Transcript
Page 1: © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys
Page 2: © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys

© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Effective Utilization of RTO with APC, Planning and Scheduling - Asia Experience

Session Name: SimSci-Esscor Solutions

Session ID #: PBSS311

Junichi Watanabe

Nov./10/2011

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Slide 3

Agenda

• APAC RTO Projects Experience in last 10 years

• Some case studies of RTO (CDU, RFCC, CCR)

• Difficulties of Development and maintaining Utilization for RTO

• RTO with Production Planning/Scheduling

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Slide 4

Invensys Enterprise Control OfferingsM

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ctu

rin

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Pro

du

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on

Op

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ns

Co

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Inte

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Pla

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Automation Invensys and Third Party

Software ApplicationsInvensys and Third Party

Enterprise Control System

Corporate Systems

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Slide 5

Integration & Collaboration

Platform

EnterpriseIntegration

Workflow

Open DeviceIntegration

Web Portal

ApplicationToolkit

Historian

Th

ird

-Pa

rty

Off

eri

ng

sS

oftw

are

Ap

plic

atio

ns

Execution

Manufacturing Execution Systems

BatchEnterprise Asset

ManagementMobile Workforce

Management

Performance

Enterprise Manufacturing Intelligence

Performance Measurement and Reporting Visualization Quality

Asset Performance

Optimization

Operator Training DesignAdvanced Process

ControlSimulation / Optimization

Control

DCS PAC SCADA HMI

Safety

Safety Instrumented Systems General Purpose Safety Turbomachinery Control

Measurement & Instrumentation

Instrumentation Controllers Recorders

Au

tom

atio

nS

oftw

are

Ap

plic

atio

ns

Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

APAC RTO Projects Experience in last 10 years

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Slide 7

APAC Optimization Project Experience

40 Actual ROMeo Projects have been implemented in Asia since 2000 (Excluding feasibility study projects)

• Closed Loop : 18 Projects

• Open Loop : 13 Projects

• Planning : 3 Projects

• Performance Monitoring, Others : 6 Projects

Total 10 engineers are RTO engineers in APAC (Japan, Korea, India, China, Thailand and Singapore)

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Slide 8

RTO/Performance Monitoring Implemented in Japan Since Y2000

Idemitsu Chiba:Site Wide

JX,Negishi: CDU, RFCC

Idemitus Aichi: Utility, H2

JX Chita: H2 Management

OPC : EthyleneJX Mizushima: Utility,CDU3,CDU2Asahi Chemical : Ethylene

Idemitsu Tokuyama : CDU, FCCEthylene

Idemitsu Hokkaido : H2 Management

Showa Denko : Ethylene

Refinery : 13PetroChemical : 7

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Slide 9

Real-Time Optimization (ROMeo, ARPM) Business in APACKorea : HDO, SK, STC

China : Petrochina

Taiwan : FPCC

Thailand : Thai Oil

BCP,PTTGSP

Malaysia : Petronas

Singapore : SRC

India : RelianceASEAN

India

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Slide 10

APAC Optimization Project Experience

94% projects come from Refineries, Utility, Ethylene projects

RTO Industries Break

59%17%

18%

3%

3%

RefineryUtilityEthyleneUp- StreamGas Separation

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Slide 11

APAC Optimization Project Experience

CDU/VDU, FCC, Reformers, H2 management are majorities from Refineries projects

RTO Refinery Break

37%

17%

21%

4%

17%

4%

CDU/ VDUFCC/ RFCCReformerHDS/ HCU

H2Refinery Wide

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Slide 12

APAC Optimization Project Experience

Closed loop projects are nearly half

RTO Control System Break

44%

33%

23%

Closed LoopOpen Loop

Monitoring

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Slide 13

APAC Optimization Project Experience

ROMeo doesn’t rely on APC package.

RTO APC (Closed) Break

33%

38%

17%

6% 6%

DMC

RMPCT

SMOC

Connoisseur

Others

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Slide 14

APAC Optimization Project Experience

ROMeo don’t rely on RTDBS

RTO RTDB Break

52%

8%

18%

22%

PHDPIIP21

Others

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Case Study CDU RTO

SAT: 2007 Jun

Closed Loop with DMC+

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Slide 16

Heater Outlet Temp.

No.3 Side Reflux flow

Kero Stripping Steam Ratio

kg/KL

℃ KL/H

PVRTO Target

APC controls to OPT targets

Change of Optimization Variables (Independent Variables)

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Slide 17

Cold Reflux Flow

LGO Draw Flow Heater Inlet Temp.

