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ConservacionConservacion de la de la CapacidadCapacidad FuncionalFuncional de de los los sistemassistemas de Control de Control e e InstrumentacionInstrumentacion
Ing. Marcelo H. Carugo
Director, Refino LatinoaméricaDirector, Refino Latinoamérica
XVIII FORO DE AVANCES DE LA INDUSTRIA DE LA REFINACIÓN
PresentadorPresentadorPresentadorPresentador
Ing. Marcelo Carugo
Director, Refining and Terminals Latin America, Emerson Process Management
President, ISA Argentina
Más de 20 años de experiencia en Más de 20 años de experiencia en justificación, diseño, instalación y comisionado de aplicaciones de automatización, control, optimización de unidades de procesos y mezcla de gasolinas y diesel en Plantas de Proceso.
2
AgendaAgendaAgendaAgenda
Pemex Refinación ha manifestado su preocupación por revertir el incremento en el numero de los paro no programados, en sus plantas de proceso, derivados de ineficientes
practicas de mantenimiento de sus activos, lo que ha llevado a una importante perdida en la ha llevado a una importante perdida en la
eficiencia de su planta productiva.
Business ChallengesBusiness Challenges
CRITICAL
FinancialFinancial••Return on Capital Return on Capital
Employed (ROCE)Employed (ROCE)
••Income and MarginIncome and Margin
••CapitalCapital
ReliabilityReliability••Unplanned ShutdownsUnplanned Shutdowns
••Capacity UtilizationCapacity Utilization
••Maintenance IndexMaintenance Index
CRITICAL
BUSINESS
CHALLENGESSafety & Safety &
EnvironmentEnvironment••IncidentsIncidents
••Spills / Emissions / Spills / Emissions /
DischargesDischarges
••Fines / PenaltiesFines / Penalties
PersonnelPersonnel••HeadcountHeadcount
••TrainingTraining
••Critical SkillsCritical Skills
Efficiency & Efficiency &
ThroughputThroughput••ThroughputThroughput
••Energy IntensityEnergy Intensity
••Cash OpExCash OpEx
••Crude Rate / Sour Crude Rate / Sour
Crude RateCrude Rate
Business Challenges:Challenges are linked, one causes manyBusiness Challenges:Challenges are linked, one causes many
CRITICAL
FinancialFinancial••Return on Capital Return on Capital
Employed (ROCE)Employed (ROCE)
••Income and MarginIncome and Margin
••CapitalCapital
ReliabilityReliability••Unplanned ShutdownsUnplanned Shutdowns••Capacity UtilizationCapacity Utilization
••Maintenance IndexMaintenance Index
CRITICAL
BUSINESS
CHALLENGESSafety & Safety &
EnvironmentEnvironment••IncidentsIncidents
••Spills / Emissions / Spills / Emissions /
DischargesDischarges
••Fines / PenaltiesFines / Penalties
PersonnelPersonnel••HeadcountHeadcount
••TrainingTraining
••Critical SkillsCritical Skills
Efficiency & Efficiency &
ThroughputThroughput••ThroughputThroughput
••Energy IntensityEnergy Intensity
••Cash OpExCash OpEx
••Crude Rate / Sour Crude Rate / Sour
Crude RateCrude Rate
NuestraNuestra VisionVisionNuestraNuestra VisionVision
� Aprovechar la tecnología mas moderna para crear la “Refinería del Futuro”
� Concentrar en seguridad y medio ambiente –los sistemas deben ser robustos
Foco en costos – Bajo costo durante la vida útil � Foco en costos – Bajo costo durante la vida útil
� Personal Entrenado – Debe ser fácil de operar y mantener
� Resistencia a la Obsolescencia – Utilizar estándares de la industria
Cuales son los Objetivos de los Cuales son los Objetivos de los lideres de refinación? lideres de refinación? Cuales son los Objetivos de los Cuales son los Objetivos de los lideres de refinación? lideres de refinación?
KPI Target
Energy Intensity Index 70
Refinery Utilization 97.5%
Mechanical Availability 99.5%
Return on Investment >30%Return on Investment >30%
Net Cash Margin >$18/ Bbl
Cash Operating Expenses <$0.30/ UEDC ($0.20)
Enhanced Automation Is A Key Contributor To These Goals!
