Motorised injection rate control.

Supports accurate, repeatable injection of offshore chemicals, reducing downtime and chemical waste.

The TESCOM™ RC-X motorised injection rate control valve, which supports accurate, repeatable dosing of offshore chemicals to maintain flow assurance for refineries and reduce overall chemical injection costs, has just been announced.

Flow assurance is a critical component in the design and operation of offshore production facilities, especially as the industry moves to deeper water, longer tiebacks, deeper wells and higher temperature and pressure reservoirs. The transition to these new environments can introduce conditions that restrict flow, such as hydration, corrosion or the buildup of wax, asphaltene, scale and emulsion.

Refineries use chemical treatment to mitigate these blockages. However, over or under injection of chemicals has several detrimental effects. Over injection increases chemical consumption and resulting costs as well as additional field trips to replenish chemical storage tanks. It can also adversely impact downstream processing or treatment programs and result in contamination penalties. Under injection can be ineffective, risking mechanical integrity and production output.

“Proper chemical dosing in deepwater and high-pressure/high-temperature refining environments can prevent blockages and flow instability, helping to ensure optimum fluid behavior, protect asset integrity and stimulate production,” said Julia Villa, product marketing manager with Emerson’s fluid and motion control business. “Specifically designed to work with Micro Motion™ Coriolis flow meters in offshore chemical injection processes, TESCOM RC-X motorised injection rate control valves enable accurate dosing that reduces downtime and chemical waste associated with over injection.”

With a short-stroke design (less than 1/8 of an inch), TESCOM RC-X control valves are accurate up to 15,000 pounds per square inch (psi) and offer ultra-low flow rates of 0.02–500 liters per hour and repeatable function with 4–20 milliampere (mA) control for precise flow assurance. Electric actuation eliminates air requirements, preferrable when compressed air is unavailable or unreliable.

Available in medium- and high-pressure models, modular TESCOM RC-X control valves are lightweight and compact, with a smaller motor footprint than similar chemical injection rate products, allowing for smaller, lighter skid designs.

The valve itself also has fewer moving parts than comparable products, reducing risk of mechanical failure over time, performing more consistently and requiring less maintenance. They’re explosion-proof, IP67-rated and are compliant to NACE MR0175.

Designed to meet a variety of industry demands, Micro Motion Coriolis flow meters deliver accurate, repeatable mass flow measurement for liquids, gases or slurries. The Emerson TESCOM™ RC-X motorised injection rate control valve helps offshore refineries achieve accurate, repeatable chemical injection, reducing chemical waste, downtime and overall operating costs.

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Planning and operational efficiency improving refining operations.

AI solution is aimed at higher refinery yield volume and efficiencies.

Emerson has announced the successful deployment of an Ai-driven optimisation solution for Aramco, one of the world’s leading integrated energy and chemicals companies. The collaboration commenced with the integration of Emerson’s Aspen Hybrid Models™ into Aramco’s existing refinery planning framework, resulting in the creation of one of the world’s largest multi-site, multi-period optimisation models.

By combining first-principles models, deep domain expertise, and purpose-built industrial Ai, Aspen Hybrid Models™ capture nonlinear relationships in yield and quality responses, significantly enhancing the accuracy of refinery planning models. The deployment has already achieved yield and quality prediction accuracy of up to 98.5% in key refinery units.

These hybrid Ai models have been implemented in Continuous Catalyst Regeneration (CCR) and Platformer Units, where they are enabling more precise feedstock blending, minimising gaps between planning and execution, and improving the accuracy of margin forecasting across Aramco’s global refining network.

Current efforts are focused on expanding the hybrid modelling approach to hydrocracker units across Aramco’s assets. This expansion is expected to further enhance model accuracy and demonstrate the scalability and robustness of this Ai-driven optimisation strategy across the enterprise.

“This deployment represents a significant milestone in Aramco’s AI strategy and our long-standing relationship with Emerson,” said Ahmad Alkudmani, director of the global optimiser department at Aramco. “We are committed to leveraging innovative technologies for smarter, more efficient refining optimisation. With improved model accuracy, we are enhancing planning decisions, reducing the manual adjustments required from our engineers, and uncovering new value across our global assets.”

Key benefits Aramco aims to achieve with Aspen Hybrid Models include:

• 98.5% yield and quality prediction accuracy – Substantially increasing yield volume and enhancing stream quality across diverse feedstocks, operating conditions and throughputs
• Efficiency through optimised feedstock blending – Diversifying feedstock selection and blending recipes to enable more profitable and sustainable operations
• Reduced planning-execution gaps – Minimising discrepancies between plans and actual plant performance, reducing the need for manual adjustments
• Enhanced model accuracy – Capturing complex non-linearities in critical unit operations such as reactors
• Improved operational efficiency – Automating model updates and reducing manual tuning requirements
• Scalable global solution – Maintaining model applicability across a wide range of refinery operations worldwide

Aramco is using Aspen Hybrid Models built and deployed in Emerson’s AspenTech Performance Engineering and Manufacturing and Supply Chain product suites. As a result, Aramco was able to create highly accurate nonlinear optimisations using thousands of converged simulation cases built upon rigorous first-principles models calibrated with actual plant data. The approach provides Aramco with a scalable, robust tool for global refinery planning.

“Aramco continues to set the standard for operational excellence through digital innovation,” said Claudio Fayad, chief technology officer of Emerson's Aspen Technology business. “This deployment of AI-driven Aspen Hybrid Models to optimise complex, multi-site, multi-period planning workflows demonstrates the tangible value of combining deep domain expertise with advanced AI. We are excited to expand our strategic relationship with Aramco as they advance their digital transformation goals.”

