ISA Saudi Section 2013

Optimization of Production Processes and Life Cycle Management by Integration of Intelligent Process Instrumentation and Analytic Technologies

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Analytic Technologies

Industrial Automation Delhi November 2012

New Trends in Process Automation

Life Cycle Management Asset Management Condition Based ManagementCondition Based Management Process / Energy Efficiency

Plant and Production OptimizationPlant and Production Optimization

Reduction of unscheduled Down Time by Preventive / Predictive Maintenance ConceptsMaintenance Concepts

Life Cycle Management – Single Source for Services A t ti I t t ti El t i l d PAutomation, Instrumentation, Electrical and Power

Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail

Become a substantial t f th t '

Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail

part of the customer's operations team for

entire scope of delivery

PLCAutomation &

OTN

Multi Vendor ServicesOperation of the maintenance concept

Planning

Value Added ServicesRemote assistance & diagnostics

Condition based

Product Related ServicesKeeping specialists – readiness for

24/7 hotline support and

Telemetry

SchedulingPerformance Improving services focused on Key Performance IndicatorsReliability guarantees on demand

Condition based monitoringModernization & MigrationsShut Dows ServicesConsultation for Energy Saving, Project

24/7 hotline support and

On-site fault elimination

Software & Hardware updates

Maintenance & uptime Services

Includes third party equipment y gManagement and Maintenance ProcessIncludes third party equipment

Life Cycle Management Conceptf f O

C biliti f j t d l t I l t ti d ti

The whole Lifecycle of Plant Operation

S t T t

Capabilities for project development, Implementation and operation

Assembly/

Erection System Test

Putting into operation

Delivery/Shipment

engineering

Project-management

Delivery/ShipmentDocumentation

Lifecycle Management

HW, SW Engineering- Product Related and Value Added Services

- Operation Related Services (Frame Agreement)

Modernization / Migration ServicesStudies / Planning

- Modernization / Migration Services

- Total Cost of Ownership / Plant Availability

Production Efficiency

Process Optimization with intelligent Analytics androcess Optimization with intelligent Analytics andInstrumentation Solutions with advanced DiagnosticInstrumentation Solutions with advanced Diagnosticfunctionalities in order to improve Plant / Energy Efficiencyfunctionalities in order to improve Plant / Energy Efficiency

From Condition based Monitoring to C diti M tCondition Management

Condition based Monitoring / Management is a major process in order toCondition based Monitoring / Management is a major process in order to optimize production processes concerning facility operation, efficiency , production quality, quantity and to achieve production repeatability particular d i th i d tiduring the running production process.

A major step is to identify the actual requirements, demands and future trends in various industries in all international regions part of this process is thevarious industries in all international regions, part of this process is the development and establishment of the competence concerning detailed segmentation of industries by total solutions, partial solutions as well as single components applications and supportcomponents, applications and support.

In order to improve the achievement of business results, a reactive and preventive maintenance process of production facilities has to be turned into a p p ppredictive concept .

S l ti C it i / R i t SSelection Criterias / Requirement Specs

Physical MeasurementsTechnology-Selectiongy

Industry-Segments Solutions

Application Database Product-Selection Solutions

From Upstream to Downstream F R fi i S i l Ch i lFrom Refineries to Special Chemicals

LNGOil&Gas

Pipeline

LNGOffshoreDrilling

TankfarmCompressionGas Storage

G

OnshoreOil&Gas Fields Refinery

Compression

Chemical Industry

Gas Treatment

Injection

HPIPetrochemicals

Basic Chemicals(e.g. Fertilizers)

HPI Air Separation

Fibers/Foils

Specialty Chemicals Bio Fine Chemicals(e.g. pharmaceutical pre-products)

(e.g. Nylon)

Specialty Chemicals(e.g. Oil additives) Chemicals

(e.g. Bio-Ethanol)products)

Process Optimization as part of Asset ManagementProcess Optimization as part of Asset Management

Advanced Automation for Emergency Shut down Systems and Solutionstions in order to avoidSystems and Solutionstions in order to avoid Blow Outs and Oil & Gas Leaks

