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02/24/2016 Page 1 Advanced PRD Monitoring Systems
Advanced PRD Monitoring Systems
Marcio Donnangelo Global Business Development HSSE Applications
Don Cramer Instrument Project Coordinator Texas City - Refining Division
Company logo here
Company logo here
02/24/2016 Page 2 Advanced PRD Monitoring Systems
Advanced PRD Monitoring Systems This presentation discusses new EPA regulations for pressure relief devices and the most cost-effective and non-intrusive solutions to comply by using PRV downstream acoustic monitoring. Marcio Donnangelo with Emerson will discuss how to continuously monitor PRV conditions, such as release, leakage and simmering; submit comprehensive data for better and faster electronic EPA filing; improve operator safety and efficiency. Don Cramer with Marathon Petroleum gives a real case example and PRV acoustic monitoring results. He discusses how Marathon complied with EPA and increased unit throughput at the same time!
02/24/2016 Page 3 Advanced PRD Monitoring Systems
Agenda • EPA key facts and challenges with compliance • Solution overview to overcome challenges with compliance • Challenges with PRDs: Leakage and Simmering • Case Study from Marathon Petroleum
• Solution • Overview • Project Description
• Results • Preliminary information • Collective approach – The game changer • The unexpected bonus • The final results
• Conclusions and Takeaways PRD Electronically Monitored
02/24/2016 Page 5 Advanced PRD Monitoring Systems
Through Five Business Platforms, Emerson Is Delivering on Our Brand Promise
Emerson Process Management
Emerson Industrial Automation
Emerson Power Network
Emerson Climate Technology
Emerson Commercial & Residential Solutions
02/24/2016 Page 6 Advanced PRD Monitoring Systems
Key Facts from EPA Regulation • Operators would install electronic monitors
on PRDs that vent to atmosphere to identify and record the time and duration of each pressure release
• Identify the source of release on the flare systems
• Corrective action required for any leakage of 500 ppm or greater
• Reporting emissions during startup and shutdown is now required
Monitoring of all PRDs handling Hazardous Air Pollutant (HAP)
must be completed within three years of signoff
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Challenges With Compliance • Manual monitoring – automated monitoring is
now a preferred option
• Traditional electronic monitoring technology is expensive due to complex installation and commissioning requirements
• Identifying time and duration of releases using process information requires extensive data interpretation, time and expertise
• Locating the source of release in your flare system requires even more complex analysis and can result in increased emissions or production slowdown
Cabling and trenching Process shut down
Hard to reach locations
Unit A
Unit B
Unit C
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02/24/2016 Page 8 Advanced PRD Monitoring Systems
Complete Real-Time PRD Monitoring Solution Addresses Your Key Challenges 1. Emerson’s non-intrusive and wireless solution enables lowest cost implementation 2. Technology designed for PRD application delivers the information you need for compliance
accessible through your existing host system or historian 3. Quickly and easily identify the source of release in your flare system
HSSE
WirelessHART®
Gateway
Rupture Disc Monitoring
Relief Valve and Rupture Disc Monitoring
Relief Valve Monitoring
1
2 3
02/24/2016 Page 9 Advanced PRD Monitoring Systems
Non-Intrusive Design Rosemount 708 Wireless Acoustic Transmitter Features • Strap-on Installation • WirelessHART® Data Communication
• Acoustic • Temperature - for pipe surface • Operating Temperature - electronic board) • Battery Charge
• Long Battery Life – 1 to 60 Second Updates • 5.8 years @ 8 Seconds • 10 years @ 32 Seconds
Probe with Acoustic and Temperature Sensors
The non-intrusive sensor clamps directly onto the PRD vent pipe surface.
It’s that simple!!! Install in just minutes.