7/11/2012 7
Nos falta informacion debido a limitaciones fisicas y de costosNos falta informacion debido a limitaciones fisicas y de costos
Have all Information to achieve best business results
Have some Information to achieve business results
Have no Information to achieve business results
Como la Refinaría Como la Refinaría inteligente reduce los inteligente reduce los incidentes? incidentes?
Modern Automation Impact Modern Automation Impact –– Cause of Cause of Serious Incidents and Possible AvoidanceSerious Incidents and Possible AvoidanceModern Automation Impact Modern Automation Impact –– Cause of Cause of Serious Incidents and Possible AvoidanceSerious Incidents and Possible Avoidance
EquipmentFailure
Human IssueHardware Failure External Cause
Natural InadequateEquipment Design ProcessOperational Natural Disaster
InadequateMaintenance
EquipmentDefect
DesignFault
ProcessUpset
OtherOperational
Error
48% 5% 2% 23% 8% 18%
Ref: Keren, N;T.M. O’Connor;M. S. Mannan
“Use of Incident Data from Various Sources
for Industrial Safety Performance
Assessment”; Proceeding of the Mary Kay
O’Connor Process Safety Center annual
Symposium, College Station, Texas, 2003
IncidentCause
PredictiveDiagnostics
Automation Impact
IntegratedMaintenance
OperatorTrainingSolutions
EnhancedControl
Enhanced SIS
10
How can modern automation reduce How can modern automation reduce serious incidents?serious incidents?How can modern automation reduce How can modern automation reduce serious incidents?serious incidents?
� Early Detection of Potential Hardware Failures
� Enhanced Operator Decision Support
� Enhanced Safety Systems
7/11/201211
Predictive AnalyticsPredictive AnalyticsPredictive AnalyticsPredictive AnalyticsE
quip
men
t P
erfo
rman
ce
100%
Catch Problems Before They Occur!Predictive Alert
12
Equ
ipm
ent
Per
form
ance
0%
Time
advanced warning = time to respond
Normal Alarm
Analyzing Data to Predict Future Analyzing Data to Predict Future Probabilities and TrendsProbabilities and Trends
Analyzing Data to Predict Future Analyzing Data to Predict Future Probabilities and TrendsProbabilities and Trends
$
OPTIMUM
CURRENT
Analyze:Extract
Prediction:Models
Acquire:Dynamic
Present:HMI,
137/11/2012
Extract Information, Patterns
ModelsDynamicEventDetection and SensorData Capture
HMI, Distribution
Move from reaction to events to anticipation and optimization
Action: Algorithms Photo Ref: Emerson Process Management
Detection = Safety
Detection of Onscale Failures
Example Example -- 3051S 3051S -- Plugged Line Detection Plugged Line Detection monitors integrity of process connectionmonitors integrity of process connectionExample Example -- 3051S 3051S -- Plugged Line Detection Plugged Line Detection monitors integrity of process connectionmonitors integrity of process connection
Prediction = AvailabilityDiagnostics enable evolution from
Reactive & Preventive to Predictive Maintenance14
Process Example Process Example ––FCC Catalyst Circulation IssuesFCC Catalyst Circulation IssuesProcess Example Process Example ––FCC Catalyst Circulation IssuesFCC Catalyst Circulation Issues
15
Abnormal Standpipe OperationAbnormal Standpipe OperationAbnormal Standpipe OperationAbnormal Standpipe Operation
StandpipeCan we detect aeration/ circulation problems before they occur?
PressureAeration
PI
Spikes indicate loss of fluidization
16
FCC Circulation Problem DetectionFCC Circulation Problem DetectionFCC Circulation Problem DetectionFCC Circulation Problem Detection
40.00
50.00
60.00
Cir
cula
tio
n, T
PM
Sta
tist
ical
Pro
cess
Mo
nit
or
Advanced calculations collected by the DCS historian 6.00
7.00
8.00
9.00
10.00
Predictive Analytics can predict failure 30 minutes before it occurs and allow avoidance of incident.
23:30
0.00
10.00
20.00
30.00
Cir
cula
tio
n, T
PM
5/29 5/31 6/2 6/4 6/6 6/8 6/10 6/12
Sta
tist
ical
Pro
cess
Mo
nit
or
23:30
23:00
Generated by Analysis
0.00
1.00
2.00
3.00
4.00
5.00
23:00
17What did this take to produce? New developments in sensors, software,
and integration with operator HMI.