Leak Detection and LocationLeak Detection and Location

Advanced Automation for Emergency Shut down Systems and Solutions in order to avoid CatastrophiesSystems and Solutions in order to avoid Catastrophies in Tank Terminals

Ethanol tank farm on fire in Australia Barton Solvents tank farm fire in Kansas, 2007

Chemical tank farm accident

Competence in Level Technologies and Solutions Advanced Overspill ProtectionAdvanced Overspill Protection

Condition Based Management - Process Efficiency

Asset and Condition Management Condition Monitoring and Process Optimization using Process Automation and Analytic Technologiesusing Process Automation and Analytic Technologieswith intelligent Diagnostics and Condition Based Monitoring Functionalitiesin in order to improve Plant Efficiency / Energy Efficiency

Major Market Trends in Process AutomationMajor Market Trends in Process Automation

Goal: Asset Goal: Reduction of unscheduled down-time, protection of equipment improvements on P

Management

equipment, improvements on safety and reduction of maintenance.

Process Analytical

PATSecurity

WirelessCommunication

M2MCommunication

IndustrialEthernet

Intelligent Field RFIDWireless MachineField

DevicesRFIDSensors Vision

P / E Effi iProcess / Energy Efficiency

The topic of energy efficiency has come to dominate the field of industryThe topic of energy efficiency has come to dominate the field of industry. This is set to continue into the future as a result of political requirements and concern about the environment and climate.

The opportunity to gain cost and competitive advantages through the more efficient use of energy will also ensure that the topic does not lose itsefficient use of energy will also ensure that the topic does not lose its importance.

Although efforts have been made in the area of energy efficiency in the past, there is still significant room for improvement in the various industrial sectors.

E Effi i

Studies show that from the energy source to the consumer up to 80 % of

Energy Efficiency

Studies show that, from the energy source to the consumer, up to 80 % of the energy currently used in the various production, transmission and conversion stages can be lost.

Source ZVEI

E Effi iEnergy Efficiency

Source ZVEI

Totally Integrated Automation:S l I t ti f Fi ld t MESSeamless Integration from Field to MES

Automation HierarchyProducts and SystemsMES

PAMSManagement level

Control level

Host computer

Monitoring & control systemsMSOS

PAMS

systems

Programmable logiccontrollers

MSOS

Field levelSensors, actuators,

drives, fieldinstrumentsCMCM CM CM CM CM CM CM

CM CM

Detectors,switches

Definition of Plant Asset ManagementDefinition of Plant Asset Management

Pl A MPlant Asset Management

Therapy / Maintenance

Proposals and support

Operation

Communication Communication of the below

Information Provision

Operation

Prediction / Prognosis

Forecast

and Archiving Maintenance

Diagnosis

Prognosis

Evaluation -> Cause -> Di i fi di

EvaluationAnalysisProcessing

Engineering

Condition M it i

Signal -> Characteristic ->

Diagnosis finding Distribution

Business admin.Monitoring Analysis

Integrated Plant Asset Management –M it i & O tiMonitoring & Operating

OS Clients with accessOS Clients with accessto maintenance area (pictures, messages, faceplates)

Maintenance Station hasadditionally direct online

C1 Cn...

OS OS MSOSMS

Maintenance Stationintegrated into the

additionally direct online access to PDM and hardware engineering...

AS1 AS2 ASn Sn

AS – Automation SystemC – Client

S1...

...AS1 AS2 ASn

integrated into the Operator Station

MS – Maintenance StationOS – Operator StationS – Server

Maintenance pictures

All diagnostic capable SIMATIC PCS 7 components + „non-intelligent“ assets

+Common and unified symbols for representing the status of all assets

+Good Announcement of request

f i t (l )Request for maintenance

k / t ti t d

Simulation

Function

Request for maintenance(medium)

for maintenance (low)

Maintenance alert (hi h)

unknown/not activated

Request for maintenance activated

Request for maintenanceicontrol/ local (high) in process

Automation Interface I t lli t S S t i t ith th A t ti S tIntelligent Sensor Systems communicate with the Automation System

f

Intelligent Intelligent SensorsSensors

FlexibilityStart upParameter SetFunction Request

InformationDigital ValueData ValidationControl Loop functionsFunction Request

Functions UpgradeSoftware Download

Control Loop functionsDiagnosis InformationAsset ManagementInformation

Field device Integration wired or wireless is crucial

Automation Interface Intelligent Sensor Systems communicate with the Automation System

