Overcoming the Challenge of Implementing Profit Controller on a Third Party DCS. Ramiro Andrés Cremaschi Julia Alejandra Perinetti Repsol YPF

Overcoming the Challenge of Implementing Profit Controller on a Third Party DCS. Ramiro Andrés Cremaschi Julia Alejandra Perinetti Repsol YPF

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. 2 2004 Users Group Americas Symposium Partners in Innovation

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. 3 2004 Users Group Americas Symposium Partners in Innovation

Introduction - Where is the Luján de Cuyo Refinery? Next to Mendoza City in Argentina, South America, at the foot of the Andes mountains. 4 2004 Users Group Americas Symposium Partners in Innovation

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 5 2004 Users Group Americas Symposium Partners in Innovation

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 6 2004 Users Group Americas Symposium Partners in Innovation

Connecting Honeywell and ABB DCS Hardware and Software provided by Honeywell Hi-Spec Solutions Profit Viewer Profit Controller PHD SERVER PHD Client and Profit Viewer Station Hardware provided by Repsol YPF PHD Client Profit Viewer NT Client Workstation Repsol YPF LAN (ongoing project) OPC RDI PHD API PHD API HCI API Local Area Network (LAN, Ethernet) OPC Server Enterprise Historian USER API Software provided by Matrikon Hardware platform provided by ABB AdvaInfo software provided by ABB ABB DCN (Distributed Control Network) 7 2004 Users Group Americas Symposium Partners in Innovation

Connecting Honeywell and ABB DCS The interface: ABB: Enterprise Historian (EH) OPC server Honeywell: Process History Database (PHD) 8 2004 Users Group Americas Symposium Partners in Innovation

Connecting Honeywell and ABB DCS ABB DCS: Programs in TCL code to handle: ON/OFF from console stations Watch Dog Set Point validation Mode switching PID loops reconfiguration 9 2004 Users Group Americas Symposium Partners in Innovation

Connecting Honeywell and ABB DCS OPC Server Developed by Matrikon (Canada) Support from Honeywell, ABB and Repsol YPF PHD Windup Status virtual configuration RMPCT Inferential calculations Events detection 10 2004 Users Group Americas Symposium Partners in Innovation

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 11 2004 Users Group Americas Symposium Partners in Innovation

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 12 2004 Users Group Americas Symposium Partners in Innovation

The FCC II gas plant First in-house project Gas plant hardware: High Pressure Separator (HPS) Naphtha Stripper Primary Absorber Secondary Absorber Debutanizer Depropanizer 13 2004 Users Group Americas Symposium Partners in Innovation

The FCC II gas plant First in-house project Gas Plant Products: Stabilized Naphtha Butane Propane/Propilene Fuel Gas 14 2004 Users Group Americas Symposium Partners in Innovation

The FCC II gas plant First in-house project 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 15 2004 Users Group Americas Symposium Partners in Innovation

RDI Execution K2GP_CTL (51") K2_WRITE (55") C2_READ_LO (00") C2_READ_MD (05") C2_READ_HI (10") K2MF_CTL (48") C2GP_CTL (14") K2HT_CTL (44") K2_READ_HI (40") RDI Clock C2RR_CTL (18") K2_READ_MD (35") C2_WRITE (30") K2_READ_LO (25") 16 2004 Users Group Americas Symposium Partners in Innovation

The FCC II gas plant First in-house project 17 2004 Users Group Americas Symposium Partners in Innovation

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). 18 2004 Users Group Americas Symposium Partners in Innovation

Results Evaluation (C4 in C3) Butane content before controller implementation Butane content after controller implementation 19 2004 Users Group Americas Symposium Partners in Innovation

Results Evaluation (C3 in FG) Propane content before controller implementation Propane content after controller implementation 20 2004 Users Group Americas Symposium Partners in Innovation

Results Evaluation (RPV) Reid Vapor Pressure before controller implementation Reid Vapor Pressure after controller implementation 21 2004 Users Group Americas Symposium Partners in Innovation

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). 22 2004 Users Group Americas Symposium Partners in Innovation

Gas recycle: The Solution Manipulation of : Gas flow from the stripper Naphtha absorbent Control: Differential temperature inside the Stripper C3 purge into the FG 23 2004 Users Group Americas Symposium Partners in Innovation

The FCC II gas plant Conclusions Utilization Index: 98% High degree of satisfaction (Operations) All objectives met Nine-month execution period 24 2004 Users Group Americas Symposium Partners in Innovation

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 25 2004 Users Group Americas Symposium Partners in Innovation

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. 26 2004 Users Group Americas Symposium Partners in Innovation

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. 27 2004 Users Group Americas Symposium Partners in Innovation

Questions? You can contact us at: rcremaschil@repsolypf.com jperinettis@repsolypf.com 28 2004 Users Group Americas Symposium Partners in Innovation