Overcoming the Challenge of Implementing Profit Controller ... · Overcoming the Challenge of...

Overcoming the Challenge of Implementing Profit Controller on a Third Party DCS.

Ramiro Andrés CremaschiJulia Alejandra PerinettiRepsol YPF

2 2004 Users Group Americas Symposium • Partners in Innovation

Ramiro A. Cremaschi & Julia A. Perinetti

Introduction - What is Repsol YPF?

• A multinational company leader in Spain and Argentina.

• Business activities in Exploration, Production, Refining, Distribution, Marketing, Chemicals, Gas and Power.

• Operations in four continents

• One of the world’s ten most important private oil companies.



Introduction - What is Repsol YPF?• LPG business• Sales over 3 millions tones/year• Third largest company in the world.

• Over un million barrels of oil per day.

• Oil and gas reserves: more than 5 billion barrels of oil equivalent.

• Refining capacity: 1.2 million barrels per day

• Nine refineries.



Introduction - Where is the Luján de Cuyo Refinery?• Next to Mendoza City in Argentina, South America, at the foot of the Andes mountains.



Background – A lesson learned.• Two [DMC] controllers in 1992:• Fluid Catalytic Cracking Unit #2 (FCC II) • Delayed Coker Unit #2 (Coker II)

• Units’ operation conditions changed

• Lack of knowledge transfer

• System abandoned and dismantled

• Mixed feelings in console operators



Background – A lesson learned.

• Reinstrumentation project in 1997

• Implementation of five multivariable control projects

• Developement of a group of specialists

• Work and training with Honeywell

• Growing responsibility and higher participation



Connecting Honeywell and ABB DCS

EnterpriseHistorian

USER API

OPC Server

PHD SERVER

Profit ViewerProfit

Controller

OPCRDI

PHDAPI

NT ClientWorkstation

PHD Client

Profit Viewer

PHDAPI HCI API

Local Area Network(LAN, Ethernet)

Repsol YPF LAN(ongoing project)

ABB DCN (DistributedControl Network)

AdvaInfo software provided by ABB

Hardware platform provided by ABB

Software provided by Matrikon

PHD Client and Profit Viewer StationHardware provided by Repsol YPF

Hardware and Software providedby Honeywell Hi-Spec Solutions




• The interface:

• ABB: Enterprise Historian (EH)

• OPC server

• Honeywell: Process History Database (PHD)




• ABB DCS:

• Programs in TCL code to handle:

ON/OFF from console stations

Watch Dog

Set Point validation

Mode switching

• PID loops reconfiguration




• OPC Server• Developed by Matrikon (Canada)• Support from Honeywell, ABB and Repsol YPF

• PHD• Windup Status virtual configuration• RMPCT• Inferential calculations• Events detection



The first five projects

• December 2000, FCC II Reactor, Regenerator and Main Fractionator

• March 2001, Coker II Furnaces, Main Fractionator and Gas Plant

• December 2001,

• Topping IV Crude Unit and Gas Plant.

• Vacuum Unit

• November 2002, Delayed Coker #1



The FCC II gas plant – First in-house project

• ABB DCS platform

• Previous successful experience on this unit

• Interface reconfiguration

• Point building on the ABB DCS and PHD module




• Gas plant hardware:

• High Pressure Separator (HPS)

• Naphtha Stripper

• Primary Absorber

• Secondary Absorber

• Debutanizer

• Depropanizer




• Gas Plant Products:

• Stabilized Naphtha

• Butane

• Propane/Propilene

• Fuel Gas




• Advance Control Objectives:

• Minimize the propane content in the fuel gas stream

• Minimize the butane content in the propane stream

• Minimize the propane content in the butane stream.

• Minimize the Reid Vapor Pressure of the stabilized naphtha

• Eliminate gas recycle problem

• Steady the product stream flows



RDI ExecutionC2_READ_LO

(00")

K2_READ_LO(25")

K2_READ_MD(35")

K2_READ_HI(40")

K2_WRITE(55")

C2_WRITE(30")

K2HT_CTL(44")

K2GP_CTL(51")

K2MF_CTL(48") C2GP_CTL

(14")

C2RR_CTL(18")

C2_READ_HI(10")

C2_READ_MD(05")

RDIClock






Inferential Calculations• Cromatographer delay: 45 minutes.• Inferentials have been built for:• Propane content in Fuel Gas stream (C3 in FG).• Propane content in Butane stream (C3 in C4).• Butane content in Propane stream (C4 in C3).• Naphtha’s Reid Vapor Pressure (RVP).



Results Evaluation (C4 in C3)• Butane content before controller implementation

• Butane content after controller implementation



Results Evaluation (C3 in FG)• Propane content before controller implementation

• Propane content after controller implementation



Results Evaluation (RPV)• Reid Vapor Pressure before controller implementation

• Reid Vapor Pressure after controller implementation



Gas recycle: Stripper-HPS-Primary absorber

• Wet gas composition, to the HPS, change due to:

• FCC reactor conditions

• External LPG streams

• Over absorption of light components in the primary absorber.

• High temperature at the stripper’s bottom: naphtha over stripping.

• Low temperature of the primary absorber outlet gas

• Low temperature of the wet gas

• Low temperature of the absorbent stream (debutanized naphtha).



Gas recycle: The Solution

• Manipulation of :

• Gas flow from the stripper

• Naphtha absorbent

• Control:

• Differential temperature inside the Stripper

• C3 purge into the FG



The FCC II gas plant – Conclusions

• Utilization Index: 98%

• High degree of satisfaction (Operations)

• All objectives met

• Nine-month execution period



Topping III: 2004 – Project in progress.

• Crude Distillation Unit

• Ongoing work – Step Test phase

• Commissioning before end of 2004

• Hands on training of new members of the team



Summary and Conclusions

Clues to Success:

• High degree of commitment from the Management.

• Deep knowledge and comprehension of the process.

• Simulation and off-line tuning.



Summary and Conclusions

• Training of console and field operators, supervisors, plant managers and process engineers.

• A scheduled and systematic monitoring activity.

• Continuous coaching to other members of the control group.

• Extensive documentation on each stage of development.



Questions?

You can contact us at:[email protected]

[email protected]

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