Transcript PPT Template

Slide 1
SSE-03 Total Performance CDU
Crude Distillation Unit Optimization
through Advanced Measurement
Solutions
SimSci-Esscor Client Conference
October 2012
Joe Fillion
John Richmond
© 2012 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.
2
Invensys proprietary & confidential
© Invensys 17 July 2015
Crude Performance by Design
Total Performance.cdu
Optimization
Optimum
Engineered Solutions based
on Established APC/RTO
Offerings
Measurement
AMS.crude
An FTNIR-based
Advanced Measurement
Solution
Performance.cdu – a comprehensive APC strategy enabled by
measurement of Crude and key product streams
Slide 3
Slide 3
2009 IPS North America Client Conference
Crude Blending, CDU Feed & Rundown
Slide 4
Product Blending
Slide 5
Examples of Measurements Being Made
TBP / Dist Points
Aromatics (Mono, Bi, Tri,
Polynuclear)
Carbon Aromaticity,
Naphthenicity, Parafinicity
Nitrogen
Freeze
Smoke*
Flash
TAN*
Cloud
% Water
Viscosity
PIONA (C3 – C12+)
Cetane
Pour Point
API / Density
CFFP
Sulfur
RON
ConCarbon
MON
Asphaltines
Benzene
Many More …
Slide 6
Crude Unit Benefits
Slide 7
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12:25:33
21:07:14
5:48:57
6:14:16
14:53:09
23:32:13
8:12:22
16:51:30
1:30:48
10:10:13
18:49:43
1:46:49
10:33:52
Tank Switch
19:21:02
5-6cc/bbl Profit
Improvement
Reported
28
27
4:08:17
1%Increase in
Throughput
causing
CDU
upset.
12:55:32
Shift to shift stability
Feed
change
31
30
29
21:42:25
Step shift in
performance
Crude
Switch
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6:29:22
Optimized Energy
35
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15:16:27
Reduced turn around
time.
Crude API 8/25-9/6/01
0:03:38
Product Quality
Improvements.
How does this help APC?
A front-end analyzer can help in two ways with an
APC system on a crude unit.
1. If the analyzer is measuring the “live” feed attributes, then it
is a feed forward to the APC system. Giving the system a
“measured” disturbance before the effect of that disturbance
is seen downstream.
2. If the analyzer is used as part of a crude blending system,
then it is being used to reduce disturbance in the first place
and then feed forward to the APC system as the feeds shift
attributes (albeit at a much slower rate).
provides dynamic feed forward rejection of feed
disturbances from crude switches, tank stratification,
or upstream unit upsets
Slide 8
Slide 8
Analyzer Enhanced Crude Switch w/APC
Slide 9
FF Enhanced Crude Switch APC
Slide 10
Total Performance CDU
Measurement, Consulting, Optimization
Process
Streams
Sample Fast
Loops
Sample
Conditioning
Application
Measurement Engineering &
Sensor(s)
Data Set
Design
Modeling,
Validation
& Updates
Multi-product Measurement Solution:
Analyzer Systems and Support Services
Consulting on
Full-scope Analyzer Project
Full-Scope Solution: Measurement Solution,
Project Consulting, and Process Optimization
Slide 11
IPS Confidential
Process
Optimization
AMS CDU History
• While many may claim they have the ability to characterize crude
oil, results are ambiguous at best
• Invensys, Bruker and a major US based oil company partnered to
redefine the art in crude oil analysis
• Invensys designed and integrated a complete solution utilizing the
Bruker spectrometer
• Successfully completed an offline study that proved the
Invensys/Bruker approach
• Proved conclusively that high resolution, repeatable spectra can be obtained for
Crude oils
• Proved that models can be built and predict well for crude oil properties
Slide 12
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Invensys proprietary & confidential
© Invensys 7/17/2015
AMS CDU
Advanced Measurement Solution for CDU
Implemented on an FTNIR Analyzer System
New Application of Established FTNIR technology
Application-optimized integration of off-the-shelf technology
• Optical subsystem optimized for Crude and heavy oil
• Best in-class FTNIR from Bruker Optics
• PAC supervisory control – Process controller for process environment
• Open environment
Slide 13
IPS Confidential
Streams and Property Examples
Slide 14
Crude
HGO
Diesel
Kerosene
Naphtha
TBP
Distillation
Gravity
Con Carbon
Asphaltines
Distillation
Gravity
Distillation
Gravity
Cloud Point
Cetane
Distillation
Gravity
Freeze point