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@EmersonExchange @AspenTech @aramco @EMR_Automation  @Emerson_News @HHC_Lewis #PAuto #Power #Ai

Modular assembly for flushing and bleeding applications.

The TESCOMTM AGI BR Series Flushing Ring from Emerson is a a comprehensive packaged solution for flushing and bleeding applications in petroleum refineries, biofuel refineries and petrochemical facilities. By providing a complete, modular valve assembly with a single part number, the AGI BR Series flushing ring streamlines ordering and allows for easy reordering with customer specific test requirements. Both traditional BRS “sandwich” and BRW “wafer” style rings are available, as well as the BR7 “integrated bonnet” design, which includes the bleed/flushing functions in the flange ring itself.

For distillation towers, hydrotreaters and more.

Most flushing ring products are sold as separate components and assembled in the field. This often involves on-site welding and non-destructive examination (NDE) requirements such as pressure testing, Positive Material Identification (PMI), dye-penetrant and radiography. In comparison, the AGI flushing ring includes valve assembly, welding, painting and testing in one comprehensive, compact package.

“Ordering and installing flushing ring products as separate components is overly burdensome and often results in additional costs and long lead times for product delivery,” said Md Wasfi, product marketing manager at Emerson. “What’s more, the entire process must be repeated when reordering. With the new TESCOM AGI flushing ring, customers can order a complete, modular valve assembly under one SKU, simplifying the process as well as reducing on-site installation costs.”

The AGI flushing ring meets piping and instrument class requirements according to the ASME B16.34 standard and is ideal for installation in processes requiring flushing of residue in front of diaphragm seals such as distillation towers, hydrotreaters, coking towers, reactors and separators. The one-piece forged design reduces leak paths and helps minimize emissions compared to conventional products. Fugitive emissions bonnets and ball valves that follow ISO 15848-1 & 2 are also available.

With the flexibility to meet each application, the TESCOM AGI flushing ring features flanged connections that are available in a range of sizes from 1 to 6 inches, pressure class ratings from 150# ANSI to 2,500# ANSI, and temperature range options from -3,143 to 1,000 degrees F (-192 to 538 degrees C). Additionally, Emerson can provide custom variations and NDE testing to meet specific project requirements.

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@EMR_Automation @Emerson_News @EmersonExchange  #Pauto

Automation for biorefinery.

Fintoil, together with Neste Engineering Solutions, has selected Emerson’s automation software and technologies to maximize the operational performance of its biorefinery being constructed in the port of Hamina-Kotka, (FIN). The plant is to be the third-largest crude tall oil (CTO) biorefinery in the world and produce advanced biofuel and biochemical feedstocks that help lower emissions and reduce reliance on fossil-based fuels.

The plant will refine CTO, a by-product of the wood pulping process, to produce a sustainable feedstock for renewable second-generation diesel, as well as rosin, sterol pitch and turpentine used in the chemicals, foodstuffs and pharmaceuticals industries. These CTO derivatives have a carbon footprint up to 90% smaller than their fossil-based equivalents.

“This state-of-the-art facility, which utilizes Neste Engineering Solutions’ NEXPINUS™ technology, uses 40% less energy than a conventional tall oil refinery, and is the perfect example of efficient and sustainable production that supports the circular economy,” explained Fintoil CEO, Jukka Ravaska. “Working with Neste Engineering Solutions and Emerson to implement the latest digital automation technologies will enable us to operate the plant safely and efficiently, minimize operating costs and deliver large-scale production of biofuel and biochemicals as a viable alternative to fossil-based products.”

To reduce project risk and ensure schedule and budget are maintained, Emerson will apply its Project Certainty methodology, which digitalizes project execution and uses practices such as remote testing of equipment. And to enhance plant security performance, Emerson consultancy services will advise on the implementation of cybersecurity best practices.

“Emerson expertise and technologies are playing a significant role in helping companies achieve their ambitious decarbonization and environmental sustainability goals, including the accelerated transition to cleaner fuels,” said Mark Bulanda, executive president of Emerson’s Automation Solutions business. “Our project expertise and latest advanced digital solutions are not only helping Fintoil develop the production capacity of a sustainable fuel, but also optimizing plant efficiency to lower its overall environmental impact. We are very pleased to have Neste Engineering Solutions as a partner in this project because of its extensive experience in the CTO business.”

In addition to providing NEXPINUS, engineering procurement and construction management for the project, Neste Engineering Solutions will also be responsible for delivering the entire application software for the new CTO biorefinery.

Fintoil, together with Neste Engineering Solutions, will implement Emerson’s DeltaV™ distributed control system, DeltaV safety instrumented system and DeltaV Live operator interface software to enable efficient production, greater visibility of operational performance and process, and emergency shutdown for improved plant and worker safety. Advanced measurement technologies that have minimal maintenance requirements and diagnostics made available through Emerson’s asset management software will enhance equipment reliability and performance, contributing to greater plant availability and throughput, and lower cost of ownership.

Construction of the facility is expected to be completed in 2022. The expected annual capacity of 200,000 tons will create a 400,000-ton reduction in carbon dioxide emissions, which is roughly 1% of Finland’s total emissions.

@EMR_Automation @EmersonExchange @NesteGlobal #PAuto #Finland

Rapidly increase for biofuels.