℃KL/H

KL/H

PVPredict

All CVs move as predicted

Change of Optimization Variables (Dependent Variables)

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Slide 18Time

Benefit

Crude Change

APC Start

Start RTO

Set the base point when RTO started

RTO Benefit

- After RTO -

Time

Benefit

Crude Change

APC Start

- Before RTO -

Set the base point when APC made stable operation

PI Data is used for evaluation

How to Evaluate Benefit

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Slide 19

Change of Benefit before/after RTOBefore RTO (+287K Yen/day) After RTO (+2,362K Yen/day)

After RTO, every case shows increasing benefit and above base

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Slide 20

Change of Benefit before/after RTOBefore RTO (+287K Yen/day)

After RTO (+2,362K Yen/day )

After RTO, every case shows increasing benefit and above base

Yearly Benefit = 493MYen/Year※(2,362 - 287)KYen/Day×0.72( Run Time % )

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Case Study RFCC RTO

SAT: 2010 Jun

Closed Loop with RMPCT

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Slide 22

RFCC Feed Modeling

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Slide 23

RFCC Modeling (Rx/Rg)

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Slide 24

RFCC Optimization Variables Optimization Variable

No. Service Tag UOM OPT ON/OFF RMPCT MV STS1 TOTAL OIL FD TO REACTOR FC73108.PV M3/HR O O2 RISER OUTLET TEMP TC73014.PV DEGC O O3 HOT FEED TO 7303-D TC73068.PV DEGC O O4 2ND STG REGEN TEMP TC73112.PV DEGC O O5 R1 CO/CO2 RATIO RX73004.PV MOL % X X6 REGEN 2 FULE GAS %O2 AI73001.PV V/V % O O7 2ND STG RG TOP PC73014.PV KG/CM2 X X8 REGEN 1ST TO 2ND DIFF PC73018.PV KG/CM2 X X9 MF OVHD RECEIVER PC73188.PV KG/CM2 O O

10 ABSB GAS CONT KO DRM VAP PC75041B.PV KG/CM2 O O11 O2 SUPPLY TO 7301B FC73A03.PV KG/HR O O12 OM LSFO FCJ1104.PV m3/h O13 OM VGO FCJ1105.PV m3/h O14 H/NAPH LEAN OIL TO 7503E FC73060.PV M3/HR O O15 ROMeo ONLY 7503-F TEMP TI75012.PV DEGC O16 FRAC OVHD TO 7307-C TC73052.PV DEGC O O17 LCO PRODUCT TOTAL FLOW (FC73044T)FC73044.PV M3/HR O O18 HCO P/A TO FRACT #21 FC73043.PV M3/HR O O19 SLURRY P/A TO 7301-E FC73057.PV M3/HR O O20 DEBUTA BTMS TO 7505-CLR FC75023.PV M3/HR O O21 Debuta Top Corrected Temp TX75034.PV DEGC O O22 DB BTMS PMP DISCH,RVP AI75003.PV KPA O O23 STPR BTMS TO 7504-E TC75029.PV DEGC O O24 DP BTMS,GC C3S AI75009D.PV MOL % O O25 DEPRO REFL TO 7505-E FC75035.PV M3/HR O O26 DEPRO OVHD TO 7509-C PC75031.PV KG/CM2 X O27 STPR BTMS TO 7513-C TI75015.PV DEGC O O28 LCO P/A FC75018.PV M3/HR O O29 H/NAPH LEAN OIL TO 72#/LCO FC75553T.PV M3/HR O O30 HCO EX RCC TO 152F FC73R19.PV M3/HR X X

Optimization Variable

No. Service Tag UOM OPT ON/OFF RMPCT MV STS1 TOTAL OIL FD TO REACTOR FC73108.PV M3/HR O O2 RISER OUTLET TEMP TC73014.PV DEGC O O3 HOT FEED TO 7303-D TC73068.PV DEGC O O4 2ND STG REGEN TEMP TC73112.PV DEGC O O5 R1 CO/CO2 RATIO RX73004.PV MOL % X X6 REGEN 2 FULE GAS %O2 AI73001.PV V/V % O O7 2ND STG RG TOP PC73014.PV KG/CM2 X X8 REGEN 1ST TO 2ND DIFF PC73018.PV KG/CM2 X X9 MF OVHD RECEIVER PC73188.PV KG/CM2 O O

