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Tendencias en Instrumentación y Controlen Procesos de Coquificación Retardada

Pablo González Jeanne - Foster Wheeler USA Corp.XII Foro en Avances de la Industria de Refinación de Petróleo

Septiembre 2006


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Tendencias en Instrumentación y Control en Procesos de Coquificación Retardada

Agenda

• Instrumentación

• Sistemas de Control

• Ingenieria y Diseño


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Instrumentación

• Servicios severos

• Aplicaciones Especiales


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Proceso de Coquificación Retardada


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Servicios Severos

• Procesos de alta temperatura y viscosidad

• Elevados puntos de fluidez

• Presencia de sólidos (partículas de coque)

• Materiales de construcción para servicios severos

• Cumplimiento con normas NACE MR0103 en servicios ágrios

• Detalles de instalación no convencionales̶ Uso de purgas y lavado̶ Sellos capilares con siliconas resistentes a altas temperaturas (DC-704)


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Aplicaciones Especiales

• Dispositivos radiactivos para medición de nivel y densidad

• Tubos de caudal acuñados (wedgemeters)

• Medidores Coriolis en servicios de medición másica

• Minimización de visores locales o uso de medidores

magnéticos con lavado y purga.

• Uso de orificios eccéntricos en servicios secundarios con

presencia de partículas de coque


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Medición de Nivel y Densidad en Tambores de Coquificación


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Wedgemeter con Tres Transmisores para Votación


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Sistemas de Control

• Uso de Fieldbus

• Control de Secuencia de Tambores

• Salvaguarda del Proceso

• Control Avanzado de Procesos

• Integración de Paquetes


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• Aplicable a lazos en sistemas de control básico (DCS)- No todo dispositivo de campo es compatible con Fieldbus- Tecnología no ha madurado lo suficiente como para migrar las

funciones de control al campo

• Requiere la ejecución de actividades tempranas- Niveles de Criticidad de Lazos y Tiempos de Ejecución de Tareas- Diseño de segmentos y validación de cargas antes de diseñar el

cableado

• Situación - Ahorros durante la ejecución del proyecto no son claros- Sistemas son híbridos, combinando el cableado de lazos

convencionales y Fieldbus- Se requiere de una clara definición de requerimientos al inicio de la

fase de ingeniería

Fieldbus


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• Ejecución de la Secuencia - Aplicación residente en PLC dedicado o DCS- Integración con ESD via cableado de funciones de salvaguarda - Integración de permisivos via enlace serial con sistema de apertura de

tambores

• Interfaz con el Operador- Paneles locales para ejecución de pasos de la secuencia- Monitoreo y manejo de permisivos supervisorios via interfaz hombre-

proceso del DCS

Control de Secuencia de Tambores


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Control de Secuencia de Cambio de Tambores de Coque

TO COKERBLOWDOWN SYSTEM

D-3001 D-3002SEQUENCE STEP: COKING QUENCHING

12. OPEN XV-732 AND XV-720.

1. CONTINUE COKE DRUM FILL WITHVALVES IN SPECIFIED POSITION.

NOTES:

-ALTERNATE QUENCH MAY BE USED WHENTHE BLOWDOWN BLOCK VALVES (SP-4BAND SP-8B) ARE OPEN AND THE QUENCHHAS BEEN GOING FOR 3-4 HOURS OR THEVENT BLOCK VALVES (XV-732 AND XV-720)ARE OPEN.-NO SLUDGE INJECTION INTO THE TOP ORBOTTOM OF THE DRUMS HAS BEENCONSIDERED FOR THIS UNIT.

2. OPEN QUENCH WATER BLOCK VALVE.3. OPEN FV-087A (QUENCH WATERVALVE) TO 10%.

6. BEGIN AUTOMATIC QUENCHCONTROL RAMP.

4. STOP STEAM FLOW (FC-723 INMANUAL AT 0% OUTPUT).

5. CLOSE STEAM BLOCK VALVE.

7. CONTINUE QUENCH RAMP FOR 5HOURS, FOLLOWING PRESSURE RISECONSTRAINTS. THE RAMP WILL BE TIMEVS. FLOW WITH PRESSURE OVERRIDE.