Global renewable fuels leader will implement advanced technologies to accelerate its digital transformation and meet global demand

Emerson has been selected to support Neste’s digital transformation of its expanded refinery in Tuas (SG).  Emerson’s automation systems and software will help Neste deliver high-performance, efficient operations, supporting Neste’s plans to increase production by up to 1.3 million tons per annum by 2023. 

“By incorporating a digital foundation, advanced analytics and mobile collaboration capabilities into its expanded refinery’s operations starting from its construction phase, Neste is well positioned for long-term operational excellence,” said Ron Martin, president for Emerson’s process systems and solutions business.

Neste is the world’s largest producer for renewable diesel and sustainable aviation fuel produced from renewable waste and residue raw materials. At the end of 2018, Neste made a strategic decision to expand its production facility in Singapore via the Singapore Expansion Project. On top of its existing 1.3 million tons annual production capacity of renewable diesel, the expanded refinery will have additional capacity to produce up to 1 million tons of sustainable aviation fuel and renewable raw materials for polymers and chemicals, supporting the company’s goal to reduce customers’ greenhouse gas emissions by at least 20 million tons annually by 2030.

To ensure the construction of the Neste Singapore Expansion Project is on time and on budget, Emerson is working with Neste to incorporate its Project Certainty methodology, the company’s approach to ensuring successful capital project execution. Emerson will help Neste complete automation system implementation smoothly to bring Neste’s expanded refinery on-line by 2023. Cloud engineering capabilities enable global engineering teams to collaborate remotely to optimise project designs and accelerate project schedules. Smart Commissioning software automates device commissioning, enabling faster, smoother start-up of the production.

Neste will apply Emerson’s DeltaV™ automation system and software to control production for efficient performance and to deliver on-demand remote access to data and analytics. Emerson’s advanced systems, software, analytics and mobility tools – part of its Plantweb™ digital ecosystem – establish the foundation to digitally transform operations by turning relevant data into new operational insights and actionable information that empower better decision-making.

@Emerson_News @EMR_Automation @NesteGlobal @HHC_Lewis #Pauto  #Singapore

Refinery methane analyser.

A refinery required a third-party certified SIL 1 solution to calculate the differential between two analyzers that measure the methane content on the inlet and outlet of a reactor, which breaks down the hydrocarbon levels in the process stream.  The methane level is always higher on the outlet side of the reactor; however, should the differential with the input exceed a predefined setpoint, these higher methane levels could reach flashpoint with a sharp trend that could lead to an explosion. 

After a Hazard and Operability Analysis (HAZOP) of the existing installation was performed, it was determined the refinery needed to mitigate the risk and install an independent SIL1 safety trip solution. Moore Industries designed a methane differential trip Safety Instrumented Function (SIF) and provided the client with an independent Safety Integrity Level (SIL) verification report.

The two independent methane analyzer measurements are sent to the SST Signal Splitters, where one output is used for the differential calculation and the other is transmitted to the Basic Process Control System (BPCS). 

The methane differential is calculated by the STZ Transmitter and sent to the STA Logic Solver, where a differential between inlet and outlet  analyzers exceeding 10% MOL will trip the safety setpoint. In addition, the STA Logic Solver retransmits the calculated methane differential to the Basic Process Control System.

#PAuto 

Instruments for Texas refinery.

Endress+Hauser has secured the Main Instrument Vendor (MIV) contract at a large Texas refinery.

Endress+Hauser defines MIV services as a contract placed with a single instrumentation specialist partner to provide a total solution for a project including valves. From feed to operation, customers can save time, reduce cost and mitigate risk with one partner to ensure consistency and avoid ambiguities.

Endress+Hauser and its representative, Vector CAG, will support the refinery’s project. “Our customers are looking for a single point-of-contact to support all field devices required, consistent documentation, and consolidated freight with clean tagging,” said Jason Knuteson, VP Marketing, Endress+Hauser. “They want to leverage purchasing for multiple suppliers and at the same time have the ability to reprioritize as the project shifts. As a focal point of the project, we are able to build relationships with the other vendors to execute the scope effectively.”

Project services will include: • Project Management • Embedded Engineering • Smart Plant Integration (SPI) • Quotation • Reporting • Procurement • Expediting & Prioritization • Documentation • Warehouse support with receiving, inspection, tagging and shipping • Onsite Construction Coordination

As the industry implements IMO 2020 regulations, expansions such as these help refiners add capacity to meet the needs of the industry. IMO 2020’s proposed regulations aim to reduce sulfur content in fuel of marine vessels and limit future greenhouse gas emissions. Endress+Hauser and Vector CAG will closely support the project timeline to help the refinery maximize its potential.

“Through our partnership with our clients and manufacturing suppliers, the MIV concept is successful given the flexibility and adaptability to what our customers need to be successful on this project,” said Jared Boudreaux, President, Vector CAG. “After listening to what they needed, we adapted our process to match those needs. Working with the engineering firms and our client together to have a successful outcome is our goal.”

#PAuto #Oil @Endress_Hauser @Endress_US @Endress_UK @vectorcag

Managing terminals!

Emerson Automation Solutions has released TerminalManager™, the next-generation software for managing all terminal operational and commercial activity. TerminalManager provides a single software platform to manage the entire terminal business process, helping operators streamline the loading processes, achieve greater connectivity to customer needs, and close the books faster.