10 ABSB GAS CONT KO DRM VAP PC75041B.PV KG/CM2 O O11 O2 SUPPLY TO 7301B FC73A03.PV KG/HR O O12 OM LSFO FCJ1104.PV m3/h O13 OM VGO FCJ1105.PV m3/h O14 H/NAPH LEAN OIL TO 7503E FC73060.PV M3/HR O O15 ROMeo ONLY 7503-F TEMP TI75012.PV DEGC O16 FRAC OVHD TO 7307-C TC73052.PV DEGC O O17 LCO PRODUCT TOTAL FLOW (FC73044T)FC73044.PV M3/HR O O18 HCO P/A TO FRACT #21 FC73043.PV M3/HR O O19 SLURRY P/A TO 7301-E FC73057.PV M3/HR O O20 DEBUTA BTMS TO 7505-CLR FC75023.PV M3/HR O O21 Debuta Top Corrected Temp TX75034.PV DEGC O O22 DB BTMS PMP DISCH,RVP AI75003.PV KPA O O23 STPR BTMS TO 7504-E TC75029.PV DEGC O O24 DP BTMS,GC C3S AI75009D.PV MOL % O O25 DEPRO REFL TO 7505-E FC75035.PV M3/HR O O26 DEPRO OVHD TO 7509-C PC75031.PV KG/CM2 X O27 STPR BTMS TO 7513-C TI75015.PV DEGC O O28 LCO P/A FC75018.PV M3/HR O O29 H/NAPH LEAN OIL TO 72#/LCO FC75553T.PV M3/HR O O30 HCO EX RCC TO 152F FC73R19.PV M3/HR X X

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Slide 25

Test Data: (MVPC + RTO) Vs MVPC Only June 2010

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Case Study CCR/BTX RTO

SAT: 2008 May

Closed Loop with SMOC

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Slide 27

Real-Time Optimizer Scope

Kerosene

( 113 ,000 T/Y)

( 364,000 T/Y)

Propane

Butane

Naphtha

B - C

Crude

#2 LER

#2

C

D

U

LPG

Naph

Kero

Gas Oil

Benzene

P-Xylene

#1 Naph

AR to VDU/DCU

AR

#2 NHT

Gas Oil

#2 LMX

#2 PLT BTX

#1 KGHT

#1 KHT

#3 GHT

( 3%)

( 20%)

( 17%)

( 20%)

( 40%)

#2 GHT

#1 Gas oil

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Slide 28

No. Unit Description UOM

1#2 NHTNaphtha Splitter

Heavy Naphtha Dist.5%(RQE)

DEG C

2#2 NHTNaphtha Splitter

Naphtha SPLITTER REFLUX FLOW M3/HR

3#2 NHTNaphtha Splitter

#2 NHT FEED FLOW M3/HR

4#2 NHTNaphtha Splitter

Naphtha Stripper REFLUX FLOW M3/HR

5#2 PLATReactor

#2 PLAT FEED FLOW M3/HR

6#2 PLATReactor

#2 PLAT REATOR WAIT DEG C

7#2 PLATReactor

H2/HC Mole Ratio -

* BTX section considered as constraints * BTX section considered as constraints

Optimization Points

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Slide 29

BZBZ

P-XP-X

NN

SS

PP #2NHT#2NHT

BTXBTX

#2PLT#2PLT

#2CDU

REF-SIM

for PLT Reactor Model

Use NIR data

For Feed comp.

Scope for Online model

OFF

NIR

NIR

Only for Simulations

Current Online model(using NIR for feeds)

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Slide 30

BZBZ

P-XP-X

NN

SS

PP #2NHT#2NHT

BTXBTX

#2PLT#2PLT

#2CDU

REF-SIMNIR

OFF

HN5%

HNFEED

T/NFEED

RXWAIT

R/NFEED

FIXED

SRNFeed

L/N

Main Benefit Points

* Found extra space for BZ product with maximizing P-X Product* Found extra space for BZ product with maximizing P-X Product

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Slide 31

>> Decreasing 3.3% of Feed SRN [ Saving Operation cost )

>> Increasing 3% of BZ ( Fixed P-X Product ]

Price Y2008 Price Y2007 Price Y2006Average

(Y2006-Y2008)

EstimatedProfit

1.2 Million 1.7 Million 1.0 Million 1.3 Million

Profit Estimation

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Difficulties of Development and Maintaining Utilization for RTO

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Slide 33

Difficulties for CDU RTO Based on our Experience

Unit Difficulties Explanation

Accuracy of inferential properties.ROMeo cannot ignore the inforentialproperties because those are APC CVs.

The inferential properties are accurate at local area.However, sometimes, the properties are different afterrelatively big change by RTO

Inferential properties up- date

Depending on the type of inferential propertiesmethods, but most of inferential properties are requiredbias up- date by LAB or on- stream analyzer. The biasup- date can cause big bump on APC and RTOoperation.

Cut point change instruction fromscheduler

Occationally, the cut point of distillate such asNaphtha FBP, Kero 95%, LGO 90%, can be changed bythe instruction from scheduler to satisfy the logisticdemand.

