Matt Willmott ADVANCED PROCESS CONTROL 26 Oct 2016 FOR UOP ... · PDF fileADVANCED PROCESS...

ADVANCED PROCESS CONTROL

FOR UOP PROCESS UNITS

Matt Willmott

Jorge Charr

26 Oct 2016

Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.

• Introduction

• Process Solution Suites for UOP Technologies

• UOP/HPS Applied Process Excellence Center

Agenda

• Matt Willmott‒ HPS Projects and Automation Solutions Marketing

• Jorge Charr‒ Advanced Process Controls, UOP Applied Process Excellence

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.

Performance Materials & Technologies

UOP and HPS together are an unmatched process technology provider

UOP

Honeywell is a global leader in designing and

creating high-quality performance chemicals,

materials and process automation technologies

Process Solutions

• 31 of 36 today’s refining technologies were developed by UOP

• UOP technology makes more than:

- 40% of the world’s LNG

- 60% of the world’s gasoline

- 70% of polyester

- 90% of biodegradable detergents

• UOP technologies offer a high ROI

• #1 in Refining & Petrochemical Automation

• Honeywell Process Solutions are installed at nearly half of the world’s refineries helping to refine nearly 40 million barrels of oil a day

• Awarded Frost & Sullivan’s 2014 “Main Automation Contractor of the Year”


UOP & HPS Working Together

Efficient Technology Transfer from Schedule A to Functional Control System

• UOP has been designing and starting up their licensed units for

many decades

• A lot of UOP knowledge and experience is not transferred through

Schedule A or through EPC project processes

• Jointly develop a way to bake UOP knowledge inside of base

automation systems

• Leveraging LEAP technologies to remove impact of independent

physical/ functional design efforts

• Drive quality into project and operational aspects on control

systems

• Reduce risk to project schedule and startup


The Honeywell Advantage With UOP/HPS

More Sustainable Value Throughout the Facility Life

Cycle

Startup Your

Facility Sooner

Operate at Peak

Performance

Proven world-class UOP

process technology, pre-

engineered automation

solutions and innovative

execution to reduce

project schedule and risk

Reach Target

Production FasterProcesses and equipment

embedded with Honeywell UOP’s

expertise, deep process

knowledge and best practices to

optimize startup and operator

experience

Honeywell process-

specific software

solutions to enhance

safety, productivity and

reliability


Process Solution Suite for UOP Technologies

Startup Your Facility Sooner

Reach Target Production Faster

Operate at Peak Performance

UOP Critical Control Applications

Experion® Solution Suites

DynAMo® Process Solution Suites

Profit® Process Solution Suites

UniSim® Process Solution Suites

Modular Automation

Connected Performance Services (CPS)

Field Instrumentation/ Modular Design


Experion® Solution Suites for UOP

Unlocking Knowledge to Drive World Class Performance

Solution

Suites

Operational Knowledge Interaction requirements based operator displays and

console workspaces, embedded operating procedures

Control KnowledgeBasic and complex loops, automated sequences

Safety KnowledgeCause and effect logic, startup / maintenance

bypasses and shutdown logic displays

Alarm KnowledgeOperator Alarm Help

Experion Pre-Integration for UOP critical control system packages


UOP-HPS – Integrated Control and Safety

• Reduce Start-up and Operations Risk

- UOP knowledge and best practices embedded into DCS and SIS

- DCS configurations on UOP processes are pre-engineered and pre-

validated

- Project collaboration between UOP and HPS to ensure no surprises

- UOP operational experience embedded into Operator interface

- Standardized HMI improve consistency for better UOP startup

assistance


UOP-HPS – Integrated Control and Safety

• UOP Intellectual Property Embedded in Experion

- Improved the visibility to the process and ensure that the process stays

within defined ranges

- UOP defined graphics built to Abnormal Situation Management (ASM)

Consortium standards using HPS standard graphics libraries

- Fully documented alarm help system to ensure the most effective

operations from day one of operations

- Embedded procedures capturing UOP’s operations knowhow to

ensure consistent operations


Solution Suite Template Structure

• For each UOP process, the Unit Templates will include:

- Asset model and display hierarchy design

- Level 1 displays with process KPIs and critical monitoring parameters,

boundary definitions, etc.