“With the release of TerminalManager, we continue to offer new ways for our customers to improve the efficiency of their operations, not just for loading and unloading operations but for the terminal business management process as well. TerminalManager is built not only to move products but to efficiently move information which optimises the order to cash cycle for the terminal and helps streamline the customer’s supply chain logistics activities,” said Pedro D’Ascola, general manager for Emerson’s Remote Automation Solutions business.

Today’s terminal operator is faced with a variety of challenges to remain profitable in an increasingly complex market environment. For terminal operators in the oil & gas, chemical and refining industries, efficiently maximising the throughput of the terminal is critical to remain as key suppliers to their customers and to be financially successful. TerminalManager helps terminal operators manage the entire terminal business process by managing customer contracts and orders through a web-based portal, efficiently planning and executing the loading operations, managing book and physical inventory, charging for services, and billing activity back to the customer.

 @EMR_Automation  #PAuto #Oil #Gas @HHC_Lewis 

Petrochemical industry embraces new testing event!

The inaugural PEFTEC event took place in Antwerp (B) in mid-November 2015, and reported feedback from conference speakers, exhibitors and delegates has been extremely positive.

PEFTEC 2015 was created to provide the petrochemical industry with an opportunity to discover the latest information on testing and monitoring, in the laboratory, in the field and on-site. A packed conference programme ran over both days and over 80 seminars took place in 8 seminar rooms that were located within the exhibition hall.

In response to demand, the organisers had to increase the floor space of the Exhibition. However, the majority of the booths were small and informative rather than promotional. Nevertheless, there were over 120 international laboratory and process monitoring equipment suppliers and analytical service providers on show, representing more than 220 organisations worldwide. As part of the PEFTEC Technical Programme, there were also 40 poster presentations – all of which were located within the exhibition hall. PEFTEC therefore represented a truly unique opportunity to see the entire market sector under one roof at the same time. Dr Oliver Sauer from Grabner Instruments agreed: “The show was a great place for networking with other suppliers in the market, with partners and customers – a sort of family reunion.”

Summarising her thoughts on the event, Elizabeth Wilkinson from Lovibond Tintometer said: “The inaugural PEFTEC event proved to be extremely successful – bringing in a great many industry experts throughout the supply chain. The organisers must be complimented on such a successful event for its first year and we certainly look forward to joining them again in 2017.”

Prof. Ralf Zimmermann, one of the Conference speakers added: “I found the meeting interesting; the scientific programme was very well organised and the show was focused, which made it very efficient, so it's a very worthwhile event to visit. Also the location was well chosen and I recommend that the event should continue in the same format.”

As PEFTEC organiser, Marcus Pattison was obviously delighted with the success of the event and with the highly positive feedback that it generated. “These are challenging times for the oil and gas sector, so it was very encouraging that PEFTEC 2015 was such a success, and we are greatly looking forward to PEFTEC 2017 which will take place 29th to 30th November, again in Antwerp."

Helping refiners optimise in-line blending units.

SmartProcess Blend, from Emerson Process Management,  incorporates a new Blend Order Management System as well as an enhanced on-line and off-line optimiser for control of continuous in-line blenders. Emerson’s SmartProcess Blend package is a complete, integrated suite of applications native to the standard DeltaV™ distributed control system (DCS). Simplified implementation and ease-of-use are key features of SmartProcess Blend system.

Process control of continuous in-line blenders enhanced by using Emerson's SmartProcess Blend package

“Blending is critical to refinery profitability,” commented Marcelo Carugo, global refining industry lead for Emerson. “Planners try to maximise the most valuable blends from available components. The problem comes when the components you’re using are not what you expected them to be, so the planned recipe will produce off-spec products and adjustments must be made on-line during the blending process. Furthermore, equipment downtime and human error can lead to off-spec product that requires re-blending and further derails the production schedule and increases costs.

“Schedulers provide some margin for unplanned events but blending is often too complex to determine the optimal corrective action manually. What you consume in the current blend affects what you have available for the next one, so deviating too far from the planned recipe can have big penalties. In addition, when correcting an off-spec blend, operators tend to play safe and overcompensate, creating quality giveaways and suboptimum blends utilising more of the expensive blend stocks.”

The new SmartProcess Blend Order Management application provides a multi-language, web-based user interface to link the refinery’s blend schedulers to the blend operators. Planners and operators are able to view a blend order, test it with current data and run the off-line optimiser from the Order Management tool. Using the DeltaV DCS environment, operators can review approved orders, select one for execution and automatically run that blend using closed-loop optimiser control.

The new SmartProcessBlend Optimizer applies closed-loop optimisation to the blend control process. Using non-linear blend models combined with on-line analysers, an optimiser continuously calculates the optimum ratios that make the batch on-spec at the lowest possible cost or as defined by user-defined penalty functions. Penalties can be set based on component cost, deviation from planned recipes, and/or deviation from target qualities.

SmartProcessBlend manages the lifecycle of a blend, from planning and scheduling, to optimisation, to on-line control of the final blend properties. The system is designed as a set of generic templates that are configured to meet the specific refinery’s blending needs. The system is capable of handling complex blending requirements such as those required for reformulated gasoline – with multiple headers, up to 25 components and up to 25 quality specifications. It can also be used for simple, recipe-based ratio blending like asphalt with fewer components and quality specifications.

SmartProcess Blend can be combined with Emerson’s expert blending consultancy to provide a turnkey solution that ensures optimal use of available components and tank rationalisation - maximising profit for both greenfield or existing refinery blending units. Emerson’s turnkey capabilities include design, construction, and installation of fully instrumented, skid-mounted in-line blenders, analyser houses and sample systems.