8. QUENCH FILL IS COMPLETE WHENLAHH-004 ALARMS INDICATINGPRESENCE OF WATER AT DRUMLEVEL ABOVE THE COKE BED.

9. CLOSE FV-087A AND B BY PLACINGFC-087A AND B IN MANUAL AT 0%OUTPUT.

10. CLOSE QUENCH WATER BLOCK VALVE.

11. WHEN DRUM TEMPERATURE ANDPRESSURE ARE WITHIN ALLOWABLERANGE, CLOSE SP-8B AND THEN SP-4B.

13. CLOSE XV-731.14. SOAK FOR APPROXIMATELY 30MINUTES.

1. CLOSE ALL FLOWING PURGE STEAMDOWNSTEAM OF SP-6B AND SP-7BMANIFOLD.

REV. REVISIONS DATE REV. BY CHK. BY APP. BY

REV.

DATE

THIS DRAWING IS THE PROPERTY OFFOSTER WHEELER USA CORPORATION

AND SHALL NOT BE REPRODUCED WITHOUTTHEIR PERMISSION

COKE DRUMSEQUENCE DESCRIPTION

DELAYED COKER FACILITY PROJECT

EST. NO. DRAWN BY: 18NOV05 Sh. 6 of 70

HOUSTON, TEXAS. United States of America

CONTRACTNUMBER 13-117067 DWG. NO.

A FOR COMMENTS 14Oct05

PG

117067-4-64-01

PG FOSTER WHEELER USA CORPORATION

APP'D.

CONCONDWG.NO.

C:\Documents and Settings\pgonzale\My Documents\RPC Coker - Chile\RPC Coke Drum Logic.VSD

M

L-3001XV-700

M

SP-6BXV-716

SP-6AXV-706

SP-5

SP-7BXV-717

SP-7AXV-707

HEATER EFFLUENT

TO COKECONDENSATE DRUM

DRAIN TO MAZE

FV-723

ALTERNATEQUENCH WATER

XV-722 XV-720 XV-732

TOFRACTIONATOR

M

SP-1BXV-711

SP-2BXV-712

SP-1AXV-701

SP-2AXV-702

D-3001 D-3002



SP-8BXV-718

SP-4BXV-714

SP-4AXV-704

SP-8AXV-708

M

M

M

MM

M

M M

M M

M M

M XV-721 M XV-731HCGOQUENCH

XV-710

RV-000A/B

P1

STEAM

FV-087A/BQUENCH WATER

P1 P1 P1


RV-002A/B

HCGOQUENCH

TDV-003 TDV-007

SP-3XV-703

M M

M

B W/ OPS COMMT’S 18NOV05 PG

0 FOR DESIGN 25NOV05 PG

FO FO


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Paneles en Secuencia de Cambio de Tambores de CoqueFIGURE 6FIGURE 6

FIGURE 5FIGURE 5

FIGURE 4FIGURE 4

FIGURE 3 FIGURE 3

FIGURE 2

FIGURE 1

L-3001XV-700

M

SP-6BXV-716

SP-6AXV-706

SP-5

SP-7BXV-717

SP-7AXV-707

HEATER EFFLUENT

TO COKECONDENSATE DRUM

DRAIN TO MAZE

FV-723


XV-722 XV-720 XV-732

SP-3XV-703

TOFRACTIONATOR

M

SP-1BXV-711

SP-2BXV-712

SP-1AXV-701

SP-2AXV-702

D-3001 D-3002



SP-8BXV-718

SP-4BXV-714

SP-4AXV-704

SP-8AXV-708

M

MM

M

M

M

M

M M

M M

M M

M M

M XV-721 M XV-731HCGOQUENCH

XV-710

RV-000A/B

STEAM

FV-087A/BQUENCH WATER

M


RV-002A/B

HCGOQUENCH

TDV-003 TDV-007


BLACK

D-3001

ZLO

FIGURE 2. DRUM OVERHEAD TO FRACTIONATOR (SP-3)

SP-3 OPEN

703AGREEN

LAMP TEST

HS703T

PI-002B

D-3002

PI-005B

HC-703

-1% -10% +1%+10%

742GREEN

XA

COMPLETE

752GREEN

XA

COMPLETE

703AGREEN

XL

SP-3 ENERGIZEDAND IN REMOTE

D-3001 HC PREHEAT D-3002 HC PREHEAT


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• Reducción de Riesgos en Cumplimiento con Normas IEC 61511

- Sistemas de salvaguarda diseñados para alcanzar niveles de integridad de hasta SIL 2 en unidades de Coquificación Retardada

• Mayor Seguridad en las Operaciones- Frecuencia de eventos inseguros han identificado fallas humanas

como su causa principal, aumentando la probabilidad en casos de múltiples parejas de tambores

- Niveles de protección independientes (IPL) deben reducir los factores de riesgo hasta alcanzar el nivel de SIL deseado para cada función de salvaguarda

Salvaguarda de Procesos


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Control Avanzado de Procesos

