9 1228 predict-pro delivers results at rompetrolæs constanta refinery crude fractionation unit v3
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PredictPro Delivers Results at Rompetrol’s Constanta Refinery
Crude Fractionation Unit
PredictPro Delivers Results at Rompetrol’s Constanta Refinery
Crude Fractionation Unit
Radu IscoviciRompetrol
Chibuike Ukeje-EloaguEmerson Process Management
AgendaAgenda
� Introductions (Presenter, Rompetrol, Emerson Team)
� Project Execution– Project Team
– Project Implementation
� CDU Control Objectives & APC Scope� CDU Control Objectives & APC Scope� Control Design, Implementation & Commissioning� Benefits Audit� Long-Term Operability� Summary
Main PresenterMain Presenter
� Radu Iscovici
� Head, Process Control Department at Rompetrol Refining SA, Romania
� In charge of: � profit increase through advanced regulatory controls
and advanced process control and optimization and advanced process control and optimization techniques
� safe and secure plant operation through safety instrumented systems implementation;
� data collection, transfer and processing into valuable information for management through implementation of IT industrial systems
Rompetrol – An OverviewRompetrol – An Overview
� A leader in the regional oil industry � Rompetrol is a multinational company with activities
in 13 countries � Strong operational base in the Black Sea and
Mediterranean Sea region � The number and the complex nature of the projects
executed at a global level have turned Rompetrol The number and the complex nature of the projects executed at a global level have turned Rompetrol over time into the best known international brand originating in Romania.
� Co. Size: 9,000 Employees� Industry: Oil & Energy� Website: http://www.rompetrol.com
� Built in the 1980’s for the Romanian National Oil company
� Now owned by Rompetrol� Largest Romanian refinery (100,000 bbl/day)� Recently modernized with Emerson’s DeltaV DCS� Continuous drive to improve operational efficiency
Constanta Refinery – A brief history Constanta Refinery – A brief history
� Continuous drive to improve operational efficiency through exploitation of new DCS functionality and smart field instrumentation
Emerson Process ManagementEmerson Process Management
� Strategic Services Group� UK Based (Middlesbrough)� Support for Europe. Middle East &
Africa� Consultancy in advanced control
and optimizationand optimization� Process experts with 10 to 30
years experience (ex operating companies)
� Experienced project managers� Process-specific technical solutions
(oil & gas, refining, chemicals, utilities)
Project ExecutionProject Execution
� Project Team� Emerson
� Emerson Romania� Strategic Services (UK)� AAT (US)
� Rompetrol� Rompetrol Engineers embedded in the execution team� Rompetrol Engineers embedded in the execution team
� Renata-Alina Orzeiu (Control Engineer)� Gheorghe Oprea (Control Engineer)� Sebastian Paul Iftene (DCS Administrator)
� This strategy ensures greater understanding of the installed system thus developing on-site champions of the APC technology
� Any DCS configuration work carried out by Rompetrol personnel
Project ExecutionProject Execution
� Project Implementation� Kick-off
� Kick-off meeting to introduce team and review project admin and QA
� Site survey for data gathering & Preliminary Step testing� Design
� Functional, Detailed & Acceptance Test Specifications developed by Emerson for review/acceptance by developed by Emerson for review/acceptance by Rompetrol
� Build� Build controllers, Step Test MV/DV, generate models
� Commissioning� Commission controllers, deliver training, SAT.� Perform APC Benefits Audit
Project ExecutionProject Execution
� Major Milestones� June 2008 – Project kick-off
� On-site kick-off, site survey & Preliminary Step testing
� July 2008 – Commence Controller Build� Designs completed, commence site work� Controllers were built and commissioned unit by unit� Controllers were built and commissioned unit by unit
� Jan 2009 – Technical Completion� All controllers commissioned and in full use
CDU Control Objectives and ScopeCDU Control Objectives and ScopeGas
Naphtha
Kerosene
To Vacuum System
Steam
Steam
1. Maximize Throughput
2
3
2. Maximize value of product recovery
3. Maximize heat Recovery
4. Maximize heater
Fired Heater
Vacuum Tower
Atmospheric TowerFired Heaters
Crude Feed
Lt Diesel
Diesel
AGO
LVGO
HVGO
Residue
Stripping Tower
SteamSteam
Steam
Steam
1
3
44
4. Maximize heater efficiency
CDU Control DesignCDU Control Design
Naphtha
Kerosene
Lt Diesel
To Vacuum SystemSteam
Steam
T
TF
F
F
F
T
F
FL
L
FBP
IBP FBP
� Interactions� Disturbances� Long Time
to Steady State
� Optimization
Why Use MPC? Gas
F F
T
P
P
Vacuum Tower
Atmospheric Tower
Crude Feed
Lt Diesel
Diesel
AGO
LVGO
HVGO
Residue
Stripping Tower
Steam
Steam
Steam
Steam
T
T
T
F
F
F
F
F
F
F
T
T
FuelF
HV
F
F
T
T
F
F
F
T
T
O2
F
F
T
T
F
F
FT
T
TF
F
FL
L
IBP
Cong.D360
T
T
P
P
Flood
O Flash
Flood
T P
Optimization
D360
O2
O2
HV Fuel
F
AirF
CO
COT
Fired Heaters
Fired Heater
F
HV Fuel
APC 4 (11 x 11)
CDU Control DesignCDU Control Design