Emerson’s broad range of flow meters, vibration, temperature and pressure transmitters, radar level gauges, and valves complement the SmartProcess system to provide an easy standardised path to integrated turnkey blending solutions.

Information and industrial automation technologies for oil refineries!

Yokogawa Solution Service Corporation - the company’s control business in Japan - and Cisco Systems G.K. are to provide a new solution for oil refineries that makes use of their respective information and industrial automation technologies. This platform integrates production, quality, progress control, and other information technologies with the control systems that are used to monitor and control production processes in real time, ensuring that facilities can be efficiently rebuilt and modified. It also improves the efficiency of corporate management by making it easier for information to be accessed by information management systems.

Background

As a result of a review of Japanese national energy policy, a new law known as the Sophisticated Methods of Energy Supply Structures Act was passed that requires the oil industry to make more efficient utilization of fossil fuels. To accomplish this, oil refining companies are now consolidating their refinery operations, as part of which they must also reestablish and reconfigure their control and information systems. This requires an environment where control, MES, and ERP systems can be quickly built or reconfigured, and where various types of complex data can be accessed in an integrated and flexible manner at each system level.

Features of This New Solution
The solution improves efficiency by structuring and standardizing a plant’s control and information systems as well as the data handled by these respective systems. This improves the portability of data, establishes a framework that facilitates the integration, construction, and modification of all of a plant’s control and information systems, and creates an environment with industry-leading security for all communications and information management. This is true not only for a plant’s own control and information systems, but also for links between plants. In addition to facilitating the consolidation of a company’s refinery operations, this solution is useful in the installation and expansion of plant facilities, and can deliver the same benefits here as well. The main features of this solution are as follows.

1. Integrated information reporting
Systems with different functions that are in various locations can now be treated as a single virtual
information platform, allowing the generation of reports whenever they are needed, and in any desired format. This improves ease of access to information and allows the free selection of Key Performance Indicators (KPIs).

2. Information access
This solution features refinery-wide network connectivity and provides a highly-secure environment, allowing a plant’s systems to exchange structured and standardized data with systems at company headquarters and other plants with industry-leading security. Information can be quickly imported from other locations, compared, and linked, ensuring that people have all the information needed to make informed decisions.

3. Analysis (business intelligence)
The ability to collect a wide range of information and make effective use of large amounts of plant data allows for the performance of multifaceted analyses that can accurately identify solutions and improve both quality and efficiency.

Outlook for the Future
This collaboration of Cisco and Yokogawa Solution Service will not be limited to the oil-refining sector. With Cisco’s proven track record in providing highly-secure, high-quality network equipment and information system services and Yokogawa’s wealth of experience in the industrial automation field, the two companies will be able to respond flexibly to market needs and provide solutions that deliver great benefits such as improving how control and information systems work together and making maximum effective use of large amounts of control data. Both companies plan to extend this collaboration to other industries, and intend, for example, to roll out this solution to the petrochemical and pharmaceutical industries later this year.

2,800 Flow and level instruments for Columbia.

The main instrument vendor (MIV) by Refineria de Cartagena (Reficar) in Cartagena, Colombia is Endress+Hauser. They have supplied more than 2,800 flow and level measurement devices to support a $3.8 billion refinery expansion and modernisation project.

The Reficar expansion project added twelve new process units, increasing refining capacity and production from 80 KBD to 165 KBD. The upgraded facility will produce ultra-low sulfur gasoline and diesel from heavy crude oil slate.

Because of the large scale of the project, Reficar wanted a MIV with a global presence, project execution capabilities, and the skills needed to handle this huge expansion and modernisation project. Reficar was also in search of a global partner that could easily meet their wide range of measurement technology needs and act as a single source supplier.

As the MIV, Endress+Hauser was able to:

•      Perform sizing and selection of Endress+Hauser and third-party instrumentation

•      Produce and manage all technical, commercial and logistics documentation

•      Coordinate all inspections, calibrations and logistics-related activities

Endress+Hauser’s local partner in Colombia (Colsein Ltda), provided additional support to Reficar through local training, calibration services and site supervision during installation, commissioning and startup.

Colsein Ltda delivered a series of training programs to Reficar using an Endress+Hauser PTU® (Process Training Unit) located in Tocancipa, Cundinamarca Colombia (approximately 16 miles north of Bogotá). The PTU is a full-scale working mini-process plant with on-line instrumentation and controls. The PTU allowed Reficar personnel to gain hands-on experience with the types of operations, diagnostics and troubleshooting used in the new and updated units.

Reficar shifted much of the logistics and invoicing responsibilities to Endress+Hauser by engaging the company as the MIV. All activities involving third-party technical inquiries and orders were routed through a single point of contact at Endress+Hauser. And by engaging Endress+Hauser as the MIV at an early stage in engineering, Reficar was able to include supplier features and part numbers in the initial version of the specification sheets, and ultimately reduce required engineering rework.

Overall, this resulted in significant cost savings and reduced engineering rework, time savings for Reficar’s procurement department, and a substantial reduction in the total number of purchase orders, quotations and invoices.

Helping to reduce emissions at advanced, low-carbon refinery in Canada!

Industry experience, expertise, and technology innovation drove selection for multi million dollar automation project in western Canada

Canada’s North West Redwater Partnership has selected Emerson Process Management to provide automation services and technology for the first phase of the innovative Sturgeon refinery northeast of Edmonton, Alberta,  (CDN). Expected value of the contract to Emerson is approximately US$86 million (€67 million).