Safety Instrumented Systems (SIS) Safety Instrumented Systems (SIS) --What Components Go Wrong?What Components Go Wrong?Safety Instrumented Systems (SIS) Safety Instrumented Systems (SIS) --What Components Go Wrong?What Components Go Wrong?
18
Takes data every up to
75ms resolution
SIS Partial Stroke TestSIS Partial Stroke TestSIS Partial Stroke TestSIS Partial Stroke Test
Data analysis & results
Actual travel & pressure data collected
19
What did this take to produce? New developments in actuators,
software, and integration with maintenance HMI.
Como la Refinería Como la Refinería inteligente aumenta la inteligente aumenta la disponibilidad mientras disponibilidad mientras simultáneamente reduce simultáneamente reduce los costos de los costos de mantenimiento ?mantenimiento ?mantenimiento ?mantenimiento ?
Maintenance Maintenance –– Downtime DilemmaDowntime DilemmaMaintenance Maintenance –– Downtime DilemmaDowntime Dilemma
$
Downtime costs: 4:1 to 14:1 times maintenance costs
Maintenance costs: •Increasing 10 – 15% annually•One third unnecessary (but don’t know in advance which third)
$$ maintenance costs
How do we do better?
Refinery Availability and Maintenance Refinery Availability and Maintenance Costs Costs –– Industry ExperienceIndustry ExperienceRefinery Availability and Maintenance Refinery Availability and Maintenance Costs Costs –– Industry ExperienceIndustry Experience
Ref: H.P Bloch; M. Hernu; “PERFORMANCE BENCHMARKING UPDATE:EXPECTATIONS AND REALITY ” Maintenance and Asset Management; Jan/ Feb 2008
MaintenanceIndex, US $/EDC
Maintenance Outage, %
?
Jan/ Feb 2008
Maintenance
Maintenance Outage, %
Figure 1
1Q 2Q 3Q 4Q
Peer Group Maintenance Index Quartiles
0 0
Maintenance Index Maintenance Outage
First Quartile Performers Have Both Higher
Availability and Lower Costs. How Is This
Possible?22
How can modern automation increase How can modern automation increase reliability and simultaneously reduce reliability and simultaneously reduce maintenance costs?maintenance costs?
How can modern automation increase How can modern automation increase reliability and simultaneously reduce reliability and simultaneously reduce maintenance costs?maintenance costs?
� Increasing Automation Equipment Reliability
– Automation Diagnostics Integration
– Reduced Calibration and Verification Time
– Integration With Other Maintenance and Operations SystemsSystems
� Increasing Process Equipment Reliability
– Integrating Process and Machinery Health Data to allow earlier prediction of possible faults and deterioration in performance
– Lower cost measurements of critical data (including wireless) which supports improved unit monitoring and modeling 7/11/2012
23
Older Automation Field NetworksOlder Automation Field NetworksAnalog 4Analog 4--20 ma20 maOlder Automation Field NetworksOlder Automation Field NetworksAnalog 4Analog 4--20 ma20 ma
Only 1 value is transmitted
Only one direction
7/11/2012
4-20mA
24
But Computers and Communication But Computers and Communication have migrated to the Field have migrated to the Field Devices………..Devices………..
But Computers and Communication But Computers and Communication have migrated to the Field have migrated to the Field Devices………..Devices………..