- Level 2 displays with critical control point definitions

- Embedded critical operating procedures

- Integrated Operator workspace design

• Within each unit, each Equipment Template will have the following

deliverables:

- Control strategies (indicators, control loops, sequences)

- Safety strategies (trips and overrides)

- HMI display templates (L3/L4 displays)

- Alarm help information


Orion Operator Workspace for UOP Units


Other Features of Solution Suites

UOP PIC system interfaces

• Fully integrated database

package for Experion and

Safety Manager based

systems

• Pre-configured interface

package for PLC interfaces

• Consistent operator displays

between DCS and UOP

packages

Operator Alarm Help

• Additional operator information

is provided for each UOP

defined alarm

• Alarm help provided with

integrated DynAMo Alarm Suite


Focused on Developing Solutions for 4 UOP

Complexes

Naphtha Complex Templates in Project Delivery Now

Oleflex Complex Aromatics

Naphtha Complex Gas Processing

A process to create jet fuel,

diesel and liquefied

petroleum gas, and

feedstocks for Aromatics (8

Units)

Preparing natural gas for

heating & appliances,

propane and other fuels and

feedstocks (5 Units)

A process that creates the

ingredients for plastics,

synthetic rubber and fuel

additives (6 Units)

Creating cleaner, higher

octane fuels and feedstocks

that can be applied to the

plastics and pharmaceutical

industries (7 Units)November 2016

Released In Process

In Process


Introducing the Applied Process Excellence

(APEX) Center

Innovate and Commercialize through a Joint Team

Joint Innovation team between HPS & UOP built under

the UOP organization

Owns continuous Innovation and product / solution

development based on HUE principles and focused on

meeting customer needs

First point of contact for developing new opportunities,

resources and offerings

Sustainexisting & under

development technology

APEX

Growth through new Innovation

Continuously connect

HPS & UOP


What is Advanced Process Control (APC)?

All this happens once/min, every day, all year.

• Advanced Process Control (APC) / Multivariable Predictive Control (MPC)

• Multi-Variable

- Variable matrix, MVs/DVs/CVs

- MPC coordinates and decouples the effects of multiple process variable

interactions.

• Model-Predictive

- MPC uses dynamic models to predict process

behavior into the future. This information is then

used to proactively control the process.

• Constraint aware

- MPC monitors and maintains MVs and CVs within

limits while it is controlling the process.

- CVs tied to Inferential Properties Estimation

• Optimized Control

- MPC has integrated optimization capabilities to drive

applications toward specified design objectives.


Improved Profit

by Changing Targets

Improved

Control

Stability

Poor Control

$

ProfitLimit

APC on Capturing

the benefits

How does APC help?

• Improve stability

• Move closer to specification limit


Normal, Comfortable

Operating Zone

Temperature

Flow

Pressure

Level

Preheat

How does APC improve performance?

$$$


What is Honeywell Profit Suite?

• Profit Suite is Honeywell Process Solutions APC offering

• Provides the capabilities to deliver advanced benefits:

- Inferential modelling

- Process testing and identification

- Unit and multi-unit control and optimization

- Performance monitoring

• Works over any DCS but has superior integration with Experion and

TPS

• Over 3000 installations in many different industries

• Supported by world-class engineering team with over 4000 man

years of experience

UniSim Model

ProfitMax UniSim Model


Process Solution Suite for UOP Technologies

Startup Your Facility Sooner

Reach Target Production Faster

Operate at Peak Performance

UOP Critical Control Applications

Experion® Solution Suites

DynAMo® Process Solution Suites

Profit® Process Solution Suites

UniSim® Process Solution Suites

Modular Automation

Connected Performance Services (CPS)

Field Instrumentation/ Modular Design


Profit® Process Solutions Suite for UOP

No other vendor can provide similar solutions

• Objective

- To deliver unparalleled control performance on UOP licensed units and

further improve benefits to customers though implementation of APC

- Higher ROI

- Sooner, faster implementation.