An artist’s rendering of the Sturgeon Refinery project (Edmonton Journal)

The Sturgeon facility will capture carbon dioxide emissions and sell them to traditional oil extraction operations, which will inject the carbon dioxide into wells under pressure to enhance extraction before permanently storing the gas in the wells. This approach is expected to reduce emissions by 1.2 million tons per year from the first phase of the refinery while also generating income for North West Redwater.

The new facility will also use technologies designed for cleaner refining, including elimination of petroleum coke, a waste product typical of traditional refining.

North West Redwater chose Emerson to automate the Sturgeon refinery based on its experience in similar refining processes, as well as its technologies and expertise that can help reduce project costs, reduce schedule risk, and increase process availability.

As the main automation contractor, Emerson will manage the automation of the refinery including providing engineering, configuration, start-up, training, commissioning support, and other services.

The automation solution for the project will include its DeltaV™ distributed control system and DeltaV SIS safety instrumented system to control and monitor operations. Both systems include Emerson’s innovative Electronic Marshalling technology with characterisation modules (CHARMs), which greatly simplifies connections between the control system and the thousands of instruments throughout the plant.

The automation solution will also include the company’s Rosemount® transmitters, Fisher® control valves, and Micro Motion® flowmeters to carry out essential measurement and control functions.

“This is one of several large automation projects we’re executing in western Canada,” said Steve Sonnenberg, president of Emerson Process Management. “We look forward to being a part of this truly cutting-edge carbon-reduction process while also supporting the conversion of non-traditional energy sources to cleaner fuel.”

• North West Redwater Partnership is a 50/50 partnership between North West Upgrading, Inc. and Canadian Natural Upgrading Limited (CNUL), a subsidiary of Canadian Natural Resources Limited. The $8.5 billion (€6.62 billion) first phase of the Sturgeon refinery project, which is expected to be complete by September 2017, will process 50,000 barrels per day of bitumen into primarily ultra-low-sulphur diesel fuel. The facility has regulatory approval to process up to 150,000 barrels per day of bitumen.  

Control system for new ultra-low-sulphur diesel fuel plant in Mexico!

Yokogawa de Mexico, S.A. de C.V. has received an order from Cobra Instalaciones Mexico S.A. de C.V., a subsidiary of the Spanish EPC firm ACS, to supply an integrated control and safety instrumented system solution for an ultra-low-sulphur diesel fuel plant that is being built for PEMEX Refinación, a subsidiary of Mexico's national oil company, PEMEX.

To reduce air pollution caused by emissions of sulphur oxide, nitrogen oxide, and particulate matter, PEMEX is promoting the use of low-suphur diesel fuel and gasoline. This project involves the construction of an ultra-low-sulphur diesel fuel plant at the PEMEX Cadereyta refinery complex, which is located in Nuevo León state in northeastern Mexico. The new plant will produce ultra-low-sulphur diesel fuel from naphtha purified at the Cadereyta refinery. This facility will have the capacity to produce 35,000 barrels per day of this desulphurised fuel, and is scheduled to come on line in the first half of 2017.

For the monitoring and control of this plant's hydrodesulphurisation unit and sulphur recovery unit, Yokogawa will deliver the CENTUM® VP integrated production control system, the STARDOM® network-based control system, the ProSafe(R)-RS safety instrumented system for shutting down the plant under abnormal conditions, the Exaquantum™ plant information management system and other solution-based software packages, the GC800 process gas chromatograph for analysing gas composition, and a variety of field instruments for flow measurement. Yokogawa de Mexico will be responsible for installation and engineering, and will also provide support with commissioning and the training of plant operators. Installation of these systems and products is scheduled to be completed by the first half of 2015.

Mexico is rich in oil and natural gas resources, and recently has confirmed the presence of shale oil and gas deposits. Investments by companies in the private sector, including overseas-based enterprises, for the development of Mexico's oil and gas resources are expected to be approved, and investment in this field is expected to increase. And, in line with the rising awareness around the world of the need to protect the environment, an increase in demand for sulphur removal facilities, particularly in developing nations, is foreseen. Yokogawa anticipates continued growth in the Mexican control systems business, and will aggressively pursue additional control system orders for sulphur removal facilities that contribute to preventing air pollution and thereby help to protect the environment.

Control system order for large 2nd generation bioethanol plant

Yokogawa América do Sul has received an order to supply the control system and field instruments for the São Miguel dos Campos second-generation bioethanol plant.

This plant will have a production capacity of 82 million litres per year and is being constructed by GranBio in São Miguel dos Campos, Alagoas state (BR). As opposed to first-generation facilities that produce bioethanol from food products such as corn and sugarcane, this plant will rely on second-generation non-food sources such as woodchips and straw. São Miguel dos Campos is the first plant of its type to be constructed in the southern hemisphere, and it will be one of the world’s largest such facilities, in terms of production capacity. It is scheduled to start commercial operation in early 2014.

As the main automation contractor Yokogawa has been involved in this project from the FEED stage, performing the basic design for a control system and field instrumentation solution that will reduce costs and improve production efficiency throughout the lifecycle of the plant. Yokogawa will supply the CENTUM® VP integrated production control system to control plant facilities such as reaction tanks and distillation units, and a variety of field instrumentation and equipment including FOUNDATION™ fieldbus enabled ADMAG AXF magnetic flowmeters, DPharp EJA series pressure/differential pressure transmitters, and control valves. Yokogawa América do Sul will be responsible for delivery, engineering, and operator training.

