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TRANSCRIPT
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.
© 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?
© 2015 by Honeywell International Inc. All rights reserved.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
Case 1: Benefit Details
11
• Crude fractionation improvement. Reduction of Vacuum Residue Yield (more VGO yield).
• Fuel Gas consumption reduction
• Steam consumption reduction
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
Case 2: Increased yield of VGO (BCDU6 unit)
15
APC System OFF APC System ON
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
© 2015 by Honeywell International Inc. All rights reserved.
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
© 2015 by Honeywell International Inc. All rights reserved.
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
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