• How we do it?

- Profit® Process Solutions Suites

- APC solutions pre-engineered for UOP process units

- Developed in direct interaction with UOP experts to capture process

knowhow, design criteria and operation guidelines

- Includes toolkits specific for UOP processes

- APC solution design captures UOP philosophy on how to optimize

these process units


Case Study: APC on UOP CCR Platforming

• CCR Platforming process produces high-octane reformate

- Used for gasoline blending

- As a source for BTX aromatics


Profit® Process Solutions Suite for UOP

• Software Components

• Profit Suite

- Profit Controller

- Profit SensorPro

- Profit Optimizer

- Profit Bridge

- Profit Stepper

- Profit Toolkit

• Toolkits for UOP process

- UOP CCR Platforming

- UOP Tatoray

- UOP Isomar

- UOP Oleflex (in progress)

C3

C4

C3 / C4


Case Study CCR Platforming APC Goals

• Feed preparation:

- Reactor feed is side stream of de-isohexanizer.

- Variability reduction.

Feedstock properties vary significantly due to various origins.

- Minimize losses of reformate precursors on overhead and bottom

streams.

• Reactor

- Increase aromatic content in reformate.

- Control reactor severity (WAIT) and H2/Hydrocarbon ratio.

- Maximize throughput.

- Protect operation via appropriate constraint settings.

Catalyst pinning in reactor.

Heaters Tube Wall Temperature.

Coke on catalyst


Case Study CCR Platforming APC Goals, cont’d

• CCR Regenerator

- Control coke burning to achieve desired regeneration.

- Control oxygen in regeneration gas and total catalyst recirculation.

- Protect operation via appropriate constraint settings:

Regenerator capacity.

Burn temperature profile.

Max catalyst recirculation.

• Reformate Stabilizer (Depentanizer)

- Minimize losses of aromatics in pentane stream (overhead product).

- Control pentane content in reformate product.

- Minimize energy.

- Protect operation via appropriate constraint settings.


CCR Platforming Toolkits in APC Solution

Reactor

APC

AROCON/

OCTCON

Regenerator

APC

CATGREGTWTPLT

COKCON

PINPLT

Depentanizer

APC

Feed prep.

APCHo

ne

yw

ell

Pro

fit S

uite Soft sensor Soft sensor

UO

P to

olk

its

Profit SensorPro

Profit Controller

CCR Platforming Toolkits

AROCON: Reformate % aromatics

OCTCON: Reformate octane number

TWTPLT: Heaters tube wall temperature

PINPLT: Catalyst Pinning Calculations

COKCON: Coke on catalyst

CATREG: Catalyst regeneration

CCR Platforming Toolkit


Case Study APC Tangible Benefits

• +6MM$ in benefits

Baseline After APCProposed

benefitsAPC benefits

Reactor

Throughput (BPD)Avg: 24750

σ: 2240

Avg: 25995

σ: 326- -

Avg: 5% increase

σ: 85% reduction

Aromatics (Wt%)Avg: 75.06

σ: 3.12

Avg: 87.19

σ: 1.141.5-2% increase

Avg: >16% increase

σ: 63% reduction

Feed

preparation

C6+ in Ovhd (Wt%)Avg: 17.27

σ: 4.11

Avg: 6.94

σ: 1.1050% reduction

Avg: 60% reduction

σ: 73% reduction

C5 reactor feed

(Wt%)

Avg: 4.39

σ: 0.97

Avg: 3.06

σ: 0.1820% reduction

Avg: 30% reduction

σ: 81% reduction


Case Study APC Intangible Benefits

• Customer feedback:

- Operational conditions are now defined by the APC applications to

achieve the desired results and goals, as opposed to before APC when

operators struggled to adjust unit conditions resulting in inconsistent

aromatics concentration results

- APC decreases human errors and improves control of product quality.

- APC has freed operator from quotidian work (chasing alarms), now

operators can focus on analysis and evaluation and continuously

improve the process operation.


