PredictPro Delivers Results at Rompetrol’s Constanta Refinery

Crude Fractionation Unit

PredictPro Delivers Results at Rompetrol’s Constanta Refinery

Crude Fractionation Unit

Radu IscoviciRompetrol

Chibuike Ukeje-EloaguEmerson Process Management

AgendaAgenda

� Introductions (Presenter, Rompetrol, Emerson Team)

� Project Execution– Project Team

– Project Implementation

� CDU Control Objectives & APC Scope� CDU Control Objectives & APC Scope� Control Design, Implementation & Commissioning� Benefits Audit� Long-Term Operability� Summary

Main PresenterMain Presenter

� Radu Iscovici

� Head, Process Control Department at Rompetrol Refining SA, Romania

� In charge of: � profit increase through advanced regulatory controls

and advanced process control and optimization and advanced process control and optimization techniques

� safe and secure plant operation through safety instrumented systems implementation;

� data collection, transfer and processing into valuable information for management through implementation of IT industrial systems

Rompetrol – An OverviewRompetrol – An Overview

� A leader in the regional oil industry � Rompetrol is a multinational company with activities

in 13 countries � Strong operational base in the Black Sea and

Mediterranean Sea region � The number and the complex nature of the projects

executed at a global level have turned Rompetrol The number and the complex nature of the projects executed at a global level have turned Rompetrol over time into the best known international brand originating in Romania.

� Co. Size: 9,000 Employees� Industry: Oil & Energy� Website: http://www.rompetrol.com

� Built in the 1980’s for the Romanian National Oil company

� Now owned by Rompetrol� Largest Romanian refinery (100,000 bbl/day)� Recently modernized with Emerson’s DeltaV DCS� Continuous drive to improve operational efficiency

Constanta Refinery – A brief history Constanta Refinery – A brief history

� Continuous drive to improve operational efficiency through exploitation of new DCS functionality and smart field instrumentation

Emerson Process ManagementEmerson Process Management

� Strategic Services Group� UK Based (Middlesbrough)� Support for Europe. Middle East &

Africa� Consultancy in advanced control

and optimizationand optimization� Process experts with 10 to 30

years experience (ex operating companies)

� Experienced project managers� Process-specific technical solutions

(oil & gas, refining, chemicals, utilities)

Project ExecutionProject Execution

� Project Team� Emerson

� Emerson Romania� Strategic Services (UK)� AAT (US)

� Rompetrol� Rompetrol Engineers embedded in the execution team� Rompetrol Engineers embedded in the execution team

� Renata-Alina Orzeiu (Control Engineer)� Gheorghe Oprea (Control Engineer)� Sebastian Paul Iftene (DCS Administrator)

� This strategy ensures greater understanding of the installed system thus developing on-site champions of the APC technology

� Any DCS configuration work carried out by Rompetrol personnel

Project ExecutionProject Execution

� Project Implementation� Kick-off

� Kick-off meeting to introduce team and review project admin and QA

� Site survey for data gathering & Preliminary Step testing� Design

� Functional, Detailed & Acceptance Test Specifications developed by Emerson for review/acceptance by developed by Emerson for review/acceptance by Rompetrol

� Build� Build controllers, Step Test MV/DV, generate models

� Commissioning� Commission controllers, deliver training, SAT.� Perform APC Benefits Audit

Project ExecutionProject Execution

� Major Milestones� June 2008 – Project kick-off

� On-site kick-off, site survey & Preliminary Step testing

� July 2008 – Commence Controller Build� Designs completed, commence site work� Controllers were built and commissioned unit by unit� Controllers were built and commissioned unit by unit

� Jan 2009 – Technical Completion� All controllers commissioned and in full use

CDU Control Objectives and ScopeCDU Control Objectives and ScopeGas

Naphtha

Kerosene

To Vacuum System

Steam

Steam

1. Maximize Throughput

2

3

2. Maximize value of product recovery

3. Maximize heat Recovery

4. Maximize heater

Fired Heater

Vacuum Tower

Atmospheric TowerFired Heaters

Crude Feed

Lt Diesel

Diesel

AGO

LVGO

HVGO

Residue

Stripping Tower

SteamSteam

Steam

Steam

1

3

44

4. Maximize heater efficiency

CDU Control DesignCDU Control Design

Naphtha

Kerosene

Lt Diesel

To Vacuum SystemSteam

Steam

T

TF

F

F

F

T

F

FL

L

FBP

IBP FBP

� Interactions� Disturbances� Long Time

to Steady State

� Optimization

Why Use MPC? Gas

F F

T

P

P

Vacuum Tower

Atmospheric Tower

Crude Feed

Lt Diesel

Diesel

AGO

LVGO

HVGO

Residue

Stripping Tower

Steam

Steam

Steam

Steam

T

T

T

F

F

F

F

F

F

F

T

T

FuelF

HV

F

F

T

T

F

F

F

T

T

O2

F

F

T

T

F

F

FT

T

TF

F

FL

L

IBP

Cong.D360

T

T

P

P

Flood

O Flash

Flood

T P

Optimization

D360

O2

O2

HV Fuel

F

AirF

CO

COT

Fired Heaters

Fired Heater

F

HV Fuel

APC 4 (11 x 11)

CDU Control DesignCDU Control Design

APC 5 (6x6)APC 1 (3x3)