Satoshi Yoshida, the President of Yokogawa America do Sul, comments as follows: “Brazil is a dominant player in the bioethanol market, second only to the United States. The biofuel market is steadily growing, and second-generation biofuel is attracting attention as an environmentally friendly energy source. Utilizing its accumulated control and instrumentation experience and know-how, Yokogawa will capitalize on the vast opportunities for growth in the renewable energy sector, a key target industry. In its role as a main automation contractor, Yokogawa will provide the latest plant control solutions and project execution services to the renewable energy sector in Brazil and other markets, and thereby work for a more sustainable future.”

Control systems for process plants at Russian refinery!

Antipinsky Refinery selects Honeywell

Antipinsky Refinery CJSC is to use Honeywell’s Experion® Process Knowledge System (PKS) to control plant processes and general refinery facilities as part of the third stage of construction of the Antipinsky Refinery in Tyumen, (RU). The commissioning of the plant will double the refinery’s capacity to 7.5 million tons annually, helping meet the growing demand for clean fuels and other oil products in Russia and the European Union.

Deploying Experion PKS is part of an initiative to create a single, central operations centre at the Antipinsky Refinery. As an additional part of this initiative, Honeywell will supply up to 60 additional workstations to the refinery, which will be installed in the unified refinery control center.

“There is significant demand for Antipinsky Refinery products, both in the region and throughout Russia and the EU,” said Leonid Sorkin, general manager, Honeywell Russia. “Honeywell’s advanced process automation systems will help the business grow efficiently and safely.”

The new construction is part of the refinery’s plan to increase its capacity of crude oil processing and to enable production of products in the next year that meet the EU quality of the Euro-5 emission standards. The project also includes the construction of a water treatment plant, sewage treatment plant, steam generation plant and other general refinery facilities. This phase of construction is expected to be completed by the end of this year.

“By selecting Honeywell, we were able to get everything we needed through a single, reliable supplier,” said Gennady Lisovichenko, general manager and member of the board at Antipinsky Refinery CJSC. “The implementation of Experion PKS will empower our workforce and greatly enhance the safety and efficiency of the refinery’s processes.”

“Experion PKS provides a continuous and more comprehensive flow of information about refinery operations,” said Alexander Rodionov, Russia sales leader, Honeywell Process Solutions. “This enables operators to spot potential problems more quickly, help them make better-informed decisions about plant operations and keep the plant running safely and efficiently.”

Automating Tuapse Refinery (RU)

Honeywell has signed an agreement with NK Rosneft, a leading Russia-based oil and gas producer, as the main automation contractor for the construction of its new refinery at Tuapsinskiy NPZ (RU).

Honeywell is to deliver a comprehensive set of services to equip the Tuapse refinery with a single integrated production control system – Experion^® Process Knowledge System (PKS). With Experion PKS, the refinery will be able to improve both the efficiency and profitability of its production process. Honeywell will also provide assistance during the design and commissioning stages of the project.

In addition, Honeywell will implement its UniSim^® Design Suite process simulation software to increase staff safety and minimize operator errors at the refinery. Honeywell will also equip the site with Advanced Process Control and Manufacturing Execution Systems to help improve the efficiency and reliability of the production process.

The refinery is currently undergoing a complete upgrade, including the construction of a new distillation unit with a total capacity of 12 million tons per year as well as a number of utilities, infrastructure and offsite facilities. The second stage of the upgrade project will involve the construction of a deep conversion facility.

“Honeywell's solutions have long proven themselves to be reliable and efficient. We know that implementing Honeywell's Experion PKS automation system will help make controlling the production process both safer and easier,” said Yegor Bagrin, head metrologist, Tuapsinskiy NPZ.

“We have been working with Tuapse Refinery for over 10 years, and this new project represents one of the most important enterprises in the south of Russia,” said Leonid Sorkin, general manager, Honeywell Russia. “Besides implementing a modern production automation system, we have also provided computer-based operator training simulators. Our solutions will help improve
cost efficiency and product quality at the refinery.”
This project continues Honeywell’s long relationship with Tuapsinskiy NPZ, where Honeywell previously supplied the refinery with both an instrumentation and control system for the plant’s crude oil and vacuum distillation unit.

Valves for Algerian refinery

Control valves and regulators to help optimise plant performance

Technip has selected Emerson Process Management as the main supplier of control valves for the Algiers Refinery rehabilitation and adaptation project. The Algiers refinery, located 10 km south of Algiers, in Algeria, is being revamped to increase crude oil processing capacity and ensure it can produce gasoline at specifications similar to those used throughout Europe.

Emerson will supply approximately 600 of its Fisher® control valves and regulators, including rotary, globe and butterfly type devices. The valves will be deployed throughout the refinery, including within the residual fluid catalytic cracking unit, naphtha processing units and new LPG storage unit.

"Emerson was selected as the main control valve supplier because its Fisher valves are proven to provide high levels of accuracy and reliability in demanding refinery applications," said Pascal Marette, Senior Procurement Manager, Technip. "The level of support offered was also critical. Emerson’s local team includes experts with extensive experience of providing solutions to refinery applications."

The modernisation of the instrumentation and control valves will help the refinery optimise the various process units. This will help to sustain the production of clean fuels both for the local and export markets, as well as reduce maintenance and plant shutdown costs.

The Fisher valves will be supplied with a range of trims and silencers. Suitable for severe-service applications, they are designed to provide long lasting, fast and safe operation, as well as reduced fugitive emissions.