APC 5 (6x6)APC 1 (3x3)
Naphtha
Kerosene
Lt Diesel
Steam
Steam
T
TF
F
F
F
F
T
T
F
T
F
FL
L
FBP
IBP FBP
T P
Gas
F F
O2 CO
T
P
P
APC 2 (4x4)
APC 3 (5x5)
Vacuum Tower
Atmospheric Tower
Crude Feed
Lt Diesel
Diesel
AGO
LVGO
HVGO
Stripping Tower
Steam
Steam
Steam
Steam
T
T
T
F
F
F
F
F
FuelF
HV
F
F
T
T
F
F
F
T
T
O2
F
F
T
T
F
F
FT
T
TF
F
FL
L
IBP
Cong.D360
T P
Flood
O Flash
Flood
T P
D360
O2
HVFuel
F
AirF
CO
T
Fired HeatersFired Heater
F
HV Fuel
CDU Control Design (Atm Section)CDU Control Design (Atm Section)
C1: MPC4
Manipulated
C2 Base Level
Base Steam Ratio
4 Product Flow Rates
AUTORCAS
AUTORCAS
AUTORCAS
Top Pressure
4 Pressure Corrected Temperatures
Control Variables
Control
H2: MPC2H1: MPC1
OutletTemperature
Total C1 Flow
O2OutletTemperature
O2
Manipulated Variables
3 Pump Around Flow Rates
4 Product Flow Rates
Reflux Drum Pressure
Base Steam RatioPass 1 Flow Rate
Pass 2 Flow Rate
Fuel Pressure
Air Flow Rate
Pass 1 Flow Rate
Pass 2 Flow Rate
Fuel Pressure
dT dT
Control Variables
Manipulated Variables
CDU Control Design (Vacuum Section)CDU Control Design (Vacuum Section)
C5: MPC5
Manipulated
C1 Base Level
Average Feed Temperature
4 Pressure Corrected Temperatures
AUTORCAS
AUTORCAS
Control Variables
H3: MPC3
OutletTemperature
Manipulated Variables
Recycle Flow
2 Pump Around Flows
Quench Flow4 Pass Flow Rates
Fuel Pressure
Total C5 Feed Flow
Manipulated Variables
Control Variables
Inferential AnalysisInferential Analysis� Product compositions are not measured on-
line but once per day in the Laboratory. � Product compositions are key constraints in
a crude unit that dictate how much product can be made.
� A full suite of “virtual analyzers” was created that predict the product properties (such as diesel pour point) in real-time.
� These virtual analyzers use a regression based on product flow rates and column based on product flow rates and column temperatures.
� DeltaV Neural is a standard component in the DCS.
� The predicted values are updated daily against the laboratory results to ensure that the predictions remain accurate.
� These predicted values are used by the controller as constraint variables to keep products on specification.
Controller ConfigurationController Configuration
� Emerson’s PredictPro™
� DeltaV™ standard component� Rompetrol DCS engineer configured 5 PredictPro™
Applications to Emerson design using Control Studio™
User Interface ConfigurationUser Interface Configuration
� PredictPro standard interface –self configuring
Step TestingStep Testing
� Automatic Step Testing
Commissioning (1)Commissioning (1)
� Model Generation:– automatic– manual adjustment
� Model Verification� Model Verification– by comparing Predicted vs.
Actual
� Controller tuning– fine tune response by
weighting CVs and MVs
Commissioning (2)Commissioning (2)
� 5 optimization scenarios configured
� Can assign values to variables
� Controller will maximize total valueUse to maximize � Use to maximize production, and minimize energy use
� Operator selectable in real-time
Benefits Audit (Summary)Benefits Audit (Summary)� Compare before and after operating
periodsCrude throughput constrained by downstream units!
� Increased production of more valuable products for a given feed rate
� Improved heater efficiency by a significant amountsignificant amount
� Quantified benefits:– Audited project benefit of US $1.8m
(3-month payback)
� Non-Quantified Benefits:– Reduced operator actions– Better response to disturbances such as
crude changes
Benefits Audit (Details)Benefits Audit (Details)� Quantified benefits (Column):
– Reduced giveaway of valuable product into AGO stream
– Quantified benefit: • US$ 1.79 million / year
� Quantified benefits (Heaters):– Improved efficiency due to– Improved efficiency due to
• Pass balancing• Improved excess O2 control
– Quantified benefit: • US$ 103,000 / year
� Payback Time:– 3 months
Long-Term OperabilityLong-Term Operability
� Since commissioning, the application has been in continuous use.
� 12 month warranty for the APC application is included as part of Emerson service.
� Since entire application is constructed from standard DCS components, the standard Emerson DeltaV DCS support service applies. – including 24/7 help line– including 24/7 help line– agreed man-hour rates if required
� How regularly will model refits be required?– Once models fitted they are tolerant of inaccuracies to a
reasonable degree.– So long as no major process modifications are made the models
will not require refitting (e.g. changing the tuning of a control loop, replacing a valve or a pump or cleaning a heat exchanger should not require refitting)
– If models do require fitting, automatic tools make the process quick and easy.
SummarySummary
� Total APC Audited Benefit of US$ 1.8 million
� Payback time of just under 3 months
� Familiar DCS Plant Type:Refinery � Familiar DCS
environment made for a quick and smooth uptake of the APC controllers by the operations crew
Refinery
Scope:Model Predictive Control on: �Atmospheric Column�Feed Heaters (x2)�Vacuum Column�Vacuum feed Heater
Thank YouThank You
� Comments / Questions?