Slug flowLoss of air
Not responding correctly
In the wrong position
Excess drive force
Wet gas
Furnace flame instability
Plugged impulse line• Paraffin buildup• Hydrate buildupElectronics or sensor failure
Empty Pipe
Calibration Error
Reverse Flow
Electronics or sensor failure
Entrained gas / liquidIn-line meter integrity verificationElectronics or sensor failureFluid properties (density)
Leading to More Data From The Leading to More Data From The FieldFieldLeading to More Data From The Leading to More Data From The FieldField
ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, RS_STATE, TEST_RW, DD_RESOURCE, ,
MANUFAC_ID, DEV_TYPE, DEV_REV, DD_REV, GRANT_DENY, HARD_TYPES, RESTART, FEATURES, FEATURE_SEL,
CYCLE_TYPE, CYCLE_SEL, MIN_CYCLE_T, MEMORY_SIZE, NV_CYCLE_T, FREE_SPACE, FREE_TIME, SHED_RCAS,
SHED_ROUT, FAIL_SAFE, SET_FSAFE, CLR_FSAFE, MAX_NOTIFY, LIM_NOTIFY, CONFIRM_TIME, WRITE_LOCK,
UPDATE_EVT, BLOCK_ALM, ALARM_SUM
ACK_OPTION, WRITE_PRI, WRITE_ALM
ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PV
OUT, SIMULATE, XD_SCALE, OUT_SCALE, GRANT_DENY, IO_OPTS, STATUS_OPTS,
CHANNEL, L_TYPE, LOW_CUT, PV_FTIME, FIELD_VAL, UPDATE_EVT, BLOCK_ALM,
ALARM_SUM, ACK_OPTION, ALARM_HYS, HI_HI_PRI, HI_HI_LIM, HI_PRI, HI_LIM, LO_PRI,
LO_LIM, LO_LO_PRI, LO_LO_LIM, HI_HI_ALM, HI_ALM, LO_ALM, LO_LO_ALM
ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PV, SP, OUT,
PV_SCALE, OUT_SCALE, GRANT_DENY, CONTROL_OPTS, STATUS_OPTS, IN, PV_FTIME,
BYPASS, CAS_IN, SP_RATE_DN, SP_RATE_UP, SP_HI_LIM, SP_LO_LIM
ST_REV, TAG_DESC, STRATEGY, ALERT_KEY, MODE_BLK, BLOCK_ERR, PV
SP, OUT, PV_SCALE, OUT_SCALE, GRANT_DENY, CONTROL_OPTS, STATUS_OPTS, IN
PV_FTIME, BYPASS, CAS_IN, SP_RATE_DN, SP_RATE_UP, SP_HI_LIM, SP_LO_LIM, GAIN
RESET, BAL_TIME, RATE, BKCAL_IN, OUT_HI_LIM, OUT_LO_LIM, BKCAL_HYS,
BKCAL_OUT, RCAS_IN, ROUT_IN, SHED_OPT, RCAS_OUT, ROUT_OUT, TRK_SCALE,
TRK_IN_D, TRK_VAL, FF_VAL, FF_SCALE, FF_GAIN, UPDATE_EVT, BLOCK_ALM,
ALARM_SUM, ACK_OPTION, ALARM_HYS, HI_HI_PRI, HI_HI_LIM, HI_PRI, HI_LIM, LO_PRI,
LO_LIM, LO_LO_PRI, LO_LO_LIM, DV_HI_PRI, DV_HI_LIM, DV_LO_PRI, DV_LO_LIM,
HI_HI_ALM, HI_ALM, LO_ALM, LO_LO_ALM, DV_HI_ALM. DV_LO_ALM
Digital FieldNetworks Require
To Support
Device Diagnostics Easily Device Diagnostics Easily AvailableAvailableDevice Diagnostics Easily Device Diagnostics Easily AvailableAvailable
7/11/201227
Bad ValveBad ValveBad ValveBad Valve BEFORE
28
Good Valve!Good Valve!Good Valve!Good Valve! AFTER
7/11/201229
What did this take to produce? New developments in actuators,
software, communication and integration with maintenance HMI.
Reliability Improvement Reliability Improvement Case StudyCase StudyReliability Improvement Reliability Improvement Case StudyCase Study
Major Refinery
� CHALLENGE– Obsolete control systems; pneumatic, Honeywell
TDC2000– Old, but working instrumentation– No automated tools for I&E maintenance staff, outdated
I&E business processes� SOLUTION
– Industry consulting services– Implemented PlantWeb architecture, DeltaV control
Pre & Post Installation as of 4thQ 2006
Compressor
Process/OpsVessel/Column/ReactorElectrical
Instrumentation
Overall
50
75
100
250
500
750
1,000
2,000
Ave
rag
e E
DC
Lo
ss
per
Inc
ide
nt
Pre-Installation (1064 days)
Hardware/Mechanical
5
20
10
Application
Refinery automation
modernization
– Implemented PlantWeb architecture, DeltaV control system, AMS Suite, Foundation fieldbus, Fisher DVCs
– Emerson MAC project services, hot cutover on operating units
– I&E maintenance process reengineering and training� OPEX RESULTS - Post-audit with support from Solomon
Associates– Reliability risk studied for Coker and Hydrocracker– Overall Equivalent Distillation Capacity loss for both
units reduced by 50%
0.00075
0.00100
0.00250
0.00500
0.00750
0.01000
0.02500
0.04000
0.05000
Incident Loss Frequency (/day)
10
25
50
Ave
rag
e E
DC
Lo
ss
per
Inc
ide
nt
Pre-Installation (1064 days)
Post Installation (486 days)
Post Installation (578 days)
Post Installation (670 days)
Reliability Growth Frequency Prediction
0.10.05 0.5
1.0
30
Fuentes de Perdida de Fuentes de Perdida de disponibilidad en las Refinerías disponibilidad en las Refinerías Fuentes de Perdida de Fuentes de Perdida de disponibilidad en las Refinerías disponibilidad en las Refinerías
What Can We Do Different?What Can We Do Different?What Can We Do Different?What Can We Do Different?