02/24/2016 Page 10 Advanced PRD Monitoring Systems
WirelessHART Communications Benefits • Reduced Engineering
• Reduced Labor
• Reduced Materials
• Faster Installation
• Assured Reliability and Performance
Pervasive Sensing Solution
Relief Valve Monitoring
Traditional Method
02/24/2016 Page 11 Advanced PRD Monitoring Systems
CAPEX Savings with Pervasive Sensing Solution
Total compliance and operational improvement at fraction of the cost of traditional method
(1) Estimated costs include monitoring of the wireless system, tamperproof secure data, and engineered services (2) Cost range dependent on application: PRV only or PRV with Rupture Disc monitoring
Total Cost of Implementation(1)
200 x PRDs Traditional Method Pervasive Sensing Solution(2)
Total Project Cost ($K) $3,520 $464 - $1,088 Total Cost per PRD ($K) $18 $2.3 – $5.4
Savings - 69% - 87%
Field Installation Intrusive Non-Intrusive Cabling and Trenches Required Yes No Technology Wired Wireless
1
02/24/2016 Page 13 Advanced PRD Monitoring Systems
Acoustic Transmitter Provides Insight Into Your PRD Release Without Complex Data Analysis Traditional PRD Monitoring Process • Observe upstream pressure peaks and valleys
around the pressure limit Challenges of monitoring with process pressure • Difficult to determine when the PRD is actually
opened or closed
Emerson’s PRD Monitoring Solution • Observe downstream acoustic signature of
PRD installation Benefits of monitoring with acoustic signature • Time and duration of each release clearly shown • Valve simmering, chattering, leakages and
malfunctions also identifiable
PRD monitoring using process data analysis can take from hours to days
Acoustic Process Pressure
Easy to identify time and duration of each pressure release
02/24/2016 Page 14 Advanced PRD Monitoring Systems
Easily Access Your PRD Information
PRV Unit Monitoring PRV PRV Active PRV State Change PRV Acknowledged Transmitter HealthWind Direction South EastUnit 1 PRV-001-009 Yes Yes Yes GoodUnit 2 PRV-002-001 No NO No BadUnit 3 PRV-003-001 No Yes No GoodUnit 4 No No No Good
The Rosemount 708*
combines ultrasonic signatures and surface temperature measurement from the vent pipe surface
Gateway connects the information directly to operators host system or historian for notification and reporting
PRD information is sent to a Gateway through the WirelessHART® protocol • Acoustic magnitude • Pipe surface temperature • Battery Life
2
* Additional configuration options available. Consult your local sales person for details.
02/24/2016 Page 15 Advanced PRD Monitoring Systems
64 Seconds
…And Integrate PRD Alerting and Reporting into Your Host System or Historian
• Alert on threshold • Visually inspect trend
for verification
• Add location and contextual information
• Easily access and share results
2
An estimated 100 lbs.* of VOC was released with wind conditions south by south east. Release was acknowledged and recorded.
*Relief valve and process constants: Spring-loaded operating relief valve, set pressure = 90 psig, valve capacity = 268 SCFM (Square Cubic Feet Per Minute) and gas temperature = 212 ˚F.
Unit 1
64
Seconds
02/24/2016 Page 16 Advanced PRD Monitoring Systems
Identifying the Source of Release in Your Flare System
• Challenges
• Not all releases are audible to human detection even when the PRD is releasing to the atmosphere
• Using process information to identify where the release is coming from requires hours to days of expert data analysis and exposure to what may be a hazardous area
Unit A
Unit B
Unit C
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Every minute spent identifying which PRD is releasing leads to increasing emissions, regulatory
fines and lost production
3
02/24/2016 Page 17 Advanced PRD Monitoring Systems
Identifying the Source of Release in Your Flare System
• Solution • Comprehensive PRD monitoring for closed recovery and flare systems enables
immediate identification and response to source
Unit A
Unit B
Unit C
Eliminate the need to slow down production and ensure minimal emissions with clear visibility to
your full system
3
02/24/2016 Page 18 Advanced PRD Monitoring Systems
In Addition to Compliance, Fast Detection of Releases and Leakages Saves You Money
• Undetected PRD leakages happen quite often
• Even a small leak (0.1% from PRV flow area) can cause tens of thousands of dollars per year of material losses
unseated
valve
Leakages caused by PRD malfunctions can waste large amounts of valuable product, along with the energy required to produce these products.