• Fraccionadora̶ Control Multivariable (Presión, Puntos de Corte, Respuesta a Cambios

de Tambor)̶ Control de Relación Vapor/Producto̶ Control de Nivel No-lineal

• Hornos̶ Control de Exceso de O2̶ Control de Temperatura de Salida de los Hornos̶ Control de Velocidad en los Tubos de los Hornos

• Tambores̶ Maximización de Carga̶ Cálculos de Llenado de Tambores̶ Control de Enfriamiento̶ Control de Inyección de Agentes Anti-espuma

• Aplicaciones Supervisorias Basadas en Conocimiento


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• Integración de Sistemas de Apertura y Decoquificación de Tambores

- PLC por paquete- Sistema hidráulico compartido

• Integración de Sistemas de Arranque de Hornos- PLC de control y monitoreo de quemadores para la unidad- Paneles de control por horno

• Integración de Sistemas Anti-oleaje de Compresores

• Todos los Paquetes Integrados con DCS Via Enlace Serial para Efectos de Interfaz Hombre-Proceso

• Cableado Directo para Funciones de Disparo / Salvaguarda

Integración de Paquetes


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Ingeniería

• Desarrollo de Ingeniería Utilizando SmartPlant Instrumentation (INtools)

• Diseño Utilizando Modelos PDS


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INtools

• Indice de Instrumentos y Hojas de Datos

• Requisiciones e Integración con Procura

• Diseño de Cableado y Diagramas de Lazos

• Asociación de Detalles de Instalación y Listado de Materiales


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Modelo PDS

• Validación de Detalles de Instalación

• Elaboración de Planos de Ubicación


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Detalles de Instalación en Modelo Tridimensional


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Planos de Ubicación


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Conclusiones

• El proceso de coquificación retardada es ampliamente conocido• El proceso se adapta a las nuevas tecnologías de avanzada en

materia de instrumentación y control• La instrumentación de campo debe ajustarse a las normas y

estándares• Los sistemas de control en la actualidad permiten un mayor grado

de automatismo e integración de sistemas• La automatización de los procesos de ingeniería y diseño permiten

reducir los tiempos de ejecución y las probabilidades de fallas• Foster Wheeler los puede ayudar a alcanzar los objetivos deseados

en su nuevo proyecto en unidades de coquificacón retardada


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Muchas Gracias

Contacto:Pablo González

Sr. Principal Control Systems [email protected]

001(281)752-3480

Career Summary

Pablo Gonzalez-JeanneSr. Principal Control Systems Engineer

Pablo has over twenty five years of experience in process control and automation, covering implementation, consultancy, project management, and supervisory roles. His years of experience include working in the Refinery, Chemical, Petrochemical, and Oil and Gas industry. His overall client responsibility for the control systems on two multi-billion refining facilities, involves all activities from engineering to installation and commissioning. His current responsibilities involve leading the discipline in complex projects for new and revamped units, both during front end and detailed engineering.

Citizen: Venezuela & France

Education: Universidad de Los Andes, Merida, Venezuela - MS, Control Engineering

Universidad Central de Venezuela, Caracas, Venezuela - BScChE

Queen’s University, Kingston, Canada – BScChE (Honors)

Qualifications: Registered Professional

Engineer – Venezuela See Professional Courses

Languages: English French Spanish

Professional Experience 2002 - Present Foster Wheeler USA Corporation

Sr. Principal Control Systems Engineer

Responsible for the development and specification of control systems and their instrumentation components on in-house projects for HPI clients. Leads the discipline on grassroots and revamping projects associated with process units in oil refineries and petrochemical plants.

Recently completed a major debottlenecking project of a heavy oil upgrader, where the design and construction activity impacted most process areas, but mainly the crude, vacuum and delayed coking units.

Currently involved in the implementation of the most current trends in Delayed Coking process control and operation, including coke drum unheading and decoking systems.

1998 - 2002 Sincor – Jose, Venezuela

Controls Systems Coordinator

Responsible for the engineering development, installation and commissioning of all the control and safeguarding systems, as well as some 12,000 instrument loops and 3,000 applications for the Sincor Upgrader Complex Debottlenecking and Main Shutdown Project in Jose, Venezuela.

This project included distillation, hydrotreater, delayed coker and environmental units, as well as the on-site production of hydrogen and utilities.

1996 - 1998 PDVSA - Cardon, Venezuela

Project Manager

Re-instrumentation and Automation of the Lube Oil Processing and Hydroprocesses units in the refinery, which were the remainder of all the units originally under conventional pneumatic control.

