Jáchym Vohryzek ADVANCED CONTROL …petroleumclub.ro/downloads/downstream/2015/Jachym...Strada George Constantinescu 3 020339 București, Romania Mobile: +40 724 377 675 [email protected]

a way to reduce operational costs an increase product yield

ADVANCED CONTROL SOFTWARE IMPLEMENTATIONJáchym Vohryzek

Răzvan Constantin

© 2015 by Honeywell International Inc. All rights reserved.


Refining Customer Challenges

Successfully answering these questions drives value

1

How do I ensure safe

and stable operations?

How do I

better manage

my assets?

How can I comply with

industry and government

regulations?

How will demand

influence my

production?

How can I enable my

workforce?



Honeywell Process Solutions

Our Business is Aligned to Meet Customer Needs

2

Strengths• Installed base (>$16B)

• Global coverage

• Applications and domain knowledge

• Legacy system evolution

• Innovative technology

• Project execution capability

World leader in automation solutions for the process industries

Customer Offering

Integrated

automation solutions

and project execution

for new and existing

plants

Projects &

Automation

Solutions

Oil & gas control &

measurement for

transportation,

terminals and marine

Engineered

Field Solutions

Maintenance and

continuous evolution

services

Lifecycle

Solutions &

Services

Outcome-based

software solutions

Advanced

SolutionsField

Products

Smart measurement

& control instruments



Advanced Software Solutions Portfolio

Software for Better Safety, Reliability, Efficiency and Sustainability

3

Reduce capital spend and operating costs through better process design

Analyze a secure archive of your process data to make your next decision a better decision

Optimize the profitability of when, where and what to produce

Anticipate opportunities and risks, collaborate across your enterprise and take the best actions

Enable your control system and operators to run your process at peak performance without incidents



Potential Benefits to Be Realized*

Typical Return on Investments are 3 months to 1 year

4

• Reduce incidents

by up to 40% -

increase operator

competency

• Support

continuous

improvement

* Results based on past customer experience

Improve Your:

• Improve plant

availability 3-8%

• Preserve and

extend asset life

• Reduce

maintenance costs

3-5%

• Improve customer

service 5-15%

• Reduce off-spec material

up to 50%

• Reduce transition material

up to 30%

• Reduce catalyst

consumption up to 1%

• Improve throughput 2-8%

• Reduce energy use 5-10%

• Improve forecast accuracy

4-20%

• Reduce inventory 15-30 %

• Reduce demurrage by 10-

15%

• Reduce green

house gas

emissions by 25%

• Ensure compliance

standards

• Reduced total cost

of ownership

• Reduce energy

consumption

through improved

efficiency

Safety Reliability Efficiency Sustainability



Potential Benefits to Be Realized*

Typical Return on Investments are 3 months to 1 year

5

• Reduce incidents

by up to 40% -

increase operator

competency

• Support

continuous

improvement

Improve Your:

• Improve plant

availability 3-8%

• Preserve and

extend asset life

• Reduce

maintenance costs

3-5%

• Improve customer

service 5-15%

• Reduce off-spec material

up to 50%

• Reduce transition material

up to 30%

• Reduce catalyst

consumption up to 1%

• Improve throughput 2-8%

• Reduce energy use 5-10%

• Improve forecast accuracy

4-20%

• Reduce inventory 15-30 %

• Reduce demurrage by 10-

15%

• Reduce green

house gas

emissions by 25%

• Ensure compliance

standards

• Reduced total cost

of ownership

• Reduce energy

consumption

through improved

efficiency

Safety Reliability Efficiency Sustainability

* Results based on past customer experience



Process Optimization Software (APC)

Keep your process at optimal performance every minute of every day

6

Installs

3,500+

Select Customers in Refining

ExxonMobil, ConocoPhillips, Sinopec,

IOCL, Tesoro, PDVSA, Saudi Aramco,

Lukoil, GPN, Slovnaft, PKN Orlen

Fact

More than $ 5 billion in measurable

benefits has been added to customers'

bottom-lines with Honeywell's Profit®

suite of products.

• Advanced Process Control (APC)

solutions to optimize process

performance and efficiency

• APC helps protect plant uptime and

safety by reducing losses caused by

control performance

• APC Improves profitability by

increasing production and decreasing

costs

What Is It?

• Profit®Controller

• Profit®Optimizer

• Profit®Sensor Pro

• Control Performance

Monitor

Key Products


Efficiency Improvements through Process Optimization

7

“Honeywell’s expertise and technology have yielded tangible improvements

in our overall production processes. We are working with Honeywell as a

team–not as customer and vendor.”

Arturo Barría, Automation Leader, Andina Mine, Codelco

Mining: Codelco, Chile

“Multi-variable predictive control & real-time optimization significantly

improved the quality of control in our plant and helped us to operate the

plant at the economic optimum.”

Advanced Process Control Technologist

Ethylene Plant 4, Basell

Chemicals: Basell, Germany


Efficiency Improvements through Process Optimization

8

“APC gives valuable online quality information, which helps us adjust

downstream unit operations.”

Constantin Dumitrache, Optimization Projects Leader

Refining: Petrotel – Lukoil Refinery, Romania

“In our APC programs, we transition from straightforward throughput

maximization targets to more sophisticated operational cost optimization,

including energy efficiency improvement and catalyst system run

harmonization.”