APC Maintenance and Benefits Guardianship

• The Problem

- APC benefits tend to decay overtime

Process changes, models mismatch

- Revamps, fouling, catalyst degradation, etc.

Changes in operational goals

Lose of expertise, engineers turnover

• The Solutions

- Honeywell BGP support for Profit Suite software

Software technical support

Updates, upgrades

Remote monitoring

Software performance support

- UOP Connected Performance Services (CPS)


CPS Service Architecture

Customer Site

On-going capture of

plant (Process/Lab) Data

STAB

110% 90% 106%

NHT ISOM 301A PreFlash

110%

DIH

2

1

3

4

5

A

D E

G

H

B

A

L

J

F

I

K

N

MF

8

9

C

S

A

T

P

R

V

OQ

CONDITIONING THE DATA:

MEANS RESTORED TO ZERO

0.00

20.00

40.00

60.00

80.00

100.00

120.00

140.00

-20.00 -15.00 -10.00 -5.00 0.00 5.00 10.00 15.00 20.00

Balance Closure

Ins

tan

ce

s

Visualization

Data

Cleansing

Advanced

Computation

Cloud

Data

Collection

Predictions & Early Detection

KPI & Operating Envelopes

UOP expert reviews

Gross Error Detection

Data Conditioning

Data Reconciliation

Pro-active, on-going

dialog & recommendations


Connected Performance Services (CPS)Knowledge Delivery as a Service

The Connected Plant Delivered with CPS

• Analyze plant performance to uncover full potential with a Cloud service

- Around-the-clock monitoring of plant data and rigorous simulation

- On-going, operational recommendations to close performance gaps

- Leveraging UOP Process Models & longstanding experience in support and

troubleshooting

• Offered as a fixed annual fee engagement (no additional upfront cost),

including pro-active monitoring and engagement as well as all maintenance &

support activities

• Emission standards

• Energy reduction

• Sub-optimal operations

• Performance vs peers

• Knowledge gaps

• Operational excellence

Key Customer ChallengesUnplanned

Downtime

Human Capital

Challenges

Underperforming

Assets

• Process issues

• Equipment failures

Energy and

Emissions


CPS PortfolioThe Connected Plant, Delivered:

A Robust Service Suite Aimed at Reaching and Sustaining Your Plant’s Full Potential

KPI & Operating Envelopes• Pre-empt process issues with

embedded root cause analysis

• Operate closer to constraints

• Drive best operating practices

Utilities Management*• Enhance heat recovery, fuel gas and

H2 systems management

• Optimize supply and demand balance

Process Optimization• Maximize profitability through

changing process and economic

conditions

• Evaluate new opportunities with

“what-if” analysis

Reliability*• Improve turn-around planning

by managing asset lifecycle

• Gain new reliability insights

through data analytics

Unit-specific Benchmarking*• Improve operations through

actionable unit advice

• Set realistic, achievable targets

*in development


APC for UOP take away…

• Profit Process Solutions Suite allows UOP process licensees achieve

higher benefits through implementation of APC and optimization.

• APC projects success depends heavily on process knowledge. Unique

Honeywell Advantage incorporates deep process knowledge from UOP

paired with Honeywell APC techniques to achieve unparalleled

performance.

• Honeywell offers technical services to help customers to maintain Profit

Solution software up to date and performing as well as first day.

• UOP Connected Performance Services (CPS) is designed to provide

customers with specific process expert guidance and

recommendations to improve process performance. APC enables

implementation of CPS recommendations efficiently while ensuring the

process is driven to optimum performance continously.


Contact Information

• If you have any additional questions or would like to discuss how

Honeywell can help you:

- Reduce your project risk

- Start-up your plant sooner

- Get to name plate capacity faster

- Keep your plant at optimum performance

• Please email:

- [email protected]

mailto:[email protected]

Matt Willmott ADVANCED PROCESS CONTROL 26 Oct 2016 FOR UOP ... · PDF fileADVANCED PROCESS...

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