CDU

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Slide 34

Difficulties for RFCC and CCR/BTX RTO Based on our Experience

Unit Difficulties Explanation

Feed properties identification

Feed properties identification is very important forRFCC such as Distillation, Sp- Gr, CCR, Sulfur, BasicNitrogen. However, there are no such a on- lineanalyzer to measure them

Reactor model accuracyFCC Reactor and Regenerator model accuracy is veryimportant

Feed compositions identification

It is required to identify the feed as pure componentbecause of accuracy of CCR reaction. It is required toidentify the Naphtha from CDU and Naphtha fromother units such as FCC, HCU so on.

Reactor model accuracy CCR Reactor model accuracy is very important

BTX ReactorsThere is no rigorous reactor model for Tatoray (orPxMax) and C9 Isomer with ROMeo.

RFCC

CCR/ BTX

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Slide 35

Importance for Utilization of RTO

Important Element ExplanationDaily Monitoring is important;Convergence and Down load rate, Optimization direction,Benefit monitoringPrice Up- date is also important. If price is wrong then theOptimization direction can be wrongSupport is important. What if some measurements becomeswrong, or what if model become not converged, or what ifcommunication wrong happen with RTDB so on.

2Close work with Planning andscheduling engineer

RTO cannot violates logistic constraint and Marketingcondition. The understanding and close communication withPlanning and scheduling are important

3Visualization and appeal tomanagement

It is required and important to expose the RTO performanceto management to understand the RTO performanceperiodically. Some of engineering effort is required to runRTO but need to justify the cost from performancevisualization

Daily Maintenance1

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Slide 36

Monitoring System Example Summary Screen

Calculation Successful rateCalculation Successful rateOptimization StatusOptimization Status

Optimization Variables Information

Optimization Variables Information

Economic Effects Reflection Rate

Data handling Successful RateData REC Successful RateOptimization Successful Rate

Optimization Variables Names

Study Low Limit ・ High LimitOptimization Value 、 Operation Value

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Slide 37

Constraints Variables Screen

Calculation Successful RateCalculation Successful RateOptimization StatusOptimization Status

Constraints Variable InformationConstraints Variable Information

Constraints Variables Name

The ratio of constraints hit

Check Low Limit ・ High LimitOptimization Value 、 Operation Data

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

RTO with Production Planning/Scheduling

The linkage between RTO and

Planning/Scheduling is very important

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Slide 39

Operation Cycle in Refinery�Investment plan (Long term Plan)�3 Month Plan (Mid term)�1 Month Plan (Short term)�Operation Guide/Instruction (Weekly)�Control Logistics�Control Tank Inventory�RTO (ROMeo for Planning)

�Crude Selection�Demand/Sales/Supply�Exchange

�APC�RTO (ROMeo)�Performance Monitor

Refinery Planning/ScheduleHQ Planning/Sales

Operation

�Process Design�Improvement�Bottle neck�RTO (ROMeo for Analysis and case studies)

Technical

Product Storage

Crude StorageCrude Tanker

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Slide 40

Operation in Refinery One Month (Planning/Schedule (1))

�1 Month Plan (Short term)�Operation Guide/Instruction (Weekly)�Control Logistics�Control Tank Inventory�RTO (ROMeo for planning)

�Demand/Sales/Supply�Exchange

�APC

�RTO (ROMeo)�Performance Monitor

Refinery Planning/ScheduleHQ Planning/Sales

Import Products

Crude StorageProduct Storage

Crude schedule is

already fixed

Operation

Export Products

Blending and Shipping

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Slide 41

Typical Production Planning/Scheduling Work�1 Month Plan (Short term)�Operation Guide/Instruction (Weekly)�Control Logistics�Control Tank Inventory�Demand/Sales/Supply

�Exchange�Purchase/Sale �Intermediate product

Refinery Planning/ScheduleHQ Planning/Sales

Day 1 510

1520

A,B…: Crude Type

One Month Operation plan is prepared by LP assuming one month

mixed average Crude or Crude tank by tank with

respecting Tank Inventory as constraint

Scheduler decides Operation targets such as Cut point, Unit

feed rate to meet the daily operation is as similar as One

month planning by Daily bases

Operation Instruction

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Slide 42

Relation between RTO and Planning/Scheduling

Day 1 510

1520

Planning/Scheduling

Refinery Wide ROMeo RTO

Unit RTO Unit

RTO

Unit RTO Unit

RTO

Shift Vector Opt.

Yield

Price InfoLogistic

Constraints

Rigorous Marginal Price

Continuously Maximizing

Benefit

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Slide 43

Thank You( ありがとうございました)

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