Judita Feketeova, Process Automation Group Leader

Downstream: Slovnaft, Slovakia


Case 1: DAV Process Optimization at Petrotel

9

• CDU/VDU unit operation control was stabilized

- DCS loops and cascade control tuning

• Advanced Process Control (APC) layer implemented

- On top of existing regulatory control (DCS)

- Optimization strategy defined

- Process control disturbances eliminated (e.g. crude composition

changes)

• Tangible economic benefits

- Increase VGO vs. vacuum residue yield – up to 1%

- Energy Savings – up to 5%

• Additional benefits

- stable operation with respect to crude changes and better handling of

perturbations

- Flexibility in operating downstream units. APC gives valuable online

quality information.


Case 1: Control Cascade

10

• APC software runs on

separate server and

safely communicates

with Basic control system

(DCS)

• Dedicated software

interface was built and

tested

• APC calculates optimum

SETPOINTs for DCS

Base Loops Manipulated

Variables to satisfy unit

profitability requirements

Advanced Process Control

MVs CVs, DVs

Source: Constantin Dumitrache, “Implementation of Profit Suite Applications on Crude Atmospheric and Vacuum Distillation Complex at Petrotel-Lukoil Refinery

Ploiesti/Romania,” HUG, Nice, France, 2013

Basic control system


Case 1: Benefit Details

11

• Crude fractionation improvement. Reduction of Vacuum Residue Yield (more VGO yield).

• Fuel Gas consumption reduction

• Steam consumption reduction


Case 2: APC Program at Slovnaft

12

• Slovnaft has implemented Honeywell APC software on most major

process units since mid 2000’s

• Over the time, APC solutions revamped

- with the process unit revamp

- to improve optimization strategy

• More complex optimization criteria

- New APC optimization targets added

- Cost optimization instead of throughput optimization

- Focus on energy efficiency


Case 2: Complex Refinery - Complex APC Program

13

GAS DESULPHURISATION

AMINE REGENERATION

GAS RECOVERY , SWS

to FCC

H2

GASOLINE

H2

H2 BLENDING

CRUDE

OIL

BADU5 PYRONAPHTHA

H2 REDIST.

BCDU6

PETCHEM

H2

H2

from DIESEL

Alkyl.

H2

BLENDING

H2

H2

FUEL OIL

H2 BLENDING

&

POWER

PLANT

BVDU5

BGHCK

BHPP Units

BRHCK

BITUMEN

BNHT2

BGHT6

BGHT7

BFCCUBVGHT

CLAUS

SHU-MTBE-ALKYL.

ISOMER.

BNHT4 BREFC REF. NAPHTHA REDIST. AROM.

APC

Revamp

APC

Start UP

2013 2013

2011

2008

20052004

2007

2006

2010

SC

2013

2012

2013

Joined to

Refinery 2013/1/1

Number of Controllers:40, CV =774, MV=309, DV=128

2009

Source: Judita Feketeova, “New approach in APC Implementation: Energy Efficiency and Catalyst Life Protection Included in APC,” HUG, Nice, France, 2013


Case 2: Increased yield of VGO (BCDU6 unit)

14

• Operator´s practice

- To rely on experience

- Operate safely below required

limit

- Keep draw-off on certain level

• Consequences

- Big gap between FBP and its

limit

- VGO components in VD

- Lost Benefit

• Operator´s practice

- Set up required quality

- Rely on inferential and APC

- Draw-off depends on required

95%BP

• Consequences

- Minimized gap between FBP

and its limit

- Maximized VGO draw-off

- Increased Benefit

APC System OFF APC System ON


Case 2: Increased yield of VGO (BCDU6 unit)

15

APC System OFF APC System ON


Case 2: Cost Optimization (BGHT7)

16

• Optimization target added to

APC strategy at Gasoil

Hydrotreater

• GO Sulfur Content

• Benefits

- avoid GO over-treating

- save hydrogen

- protect catalyst life


Case 2: Additional APC Energy Saving Targets

17

FeedH601 R601

D601D602 D603

H602

C601

D630

Sour gases

HN from

BGHCK Feed for

BREFC

G601

Recycle H2

15

R551

C601

R501

R502

R503

R504

H501-

H504

K501 K502H505

D506

Feed from

BNHT4

H2

Recovery +

Reformat

LPG

Sour gases

Stabilizer

Maintained COT

Decreased O2% content in flue gas

Pass-balancing

Stabilizer pressure minimization with respecting quality constraints

Reduced electricity usage on the Net gas compressor by minimized spill-back between two stages

Naphtha Hydrotreater & Reformer Units


How Does APC Deliver Those Benefits?

18

Temperature

Pressure

APC

Operating

Region

Valve Positions

Compressor Speed

D P

Purity

Operator's

Preferred

Operating

Region

Need to Increase

Operating Region

Optimizer

Operating

Region

True Economic Optimum



So what is APC?

Every minute, twenty-four hours, throughout the year!

19

Advanced Process Control…

……is the replication of the

most efficient and knowledgeable operator

who understands the plant dynamics

is able to predict the plant behavior

control the process

concurrently utilize every opportunity to optimize

within hard and soft constraints


20

Thank You!

Răzvan ConstantinBusiness Development Manager HPS Romania

Honeywell | Performance Materials & Technologies

Strada George Constantinescu 3

020339 București, Romania

Mobile: +40 724 377 675

[email protected]

Jáchym VohryzekAdvanced Solutions Sales Manager CEE

Honeywell | Performance Materials & Technologies

V Parku 2326/18

148 00 Praha 4, Czech Republic

Mobile: +420 602 377 941

[email protected]

Documents

Jáchym Vohryzek ADVANCED CONTROL …petroleumclub.ro/downloads/downstream/2015/Jachym...Strada George Constantinescu 3 020339 București, Romania Mobile: +40 724 377 675 [email protected]