DistributionPROFIBUS DPPROFIBUS PA

Ethernet

PROFIBUS PAFoundation Fieldbus4…20mA with HART

Improvement on Production EfficiencyCondition Based Management and Energy Efficiency From 1st to 2nd Generation – Bioethanol Production

YeastEnzymes Methylation

Petrolium spiritDehydration

Delivery Storage

Milling

Liquefaction

Saccharification

Fermentation Distillation Storage

Water

Yeast

Co2 Distillation

Enzymes

Fraction

ation

Methylation

Superheated

steam

Bioethanol

Destiller‘s wash

Cooling tower/cooling plant

SyrupConcentration

Separation

Drying

DDGSDGS

Bioethanol

Syrup

Storage / Loading

Production Process Optimization with advanced P A t ti I t t ti d A l tiProcess Automation, Instrumentation and Analytics

YeastEnzymes Methylation

Petrolium spiritDehydration

Delivery Storage

Milling

Liquefaction

Saccharification

Fermentation Distillation Storage

Water Co2 DistillationFractionat

ion

Superheated steam

Bioethanol

Destiller‘s wash

Cooling tower/cooling plant

Separation

Drying

DDGS

Destiller s wash

Bioethanol

SyrupConcentration

DDGSDGS

Storage / Loading

T t ll I t t d A t ti

Operator Workstations

Totally Integrated Automation

EngineeringWorkstation

MaintenanceWorkstation

RedundantController

Storage and Load Out InterfacesRedundant Fiber Optic PROFIBUS DP

Area 1 Area 2 Area 3Distributed I/O Distributed I/O Distributed I/O

PROFIBUS PA Devices PROFIBUS PA DevicesPROFIBUS PA Devices

SMART MCC SMART MCC SMART MCC

Typical Application of a Digital Bus Network in an Ethanol Production Facility

Process Optimization with advanced Diagnostic FunctionalitiesDiagnostic Functionalities

Evaluation of Frequencies / Frequency Shift / Phase Shift /differiential Frequencies/ Frequency Attenuation

Flow TechnologiesFl V l D it C t ti d M fl tFlow, Volume,Density, Concentration and Massflowmeters

Open Channel,non-filled pipesSolids Flow/Impact Flow

Belt ScalesMass Dynamics

Flowmeter

t l

VenturiUS Flow

Magn. ind.Flowmeters

Closed pipes

Impact Flow Mass Dynamics rectangle-,triangle weir

Volume-meters

Volume-flowmeters

applicable

Mass-flowmeters

Non Pipe

Ultrasonic Flowmeters

Coriolisomega /bent tube

Vortex flowmeterCoriolis

parallel

Rotary piston meter

Intrusive

Oval wheel meter

restricted

applicable

non applicable

SingleBeam

Multi Beam

SingleBeam

MultiBeam

SpoolPiece

Intrusive (Clamp on)

Variable Area-flowmeters

Effective PressureTechnology

paralleltubes

A li ti

Twist flow-meter

Turbometer,Positiv-

displacement

Coriolis single

straight tube

Comparison Beam BeamBeam Beam

Transit Time

TransitTime

Doppler

Magn. Ind.flowmeters

Pulsed AC ACPulsed DC

Applications meter,Woltman-

meter Thermal

Wide Beam

Narrow Beam(Shear Mode)

TransitTime

DopplerTransitTime

Narrow Beam(Shear Mode) Beam (Shear Mode)(Shear Mode)

Technology Comparison, e.g. Detection of Flow, V l D it C t ti MVolume, Density, Concentration, Mass

Magnetic Flowmeter Condition MonitoringMetal Particles in MediaMetal Particles in Media

Metal particles in media

Reduction on waste of Natural Sources

Environmental Cleaning Costs > 1 Mio €

Leak Detection / Leak Location as part of Condition Based Monitoring

Condition Monitoring on Gas and Liquids Flow Lines in order to reduce the waste on natural