Flash point
Napthalenes
Distillation
Gravity
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Invensys proprietary & confidential
© Invensys 7/17/2015
AMS.cdu – Four Pillars of Design
A. Sampling
1. Heating and Temperature Control. The high viscosity of heavy crudes and heavy oils
requires sampling at an elevated measurement setpoint temperature, e.g. 80 °C, while
strict temperature control at setpoint ± 1 °C is necessary to minimize temperature-
dependent variation in spectral response (shape and position of absorption bands)
2. Homogenization. Crude oil samples’ inherent in-homogeneity and propensity to stratify
is addressed through distributed sampling of the liquid column to maximize sample
uniformity during data acquisition
3. Flow control. Maintaining flow rate approximately constant during sample analysis
facilitates temperature control and enhances spectral homogenization through
time-distributed spectral acquisition (See Pillar C below)
Slide 15
Four Pillars of Design
(cont’d)
B. Optics
1. High-efficiency optics. Though compounds in crude oil make it appear visibly dark,
these compounds are not “dark” in the NIR. But what complicates the optical
spectroscopy of crude and heavy oils, in contrast to conventional NIR analyzer
configurations applied for the analysis of clear hydrocarbon liquids, is the presence of
microscopic particulates of asphaltenic or carbonaceous material. These cause
wavelength-dependent scattering of NIR light that complicates spectral analysis, e.g.
through baseline distortion. The short-focal-length (high-f) optical geometry of the
AMS.cdu minimizes this effect.
2. Long Path length. Due to scattering effects identified above, conventional approaches
to crude oil analysis rely generally on very short optical path lengths, e.g. around a half
millimeter, though occasionally longer path lengths have been used. But the former
precludes analysis of crudes that are heavy (because they do not flow easily through
short path length cells, even at elevated temperatures) while the latter precludes
analysis of crudes that are highly scattering (the longer the path length, the more
severe the scattering effect). High-efficiency optics allow use of longer (1-2 mm) path
lengths.
Slide 16
Four Pillars of Design cont’d
C. Time-distributed Spectra Acquisition (TDSA)
1. Off-line and At-line. Simply put, TDSA is the practice of acquiring spectra as the
sample flows continuously from a fixed-volume sample cylinder through the analyzer and
ultimately through the optical cell. This means that the spectral signature of every
fractional milliliter of sample is represented in the aggregate spectral record acquired
while the cylinder contents flow from the cylinder through the optical cell.
2. On-line. Though not volume-limited as in the case of off-line or at-line analysis of
sample from a cylinder, the practice of acquiring sample spectra on continuously-flowing
sample eliminates the effect of transient (local) variation in sample composition. Instead,
TDSA permits acquisition of a spectral record that represents a large volume of sample,
i.e. an aggregate spectral signature in which local in-homogeneities are averaged out.
3. Data Qualification. TDSA yields a population of spectral, the quality of whose individual
members can be evaluated for determination of worthiness for inclusion in the final,
combined result.
Slide 17
Slide 17
Four Pillars of Design cont’d
D. Spectroscopy
1. Spectral Region. As indicated in the discussion about optics (Pillar B.), the severity of
scattering by crude or heavy oil is generally highest when API gravity is low and viscosity
is correspondingly high. At long wavelengths where scattering effects in the first
combination overtone (FCOT) region of the NIR (in the 2000 – 2500 nm region) are
minimal, the applicable path length (approx. 0.5 mm) is impractically short due to
viscosity considerations. But while sample flows more readily through a cell whose path
length is 1-2 mm, intensities of the FCOT signals become too large, necessitating use of
lower-intensity first C-H overtones (FCHOT) at approximately 1400 – 1800 nm where
scattering effects are much more pronounced – hence the benefit of using high-efficiency
optics.
