APPLICATION OF SMART MODULAR SAMPLE SYSTEMS AT

AN OLEFINS PLANT

John B. Cumbus

ExxonMobil Chemicals

Baytown Olefins Plant

History

• Concept first described at 1998 WAN Meeting

• Dan Podkulski active on IP 76 “footprint” Committee

• Industrial Experience has shown benefit of monitoring

• Semi-conductor industry experience • CPAC NeSSI effort

Expected Advantages

• Minimum Engineering /Drafting Effort

• Simplicity of Construction

• Ease of Maintenance

• Leverage Technicians for Higher Priority Activity

• Higher Service Factors

Installation Considerations

• Designed for relatively clean, dry process streams (light hydrocarbons)

• Sensors connected to gas chromatograph (analog inputs and analog outputs)

• Power for sensors originates in the analyzer

SupplyFilter

Bypass FlowController

SampleSupply

SampleBypass

SupplyPressure

ToAnalyzer

CalibrationSupply Stream

Valve(config-1)

GuardFilter

StreamValve

(config-2)

FromAnalyzerAnalyzer

Return

F

SupplyShut-Off

NC

NO

NC

NC

NC

Atmos.Vent

Calib.Shut-Off

FE

PI

F

Analyzer FlowController

FE

PE

PressureTransmitter

Engineering Package

• Provided by Configurator

• Pressure Indicator left for Technicians

• Eight Single Stream and One Dual Stream

• Three Analog Outputs, Two Inputs

Modular Sample System (minus MFMs)

Modular System Connections Inside Enclosure

New System in an Old Box

Assembly Test of Smaller System (76 Pieces)

Assembly Test Configuration

Assembly Drawings Provided

Completed Assembly

Example of Mechanic’s Previous Work

The “Mechanic”, Age 9

Comparison of “Old” and “New” Sample Systems

Sample System (Exterior) and Gas Chromatograph (Interior)

Gas Chromatograph Display Panel

Experience So Far

• Six of Nine Systems have been in Service since early to mid December

• Minor Start -Up Problems Encountered with Wiring Inside Sample System

• One MFM Operated Briefly, then Ceased to Control Flow

• No other Problems Encountered

Conclusions

• Smart Modular System has performed as expected in limited evaluation time

• Expected benefits appear to be realistic• Thought should be given to GC/Controller

programming and what to do with system data

• Need to expand parts availability,meet electrical classification of at least Div 2

John B. Cumbus

• Master’s in Analytical Chemistry from Auburn University in 1979 (After Pat Sullivan, but before Bo Jackson)

• Analyzer Engineer at Celanese in Bishop, Texas 1979-1981

• Analyzer Engineer at Exxon Baytown Olefins Plant 1981-Present

• Chairman Exxon Chemicals NA Analyzer Network 1987-1990

• Chairman ExxonMobil Worldwide Analyzer Network 1998 to Present

• Proudest of: Two Daughters and One Son

• Favorite Activities: Traveling to Florida’s Beaches, Enjoying Fine Rum, and Shooting Handguns (Not at the Same Time)