Environmental Cleaning Costs > 1 Mio €

order to reduce the waste on natural resources and optimize Energy Efficiency on Pumps, Compressors, Filters andShut Down Time for claening purposes

Differential Pressure Condition Monitoring

Fouling of Impulse Lineg p

Impulse

Line

L l M t T h l iLevel Measurement Technologies

Electronic OverfillMechanical Electronic

Point LevelContinous

Interfacecontact ProtectionMechanical Non contact

ServoDisplacer

OscillatingVibratingCapacitance

Servo TDR Optical Capacitance

ServoDisplacer

Capacitance

Ultrasonic

Interface

Ultrasonic

Sense Disc

Float

Magneto-strictive

TDR

Conductive

Laser

Nucleonic

Static weighing

Capacitance

Conductive

Nucleonic

Capacitance

TDR

StaticWeighingstrictive weighing

Hydrostatic

OpticalLaser

Radar

S b iblHydrostatic

Weighing

Hydrostatic

Delta P P lChi

Radar

Ultrasonic

Radar

TDR

FMCW

CW

Reflectometer

Low / HighF

Absolute Bubble System

Submersible

P K b d

Delta P PulsChirp

TDRCWFrequencyPressure Keyboard

L l M t T h l iLevel Measurement Technologies

Sitrans LG Sitrans LU Sitrans LR Sitrans LR Sitrans LR Sitrans LCSitrans LGGuided Wave Radar / TDR

Sitrans LUUltrasonic

Sitrans LR 2 wire

Pulse Radar

Sitrans LR 4 wire

Pulse Radar

Sitrans LR 4 wire

FMCW Radar

Sitrans LC Capacitance

LEVELI t f Technology ApplicationLEVEL TECHNOLOGIESInterface Technology

DescriptionApplicationSimulation

Simulation of Process Conditions / ApplicationsSimulation of Process Conditions / Applications

Pulse 6 GHz RadarSitrans LR 200/300

PressureSitrans P

FMCW/Pulse 24 GHz RadarSitrans LR 400/460/250

CapacitanceSitrans LC500

UltrasonicSitrans LU

Guided Wave Radar Sitrans LG200

Process Optimization in Petrochemical Production Processes

Customized Solution in Synthol Production Processes Optimization of Separation Process with advanced

GAS WATER & OIL SEPARATOR

p pInterface Detection

GAS, WATER, & OIL SEPARATORProcess Details and

RequirementsDE-MISTER PADS

HEAT EXCHANGERS1. Measurement section determines transmitter oscillator frequency

Gas intakeGASoscillator frequency.

2. Driver circuit applies same frequency to active shield.

3 Electrical potential betweenDP TX for Oil Level

OIL\WATER /INTERFACE MEASUREMENT OIL

INTERFACE

OIL OUTLETOIL

3. Electrical potential between shield and measurement section is zero.

Result:

WATER

WATER OUTLET

Ignores dust, vapor, and material deposits on the active shield portion of the electrodeelectrode.

Capacitance vs. TDR Interface MeasurementCapacitance vs. TDR Interface Measurement

Sitrans LC 500 Sitrans LG200Sitrans LC 500Capacitance

Sitrans LG200 TDR

Max Span: 20 mA – 59 pF 100 % Water

Min Span: 4 mA – 6 pF

Referenz: 12 mA – 44 pF 50 % Water / 50 % Test Benzine

Min Span: 4 mA – 6 pF 100 % Test Benzine

Process Optimization in Chemical Production Processes

ZUARI

Safety Requirements (Burst Conditions)Operation on Styrene / Styrol ProcessesOperation on Styrene / Styrol Processes

Design related to Burst Safety Requirements 300 deg C at 40 bars

Maintenance optimization with advanced Instrumentation Technologies Safety Check during Operation of the ReactorTechnologies Safety Check during Operation of the Reactor without Shut Down of Production

10dBD t

Level Radar

DustVapourSteam

ConstructionConstruction ObstaclesTubings

Interference

Foam

Turbulent Product surface

Votex

30dBAgitator

Heating Coils

Reduction of unscheduled Down Time

Process Optimization in the Chemical Production Processes

C t i d S l ti i th F tili I d t S tCustomized Solutions in the Fertilizer Industry Segment

The fertilizer plant produces both simple (classic) and composed fertilizers. The process which is at concern here goes about the basic fertilizers and comprises several reactors in line, where mainly acids

t li d ith iare neutralized with ammonia, which is a known basic component for fertilizers.