2. Spectrometer Configuration. Having dealt with the issue of viscosity through the use
of longer path length, and the attending increase in scattering effects through use of
high-f optics, possibility now exists to use conventional NIR fiber optics (relatively low
cost quartz) whose optical cutoff is around 2000 nm, making the FCOT inaccessible.
Slide 18
Four Pillars of Design - Additional Detail
• Significant elements of the Pillars A and C have general significance beyond their
integration with FTNIR technology in particular to facilitate the measurement of crude
and heavy oils.
• Pillars A and C give capabilities that have broad relevance for the at-line or off-line
application of any sensor technology, optical or otherwise, to the measurement of
samples where representative sampling with preservation of sample integrity during
analysis and/or tight temperature control are critical for measurement integrity and can
impact the overall measurement outcome.
– Examples include NMR or sensors that measure, exploit, or respond to a sample’s
physical or chemical properties
– In the general case, the benefits of this sampling technology are not limited to samples
that exhibit optical scattering or whose viscosity is high, e.g. relative to water.
Slide 19
Four Pillars of Design - Additional Detail
(cont’d)
• The generalized implication of Element 2 of Pillar B is that Pillars A and C can facilitate
static or continuous-flow analysis in a sensor cells with a large volume, e.g. as large as
50% that of the container from which the sample is introduced to the analyzer for
measurement while maintaining sample homogeneity and temperature control.
• In summary, Pillars A and C in combination with a sensor interface (measurement cell)
address the following issues of concern, either alone OR in any combination:
– Representative sampling of a large (> e.g. 200 mL to 2000 mL) volume
– Sample conditioning to achieve tight temperature control, e.g. 1 deg C to +/- 0.1 deg C
– Sampling at elevated temperatures, e.g. > 10 deg C above ambient to 100 deg C
– Preservation of sample integrity (minimize contamination OR the loss of volatiles)
Slide 20
FTNIR Analyzer System, 1 Channel /
Process
Slide 21
IPS Confidential
Process
Slide 22
IPS Confidential
Process
Electronics Module
• Wonderware User Interface / Data
Manager
• Runs Bruker OPUS software
• LCD
• OPC communication to DCS
• Choice of chemometric environments
• Purged for ATEX/Class I Div 2
• Temperature controlled
Sampling Module
• Optical subsystem by the leading
supplier of sample cells and transfer
optics
– Optical efficiency optimized for dark, scattering
samples (crude oil)
• Liquid Switching
– Sample and standards Temperature Controlled
Slide 23
IPS Confidential
Lab
Spectra are equivalent to those
measured online with the Process
• Sample heated to process
temperature to ensure spectral
integrity
• Sample is totally confined to ensure
sample integrity
Models developed with lab system
during Phase I can be deployed
directly online in Phase II
Analysis Cell, CPU, and FTNIR
Spectrometer are interchangeable
with Process
IPS Confidential
Slide 24
• Components in Lab provide “hot
swap” capability
Process and Lab
FTNIR
Spectrometer
Module
Optical Subsystem
including Flow Cell
Sampling
System
Core spectrometer components in
Process and Lab are identical
IPS Confidential
Slide 25
Multi-Point Fiber Optic FTNIR Process
Multiple Remote Sampling
Points
Temperature controlled flowthrough cells
• Analysis at applicationappropriate temperatures
• Heavy streams / Higher T
• Lighter streams / Lower T
Sampling System installed
proximate to one or more
sampling points
Single or multiple steams can
be analyzed with each cell
Base system configurable with
up to 6 optical channels / cells
Slide 26
IPS Confidential
Crude Spectra in the first overtone
region as recorded and after preprocessing
Slide 27
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Invensys proprietary & confidential
© Invensys 7/17/2015
Crude Spectra in the combination
region as recorded and after preprocessing
Slide 28
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Invensys proprietary & confidential
© Invensys 7/17/2015
Thank you
© 2012 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.