Emerson’s new FIELDVUE™ DVC6200 digital valve controller, incorporating performance diagnostics and the latest HART® (version 7) communications, will enable control valves to be easily integrated into the existing control system. ValveLink™ software will work with the existing control system to provide online diagnostics that can help users identify potential problems so that they can be addressed before operations are affected.

The Algiers refinery was constructed in 1964 and produces motor fuels and LPG for the local market, and naphtha and fuel oil for export. The refinery is owned by Sonatrach, which is the largest oil and gas company in Algeria and Africa. Technip is the EPC contractor for the Rehabilitation and Adaptation project. The project is part of a broader refinery upgrade programme initiated by Sonatrach for the production of clean fuels in Algeria

Improving safety, reliability and environmental performance of refineries!

Innovative HF Alkylation measurement solution supports cost control, real-time safety and environmental excellence

Invensys Operations Management has signed a multi-year licensing agreement with Valero Energy Corporation, allowing use of Invensys Operations Management’s patented ACA.HF Advanced Alkylation Measurement Solution. In the first phase, Valero will implement the solution at seven refineries globally. The Invensys solution monitors and measures hydrofluoric acid levels in real time by analysing differential responses from online sensors, helping to improve the safety, reliability and environmental performance of the refinery and creating new opportunities to reduce operating costs.

Commonly used in petroleum processing, hydrofluoric acid is a highly toxic catalyst that must be carefully managed and controlled. Accurately analysing how much HF is re-circulating within the process contributes significantly to increasing the efficiency of the refinery because it can improve crude stock yield and associated costs. Early approaches to HF monitoring involved taking manual samples and analysing them in a laboratory. This approach however, even when carefully executed, potentially exposed lab workers to severe toxins, and its accuracy was limited. And while more recent techniques can produce more accurate readings, their adaptation for real-time online monitoring is complex and costly.

Invensys Operations Management’s advanced measurement solution, however, brings new levels of simplicity, cost effectiveness and employee safety to that task. By using real-time online sensors instead of people, it significantly reduces the possibility of accidental exposure, thereby diminishing the risk to employees and curtailing the potential for environmental hazards. And because it replaces conventional manual laboratory sampling and other types of analysis, it can drastically improve the efficiency of the operation while lowering costs.

“We are committed to developing and delivering innovative solutions that help our clients, including Valero, increase the safety and reliability of their operations,” said Maxie Williams, vice president and enterprise client executive, Invensys Operations Management. “An integral component of our InFusion™ Enterprise Control System, our HF alkylation measurement solution can openly communicate with a larger refinery and enterprise-wide control, information and decision-support system to provide real-time data and analysis. And because it is built from rugged materials long proven in industrial HF applications, implementing it costs about half that of other systems and requires little maintenance, with estimated mean time between failures exceeding 29 years. It is a perfect example of how we are combining advanced control and instrumentation to improve and optimise the real-time safety and performance of the operation.”

IRIS for Saudi Arabia

Invensys Operations Management has signed a multi-million dollar contract to implement an integrated refinery information system (IRIS) for Saudi Aramco Total Refining & Petrochemical Company (SATORP).

Under the terms of the agreement, Invensys Operations Management, in a strategic alliance with Wipro Arabia Limited, will provide an integrated InFusion® enterprise control system solution encompassing total supply chain management; refinery planning and scheduling; operations management, including health, safety and environment management; quality control and assurance; and performance control and management. The company will also provide data validation and reconciliation, mass energy balance, utilities optimisation, electronic logbooks and control performance solutions to help SATORP achieve operational excellence. Wipro Arabia Limited is a joint venture between Wipro Limited, a leading global IT services provider based in India, and Dar Al Riyadh, a Saudi Arabia-based company with business expertise in engineering services, industrial products, systems integration and information technology.

“The Invensys system and the real-time operations management information will be a critical part of our plan to integrate fuels and petrochemical processes. It is the deep conversion technology we need to produce a high percentage of light products and value-added petrochemicals, and it facilitates our business strategy to hit the ground running,” said Mohammed Ruwaii, IT manager, SATORP.

A joint venture between Saudi Aramco and Total France, SATORP is constructing a state-of-the-art, 400,000 barrel-per-day refinery in Jubail, Saudi Arabia, that is expected to be operational before the end of 2013. The refinery will produce diesel, jet fuel and gasoline, as well as petrochemicals like paraxylene, aromatic benzene and propylene. The integrated refinery information system will manage the new refinery’s supply chain, planning and scheduling functions, as well as oversee its operations management, performance management and business process optimisation functions. 

“One key advantage of the InFusion enterprise control system is that it provides open integration, both horizontally and vertically—linking ERP, planning, operations and control systems—from Invensys and other suppliers alike,” said Franco Restelli, president, Invensys Operations Management, Middle East and North Africa. “Leveraging our deep domain knowledge and technical expertise, we look forward to working with SATORP to deliver a robust, scalable and easy-to-maintain system that will improve real-time decision making, analysis and performance control and management. We are pleased that SATORP is relying on Invensys and Wipro to help them become agile, competitive and profitable from the first day of operation.”

This success follows the multi-million dollar contract Invensys signed with SATORP in 2008 to deliver a comprehensive refinery-wide operations management solution, including its Foxboro® I/A Series® distributed control system and Triconex® emergency shutdown and alarm management systems, as well as fire and gas, compressor control, electrical control and asset management systems. The company has also provided its SimSci-Esscor® operator training simulator.