Monitoring of Deposit and Corrosion on Sensor Probe and Reactor in order to increase Production Efficiency and reduction eacto o de to c ease oduct o c e cy a d educt oon Maintenance Costs purging and coating of sensor probes

highly adhesive endhighly adhesive end product

hardens out very fast

consistency of cementconsistency of cement

existing solution inaccurate

Coated SensorProbes

In the reactors this process causes aIn the reactors, this process causes a very erosive, abrasive and corrosive liquid which ends up as a solid final product This hardens out very fast and isproduct. This hardens out very fast and is then granulated.

Reduction of unscheduled Down Time

Monitoring of Deposit on Sensor Probe and Reactor Condition in order to increase Production Efficiency and reduction on

Application: Process requirements: Encrustation inside the

in order to increase Production Efficiency and reduction on Maintenance Costs by controlled cleaning in place

Process requirements: Measuring safe and maintenance free level- and volume detection Use of a integrated purge kit

Raw materialsantenna

integrated purge kitTechnologies:

Process RadarSolution:

20mA

Flushing in/out20dB

Solution: Condition ManagementBy the comparison of the internal antenna reflection th i t t d fl hi

Encrustation

the integrated flushing system is activated and deactivated.The additional status and diagnosis information

4mAdiagnosis information avoids production interruptionTitan dioxide production Very dirty and sticky

30dBProduction Operation

Very dirty and sticky dioxide process reactor

Reduction of unscheduled Down Time

Foam Layer Monitoring in order to avoid overspill of Foam, increase of Production Efficiency and reduction onincrease of Production Efficiency and reduction on Maintenance Costs

Application:ppResin production Foam during vacuum phaseProcess requirements:

Vacuum

Vacuum outletCondensation filter

Condition MonitoringLevel control and reduction of foam layer Avoidance of pipe and filter

20mA

Avoidance of pipe and filter blockagesTechnologies:Process Radar Instrumentation Resin

10cm Foam

Solution:Condition Management

Foam layer control by evaluation of attenuation of the microwave 4mA

Resin products

radiation while penetrating through the foamStart and stop of vacuum phase

t ll d b fid h B ili ti l t d

Production Operation

40dB

controlled by confidence echo Boiling process stimulated by vacuum

Reduction of unscheduled Down Time

Pressure Technologies

Piezo resistive Capacitance InductiveResonance

B bbl t

DiaphragmRemote seal Dry / ceramic cells VibrationCeramic cell

Absolutepressure Submersible

Bubble systemair/nitrogen

Injection

Differentialpressure

Gaugepressure

S b iblAb l t Bubble-LEVEL Differential SubmersibleAbsolute Bubble-system

Air/ nitrogenInjection

LEVEL e e t apressure

Differentialwith PLC

FLOW Orifice

Hydrostaticincl. density

CLOSEScreen

condition

FLOW Orifice

Gold-plateddiaphragmCalibration

CLOSE detection

Venturi

p g

P300Steam Shock

Pressure Measurement

d l f lCondition Monitoring - Fouling of Remote Seal

Condition ManagementCondition Management

Remote Seal Purge Kit

Advanced Diagnostics on Positioner Technologies

Actuaters Electric Pneumatic Hydraulic

RotaryLinearValves

Perforated Plug Valves

Linear Plug Valves Ball ValvesFlame proof

PS3 EnclosuresEccentric Plug Valves

Bray Butterfly Valve

Sliding Gate Valves Turn Plug Valves

Gate Valves

Stainless SteelPlastic Damper Drive

Positioners Pneumatic Electro Pneumatic

Electro Pneumatic

DigitalIntelligent

Single Acting

Intelligent

Double Acting

CLOSE

Double Acting

ConfigurationSimulationExploded view

Diagnostics3D PDF

Kompetenz in Lösungen mit StellungsreglernAsset Management / TCO / Condition ManagementAsset Management / TCO / Condition Management Optimization on Configurations of Valves and Positioners

