ul>

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Operate Smarter, More Efficiently <ul><li>Diagnose and Alert problems prior to failure or safety incident </li></ul><ul><li>Opportunity to act on information to prevent failure or safety incident </li></ul><ul><li>Identify root cause of problem prior to going into the field </li></ul><ul><li>Quickly see KPI Dashboards to detect abnormal operation </li></ul>

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Questions? <ul><li>Questions? Comments – contact [email_address] </li></ul><ul><li>More material on subject: </li></ul><ul><ul><li>www.SmartRefinery.com </li></ul></ul>