Pumps - Past Practice
� No monitoring
– changeover pumps based on history of pump failure
� Manual spot-check monitoring from field operator or technicianfrom field operator or technician
– Predict when to repair pump
� Preventive Maintenance Program
– Repair pumps on a scheduled time and repair all whether it needs it or not
Typically, only critical
pumps have automated
monitoring
7/11/201232
Pump Health Monitoring:Pump Health Monitoring:Solution ArchitectureSolution ArchitecturePump Health Monitoring:Pump Health Monitoring:Solution ArchitectureSolution Architecture
Cut away view of pump showing seal flush systemRosemount 3051S
Wireless Pressure Transmitter
Rosemount 2160
Wireless Vibrating Fork
Liquid Level Switches
CSI 9420
Wireless Vibration Transmitter
Rosemount 3051S
Wireless Pressure Transmitter
-
1420 Smart Wireless Gateway
Wireless Vibration Transmitter
Rosemount 702
Wireless Discrete Transmitter
with TraceTek® sensor
Rosemount 3051S
Wireless dP Transmitter
What did this take to produce? New developments in sensors, software,
communication, application modeling and integration with
maintenance HMI.
Vibration Spectrum Computed Real Vibration Spectrum Computed Real Time In A Wireless Transmitter! Time In A Wireless Transmitter! Vibration Spectrum Computed Real Vibration Spectrum Computed Real Time In A Wireless Transmitter! Time In A Wireless Transmitter!
Automatic Detection of Imbalance
34
Save Millions per year by Save Millions per year by monitoring Steam Trapsmonitoring Steam TrapsSave Millions per year by Save Millions per year by monitoring Steam Trapsmonitoring Steam Traps
•Typical Plant loses
10% of Energy Costs
with defective Steam
Traps
•This is around US$ 10
million/year
•Wireless monitoring of
steam traps eliminates
the waste.
Case Study Case Study -- Impact of Modern Impact of Modern Automation And Changed ProceduresAutomation And Changed ProceduresCase Study Case Study -- Impact of Modern Impact of Modern Automation And Changed ProceduresAutomation And Changed Procedures
Petrochemical facility
� Maintenance costs too high
– Reactive tasks 70% of monthly work orders
– Lack of sufficient maintenance task documentation
� Changing business processes to planned maintenance
– Asset Priority on 30,000 assets
– Develop Maintenance Tasks on 10,000 most critical assets
• Created 3,000 new tasks
Site: North America
• Created 3,000 new tasks
– Generate Maintenance Strategy Blueprint
– Technology Deployment
• AMS Device Manager – import ~2,500 smart devices
• AMS Machinery Manager – all route-based machines
• AMS Asset Portal – to sustain changes
� Reduce maintenance costs $801K* annually on Phase 1 (4,000 assets)
– Remove 183 OT hours coupled with reactive work
– Reduce monthly work orders by 8% (285 � 260)
– Shift planned work mix from 25% � 41%
Results At Shell
ConclusionConclusionConclusionConclusion
El integrar las nuevas tecnologías a las practicas operativas y de mantenimiento de la Refinería, conduce a mejorar sustancialmente los índices operativos.
7/11/2012
A través del uso apropiado de los diagnósticos de la instrumentación, mediciones en áreas esenciales, y practicas predictivas de mantenimiento se consigue la reducción de paradas no planificadas.
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