02/24/2016 Page 19 Advanced PRD Monitoring Systems
OPEX Savings Possible with this Pervasive Sensing Solution
Potential Annual Savings = $3,200,000 Example based on a 250 bpd refinery
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Summary of PRD Monitoring Solution Benefits • Simple and accurate EPA compliance
• Minimum capital expenditure
• Increased throughput
• Improved productivity and safety
• Greater insight into overall process
• Establishes infrastructure for future operational improvements using Pervasive Sensing solutions
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Wireless Field-Proven Technology
Billions of hours of operating experience
Thousands of Smart Wireless field devices
Thousands of Wireless Field Networks
02/24/2016 Page 23 Advanced PRD Monitoring Systems
Marathon Petroleum, Canton – OH Facility Marathon Petroleum Company
• 1.7 million barrels per day • Fourth largest transportation fuels refiner in the nation • Seven-plant refining network strategically located to serve major markets.
The Canton refinery: • 180 acres and is approximately 60 miles southeast of Cleveland, Ohio. • 360 employees • 80,000 barrels of crude oil per day • Products: Gasoline, diesel fuels, kerosene, propane, sulfur, asphalt, roofing
flux, home heating oil, #6 industrial fuel oil, and low sulfur gasoline.
02/24/2016 Page 24 Advanced PRD Monitoring Systems
Relief Valve Challenges • Pressure relief valves are known to
experience problems re-seating • Small leaks are difficult to detect
• Continuous relief due to chattering
• RVs can also get “stuck” open, or break • Release for a duration equal to the
time it takes to pinpoint the correct valve.
There is a need for individual electronic RV monitoring.
02/24/2016 Page 25 Advanced PRD Monitoring Systems
Solution Overview • 15 x wired flowmeters on fifteen flare headers.
• Wireless acoustic transmitters were installed on 69 RV’s in high H2S service or high hydrocarbon flow.
• One non-invasive Rosemount 708 Wireless Acoustic Transmitter was attached directly to the outlet side of the process piping of each valve
Solution allows individual monitoring of RVs without a lot
of infrastructure and cost 300 ft.
Gateways location
Plant overview: Gateway and Relief Valve location
02/24/2016 Page 26 Advanced PRD Monitoring Systems
Wireless Acoustic Transmitter and Gateway Installation
Cable
Without any interruption to the process! 69 x acoustic transmitters were easily
installed in a month’s time
Pipe Clamps
1420 Gateway Extended Antenna
Detail
02/24/2016 Page 27 Advanced PRD Monitoring Systems
Mesh Network and PI Integration • Seamlessly integrated WirelessHART into
the PI system through Delta-V • Operators data access:
• Can graph any relief event • From the event onset until the event has
stopped. • Scan rate set at 4 seconds
• Expected delay between the wireless gateway and the PI system is 10 seconds.
• Best chance to see short, frequent releases
New OSI PI Connector enable native integration to WirelessHART
02/24/2016 Page 28 Advanced PRD Monitoring Systems
How the System Works • Validation that a RV has truly relieved by an increase in flow rate in the Unit’s
flare header • Pinpoint which valve is in alarm immediately after a flow alarm is generated • The temperature measurement (SV) on the 708 Acoustic Transmitter can be
used for part of the RV diagnosis • The operators for that Unit are called immediately:
• Problem diagnosed within an hour • The ability to pinpoint broken or stuck-open RV’s saves weeks and even months of
high flow releases • The ability to detect “undetectable” slow or intermittent releases is equally valuable
Overtime, all these actions combined, have a significant impact of reducing the total H2S and hydrocarbon flow to the Flare.