Competence in Valve Positioner TechnologiesAsset Management / TCO / Condition Management

ShaftStopfbuchse

Spindel

g gValve and Positioner Configuration Optimization

Stopfbuchse

VentilsitzValve

Condition Monitoring and Managementon Valves and Flow Lines in order to optimize Plant Operation and SafetyFlow Lines in order to optimize Plant Operation and SafetyPartial Stroke Test, Leak Detection, Valve Wear and Deposit

Energie Savings with advanced Condition Based Monitoring 500 000€/a Energy Savings on Motors Drives

Condition Monitoring on Valves and Pumps Wirtschaftlichkeitsvergleich

Monitoring 500.000€/a Energy Savings on Motors, Drives, Pumps of 137.000€/a

Condition Monitoring on Valves and PumpsOptimization of Energy Efficiency, Production Efficiency and Operation Costs with intelligent Prozess Sensors and Analytical Technologies

ands

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geiner Schlauch-Membran-Kolbenpumpe

mit und ohne Online-Ventildiagnosesystem

300.000 €

400.000 €

500.000 €

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300.000 €

400.000 €

500.000 €

Kos

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(Inv

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und

Insta

0 5 10 15 20 25 300 €

100.000 €

200.000 €

Jahre

Kos

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(Inv

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und

Insta

0 5 10 15 20 25 300 €

100.000 €

200.000 €

Jahre

Process Optimization with advanced Process Analytic TechnologiesSolutions and Applications

Oxygen

UV Single or few components

Stack Emissions Monitoring

Continuous Gas Analyzers

yg

FID

Hydrogen

Combustion Control

Incinerator Measurement

StandardGas Chromotagraphy

y g

Infrared

Multi Component

H2O/Trace H2O

Standard

Miniature

Gas Chromotagraphy

Laser Spectrometry

Multi Component

Complex Gas Streams

Single or few components

Spectrometry

Laser Spectrometry

Mass Spectrometry

AOTF

Single or few components

Stack Emissions Monitoring

Combustion ControlAOTF

FTIR/FTNIR

Combustion Control

Incinerator Measurement

H2O/T H2O

E-box

SibenchExhaust Gas Analysers H2O/Trace H2O

Recovery of Hydrocarbons with an Energy E i l f 7 i Lit f C d OilEquivalence of 7 mio Liter of Crude Oil per year

The Cooperation as part of Customer RelationshipC t d i f diff t j t h b id tifi dCost drivers for different project phases can be identified

CAPEX OPEXPre CAPEX Modernisation/ Decommissioning

Advanced automation and instrumentation technology knowhow made it possible to find flexible solutions for various harsch applications, p ppbased on the creativity of the customers and supplier. Optimization on configurations and application knowledge opens doors in industry segments for reliable and cost saving solutions.doors in industry segments for reliable and cost saving solutions. The cooperation between industries and suppliers very close, the support and testing are done within a framework of consequent partnershippartnership.

Safety Requirements Regional Requirements g qApprovals, Certificates, Declarations, Typ Testing

Chemical CompaniesA id t & C t t hAccidents & Catastrophes

Algeria 2007: The explosion in the industrial town of Blida killed 5 people and wounded 10 others

Chemical CompaniesA id t & C t t hAccidents & Catastrophes

Texas, 2005

Condition based Monitoring / Management

Health & SafetyHealth & Safety

The goal and target is competent support starting with the planning process ofThe goal and target is competent support starting with the planning process of production facilities until the commissioning and start up as well as support and consultancy over the whole facility life cycle in order to reduce follow up costs as part of Total Costs of Ownership and Down Time and avoid additional unexpected modifications to optimize production volume and quality.

The key tasks for the increase of efficiency during the implementation of condition management are:

Reduction of unexpected down timeReduction of unexpected down timeProduction qualityProduction quantityProduction effectivity and repeatabilityy p yProtection equipment and componentsIncrease of safetyReduction of non useful preventive maintenance

Up to 50% of preventive maintenance investments are not necessary, these expenses can increase up to 20% of the total maintenance costs.This conclusion is a clear statement and fact to change from preventive to predictive

i imaintenance strategies.