Naphtha

Kerosene

Lt Diesel

Steam

Steam

T

TF

F

F

F

F

T

T

F

T

F

FL

L

FBP

IBP FBP

T P

Gas

F F

O2 CO

T

P

P

APC 2 (4x4)

APC 3 (5x5)

Vacuum Tower

Atmospheric Tower

Crude Feed

Lt Diesel

Diesel

AGO

LVGO

HVGO

Stripping Tower

Steam

Steam

Steam

Steam

T

T

T

F

F

F

F

F

FuelF

HV

F

F

T

T

F

F

F

T

T

O2

F

F

T

T

F

F

FT

T

TF

F

FL

L

IBP

Cong.D360

T P

Flood

O Flash

Flood

T P

D360

O2

HVFuel

F

AirF

CO

T

Fired HeatersFired Heater

F

HV Fuel

CDU Control Design (Atm Section)CDU Control Design (Atm Section)

C1: MPC4

Manipulated

C2 Base Level

Base Steam Ratio

4 Product Flow Rates

AUTORCAS

AUTORCAS

AUTORCAS

Top Pressure

4 Pressure Corrected Temperatures

Control Variables

Control

H2: MPC2H1: MPC1

OutletTemperature

Total C1 Flow

O2OutletTemperature

O2

Manipulated Variables

3 Pump Around Flow Rates

4 Product Flow Rates

Reflux Drum Pressure

Base Steam RatioPass 1 Flow Rate

Pass 2 Flow Rate

Fuel Pressure

Air Flow Rate

Pass 1 Flow Rate

Pass 2 Flow Rate

Fuel Pressure

dT dT

Control Variables

Manipulated Variables

CDU Control Design (Vacuum Section)CDU Control Design (Vacuum Section)

C5: MPC5

Manipulated

C1 Base Level

Average Feed Temperature

4 Pressure Corrected Temperatures

AUTORCAS

AUTORCAS

Control Variables

H3: MPC3

OutletTemperature

Manipulated Variables

Recycle Flow

2 Pump Around Flows

Quench Flow4 Pass Flow Rates

Fuel Pressure

Total C5 Feed Flow

Manipulated Variables

Control Variables

Inferential AnalysisInferential Analysis� Product compositions are not measured on-

line but once per day in the Laboratory. � Product compositions are key constraints in

a crude unit that dictate how much product can be made.

� A full suite of “virtual analyzers” was created that predict the product properties (such as diesel pour point) in real-time.

� These virtual analyzers use a regression based on product flow rates and column based on product flow rates and column temperatures.

� DeltaV Neural is a standard component in the DCS.

� The predicted values are updated daily against the laboratory results to ensure that the predictions remain accurate.

� These predicted values are used by the controller as constraint variables to keep products on specification.

Controller ConfigurationController Configuration

� Emerson’s PredictPro™

� DeltaV™ standard component� Rompetrol DCS engineer configured 5 PredictPro™

Applications to Emerson design using Control Studio™

User Interface ConfigurationUser Interface Configuration

� PredictPro standard interface –self configuring

Step TestingStep Testing

� Automatic Step Testing

Commissioning (1)Commissioning (1)

� Model Generation:– automatic– manual adjustment

� Model Verification� Model Verification– by comparing Predicted vs.

Actual

� Controller tuning– fine tune response by

weighting CVs and MVs

Commissioning (2)Commissioning (2)

� 5 optimization scenarios configured

� Can assign values to variables

� Controller will maximize total valueUse to maximize � Use to maximize production, and minimize energy use

� Operator selectable in real-time

Benefits Audit (Summary)Benefits Audit (Summary)� Compare before and after operating

periodsCrude throughput constrained by downstream units!

� Increased production of more valuable products for a given feed rate

� Improved heater efficiency by a significant amountsignificant amount

� Quantified benefits:– Audited project benefit of US $1.8m

(3-month payback)

� Non-Quantified Benefits:– Reduced operator actions– Better response to disturbances such as

crude changes

Benefits Audit (Details)Benefits Audit (Details)� Quantified benefits (Column):

– Reduced giveaway of valuable product into AGO stream

– Quantified benefit: • US$ 1.79 million / year

� Quantified benefits (Heaters):– Improved efficiency due to– Improved efficiency due to

• Pass balancing• Improved excess O2 control

– Quantified benefit: • US$ 103,000 / year

� Payback Time:– 3 months

Long-Term OperabilityLong-Term Operability

� Since commissioning, the application has been in continuous use.

� 12 month warranty for the APC application is included as part of Emerson service.

� Since entire application is constructed from standard DCS components, the standard Emerson DeltaV DCS support service applies. – including 24/7 help line– including 24/7 help line– agreed man-hour rates if required

� How regularly will model refits be required?– Once models fitted they are tolerant of inaccuracies to a

reasonable degree.– So long as no major process modifications are made the models

will not require refitting (e.g. changing the tuning of a control loop, replacing a valve or a pump or cleaning a heat exchanger should not require refitting)

– If models do require fitting, automatic tools make the process quick and easy.

SummarySummary

� Total APC Audited Benefit of US$ 1.8 million

� Payback time of just under 3 months

� Familiar DCS Plant Type:Refinery � Familiar DCS

environment made for a quick and smooth uptake of the APC controllers by the operations crew

Refinery

Scope:Model Predictive Control on: �Atmospheric Column�Feed Heaters (x2)�Vacuum Column�Vacuum feed Heater

Thank YouThank You

� Comments / Questions?