02/24/2016 Page 29 Advanced PRD Monitoring Systems
Process Book (PI) Screens
Acoustics in Alarm Sub-header 7
Flare System selection screen
Flow Header PI screen view
Sub-header detail
Quick identification of increased header
flow
02/24/2016 Page 30 Advanced PRD Monitoring Systems
Process Book (PI) Screens (Continued)
Quick identification of lifting relief valve
Sub-header 7 detail scree
Rosemount 708 – Battery Life
02/24/2016 Page 31 Advanced PRD Monitoring Systems
Process Book (PI) Graph
Leakage Releases Simmering
Acoustic
Temperature
Rosemount 708 Wireless Acoustic Transmitter
02/24/2016 Page 32 Advanced PRD Monitoring Systems
Process Book (PI) Graph
You can not always rely on pressure, temperature or flow to indicate if an RV is
releasing
Acoustic
Pressure
Acoustic and Pressure Graphic
Missing Pressure Data
02/24/2016 Page 33 Advanced PRD Monitoring Systems
Results from the 69 Acoustic Monitors • More then 200 lifts and reseating events over 15 month
• Inspection is required to fill out a RV Post Activation Report each time a RV lifts
• 20 Problems were identified and resolved
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Business Results Achieved • Reduction in loss of hydrocarbon to the Flare System
• Capturing before-and-after data for duration of RV lifts
• Timely detection and intervention of faulty valves
• Improved operation of our process Units
• The acoustic data shows when we are operating outside of operation limits, and now we have more confidence to increase throughput of the units
• The project paid for itself within 5 months • Estimated ROI at 271% annualized over 20 years
• We plan to expand the use of acoustic monitoring for 80 more relief valves on smaller flows of H2S and hydrocarbon
02/24/2016 Page 35 Advanced PRD Monitoring Systems
The Unexpected Bonus • 216 lifts occurred in a 15 month period on 69 RVs, with potential high flow
and high H2S
• Expected and realized environmental benefits: • Tamper-proof environmental reporting
• Reduction in post-lift reports
• Time-stamps correlated with process conditions and timely intervention that enabled better environmental stewardship
“The increased throughput and revenue was an unexpected bonus”
02/24/2016 Page 36 Advanced PRD Monitoring Systems
The Flare System Team, Enabled by Pervasive Sensing Strategy, Achieved Same Challenging Results
• The amount of actionable information has grown thanks to Relief Valve Acoustic and Temperature monitoring, Header flow monitoring in addition to previous instrumentation implemented in the process, such as pressure, temperature, level, etc.
• PRV and Flare Header data information available and integrated into PI helps the flare system team develop targeted action plans: • Read-out Process Book (PI) alarms and Flare system activities
• Set process priorities
• Perform root cause analysis as part of continuous improvement plan to avoid the same release happening again
02/24/2016 Page 37 Advanced PRD Monitoring Systems
Plans for Pervasive Sensing Applications • Detroit Plant:
• Installing > 70 Acoustic Monitors
• 17 will be installed this year with the rest to be installed next year
• Texas City Plant: • 50 last year
• Canton Plant: • 69 installed
• Team is looking at adding more Acoustic Monitors
• Future plan: Galveston Bay, Robinson, Garyville and Catlettsburg.
• This project has enabled the Wireless HART backbone for the refinery to implement other application such as Safety Showers, Levels, Temperature and Pressure surveys, etc.
02/24/2016 Page 38 Advanced PRD Monitoring Systems
Additional Tips • Visit Emerson booth #28 on the tradeshow floor to see a live demo.
• http://www.emersonprocess.com/PRDWirelessMonitoring • For video, whitepaper, presentation and flyer.
• Additional resources: • http://www3.emersonprocess.com/rosemount/powermodulelifecalculator/default.aspx
• http://www3.emersonprocess.com/rosemount/SWirelessGCEstimator/Default.html
• http://www2.emersonprocess.com/en-us/brands/rosemount/documentation-and-drawings/pages/index.aspx
• http://www2.emersonprocess.com/en-us/plantweb/wireless/pervasive-sensing/pages/index.aspx