The project included the design, construction and commissioning of a refurbished control building, making it blast resistant, installation of new control systems, full re-instrumentation of the units, and incorporation of additional instrumentation and process analyzers; the commissioning and cutover was done with the units in operation.

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Pablo Gonzalez-Jeanne Sr. Principal Control Systems Engineer

1992 - 1996 PDVSA - Cardon, Venezuela

Automation Coordinator

Responsible for the engineering, commissioning and start-up of all control and safeguarding systems, advanced process control and information systems for a 2.5-billion dollar expansion.

This work included new hydrotreater, catalytic reformer and delayed coker units, as well as the integration with operating refinery units.

This work involved interfacing with three different international Engineering and Construction contractors, as well as multiple vendors, and it added over ten new process units while impacting the overall refinery operations configuration.

1990 - 1992 PDVSA – Cardon, Venezuela

Assistant Specialist in Automation and Process Control

Commissioned to progress as a specialist/consultant, providing assessment and expertise in control systems, advanced control and optimization of refinery processes, PDVSA, Cardon, Venezuela.


Process Control Supervisor

Responsible for the day-to-day maintenance of supervisory control strategies, with a staff of seven technologists.

Responsible for coordinating all process control issues in the design, construction and start-up of new automation projects within the refinery; PDVSA, Cardon, Venezuela.

1983 - 1987 SPDVSA – Cardon, Venezuela

Process Control Technologist

Participated in the design, engineering and construction phases of an instrument rejuvenation project for four distillation units.

Responsible for the design, programming and start-up of all associated supervisory control strategies.

Participated in the development of the current Automation Master Plan for the refinery, PDVSA, Cardon, Venezuela.


Chemical Engineering Trainee

Assigned to the Distillation area, covering four major units in a 360,000-barrel per day refinery, PDVSA, Cardon, Venezuela.

Professional Courses

Understanding Codes and Standards for the Process Industries (PSI) Process Plant Start-Up (PTS) I/A Series Configuration (Foxboro) Advanced Negotiations (CIED) Pre-Project Planning (Construction Industries Institute) Short Course on Project Management (Construction Industries Institute) Project Planning and Design (University of Texas at Austin) Advanced TDC-3000/APM Configuration (Shell) Advanced TDC-3000/APM Configuration (Shell) TDC-3000 US Implementation and Graphics Building (Honeywell) Effective Delegation (CEPET) Process Control Supplementary (Shell) Process Control Review (Foxboro) Corporate Supervisory Behavior II (PACI)

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Pablo Gonzalez-Jeanne Sr. Principal Control Systems Engineer

Professional Courses (Cont’d)

Basic Computer Control Applications (Procontrol) Statistical Tools for Quality Management (Maraven) On-line Analytical Instrumentation for Industrial Process Control (Clevett Associates) Corporation Supervisory Behavior I (PACI) Multivariable Control (Shell) Basic and Advanced LOTUS-123 (CEPET) Troubleshooting Hydrocarbon Processes (Lieberman) Advanced Process Control (Honeywell) Basic Statistical Analysis, SAD (RODIN) Sample Handling Systems for Analyzers (Exxon) Building Safety into Plant Design (Exxon) Advanced Oil Fractionation Control (Setpoint) Advanced Distillation Control (Setpoint) Advanced Process Control Applications (Applied Automation) Selection, Installation and Operation of Rotating Equipment for Refineries (Colegio de

Ingenieros de Venezuela) Process Control (Shell) TDC-3000 Universal Station Implementation (Honeywell) Troubleshooting, Decision Making and Planning (CEPET) Fire Fighting Technology (Maraven), 1985 Applied Linear Programming for Refineries (Maraven) Fluid Flow Calculation Methods (Shell) Process Control and Instrumentation (Shell) Distillation Calculations (Shell) Industrial Safety for Supervisors (Maraven) Computer Control (Shell), 1981 Energy Conservation (Shell) TDC-2000 Project Engineering (Honeywell) OPTROL-7000 Users' Course (Applied Automation)

Professional Affiliations

Canadian Institute of Chemical Engineers, 1980 – 1983 Venezuelan Institute of Engineers, Registered Professional Engineer 45145, 1981 – Present Instrumentation, Systems and Automation (ISA) Society, 1990 – Present

Publications

"Statistical Analysis Updates On-line Predictive Models" Hydrocarbon Processing, May 1992 “Proper Planning Pays Off for Maraven APC Project” - Flashpoint, Vol 3, Number 1, 1996 “Maraven Automates Refinery Expansion” - The Journal for Industrial Automation and Control (Honeywell), Vol 4, Number 1, February 1997

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