The oil & gas downstream industry has been facing an increasing number of challenges in recent years. These include the changing characteristics of the feedstock to be processed, aging of process facilities and equipment, rising cost of energy, lack of skilled plant operators who can run a refinery safely and efficiently, and the ever-changing requirements from both the market and the customer.
Over the years, Yokogawa has partnered with many downstream companies to provide industrial solutions focused on solving these challenges and problems. Yokogawa's VigilantPlant solutions have helped plant owners to achieve maximum profitability and sustainable safety within their plants.
In the ever changing marketplace, refineries are seen not only as crude processing units but also as profit centers. At the same time, there is a keen awareness of the need for safety at such facilities. A total production solution that encompasses planning, scheduling, management, and control is required to achieve long-term goals for profitability, efficiency, and environmental protection. With years of expertise in the automation field, Yokogawa can bring you affordable total solutions for improved operability and a cleaner world.
Today, many end-users not only in the oil, gas, and petrochemical industries, but also in the LNG/LPG and bulk industries are facing common logistical challenges. Those challenges include shortening the product delivery time, improving loading efficiency, adapting to changes in the manufacturing process, improving safety, increasing administrative efficiency, reducing labor costs, integrating data systems, visualizing operations, managing traffic, and so forth.
Yokogawa has been providing solutions to meet customers’ needs for terminal automation and management for decades.
In lubricant manufacturing, there are ever-changing complex and exacting formulation requirements, whether the material is processed in an in-line blending system or as a batch process. Accordingly, the control and information system must provide the flexibility to keep changing the formulas and procedures, while also being highly reliable and accurate.
Universal Terminal (S) Pte Ltd, one of the largest independent petroleum products storage terminals in the Asia Pacific, has been built on Singapore's Jurong Island at a cost of S$750 million.
PetroChina Guangxi Petrochemical Company has completed construction of a combined refinery and petrochemical production complex in Qinzhou, a port city in China's Guangxi Autonomous Region. With a 10 million ton per year capacity, the refinery is one of China's largest, and is truly world class, using a highly advanced hydrogenation process, with the main process technologies coming from the USA and France.
The Mathura refinery is a strategically important facility that supplies diesel, gasoline, aviation turbine fuel, kerosene, liquefied petroleum gas, furnace oil, and bitumen to customers throughout northwestern India.
Operators must receive diagnostic information before a line block leads to a malfunction. Yokogawa provides predictive diagnostics based on trend analysis of the blocking factor, which improves maintenance efficiency and reduces maintenance costs.
Steam is still one of the most popular methods of providing an energy source to a process and its associated operations. The more accurate and reliable measurements that are made, the more informed decisions can be taken that affect costs and product quality.
Level transmitter configuration can be very time consuming. DPharp transmitters with advanced software functionality eliminate this time consuming task. With maintenance shops getting smaller, finding equipment that allows us to do more with less becomes a priority.
One of the most common applications for differential pressure transmitters is flow measurement. DPharp differential pressure transmitters have some unique signal conditioning features to eliminate instability at low flow rates.
Recently, air pollution legislations such as the Clean Air Act to reduce the amount of air pollution are increasing worldwide. The Clean Air Act address numerous air quality problems. One of these problems is acid rain caused by sulfur dioxide and nitrogen oxide emissions from fossil-fueled power plants and other industrial and transportation sources.
The oil refining industry today faces increasingly strict regulations that dictate both the quality of its products and the diligence of its production processes. As the pioneer of the vortex flow meter technology, Yokogawa's challenge in bringing innovative flow measurement solutions to users in various process industries continues to this day.
O2 measurement in hydrocarbon vapor is used for safety monitoring in vacuum distillation columns in petroleum refining. With conventional paramagnetic oxygen analyzers, O2 concentrations are obtained through an extractive sampling system, which conditions the sample prior to being analyzed.
Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.
The top gas generated at the top of a distillation column in a petroleum refinery's fluid catalytic cracker (FCC) is used to produce gasoline and LPG. The GD402 Gas Density Meter features an intrinsically safe and explosion-proof design, fast response, and a dust-proof, anti-corrosive, and flame-proof construction.
Storage tanks are used in a variety of industries ranging from holding crude oil to holding feedstock for vinyl chloride monomer (VCM).
Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry. Because the large amount of fuel such as gas or fuel oil which is consumed in these processes, their combustion efficiency directly affects the performance and operational costs of the production facilities.
With industrial and economic development comes increasingly large and advanced power plants and factories. Nevertheless, we find many cases where the original cables, cable tunnels, and other components of the power infrastructure have languished under continuous operation.
Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry.
In limestone-gypsum flue gas desulfurization systems, the consumption of a desulfurization agent (lime) is controlled using online pH analyzers.
Fired heaters are used for various processes in oil refining and petrochemical plants.
Delayed Coker is a type of coker who's process consists of heating residual oil feed to its thermal cracking temperature in a furnace. The most important variable in industrial furnace control is temperature. Temperature is measured throughout the furnace in different zones and temperature effects the materials being manufactured and therefore must be precisely monitored to prevent deviations in quality of the final product.
Repeater is installed on high place between control room and monitor position. The extend cable is used for antenna of Gateway.
The client wanted to monitor the temperature on a chimney. Exhaust air is exposed to the heat on the way traveling from the inlet to the outlet in the chimney. Then constituent of the air transform to harmless elements. It is important to keep the temperature in the chimney as designed.
A multivariable model based predictive control (MPC) was implemented at the FCCU "A" in YPF S.A. Refinería La Plata.
There are three MPC controllers installed: one covering the reactor-regenerator-main fractionator, other controlling the gas con- centration plant ant the third controlling an isolated depropanizer column. The paper describes the implementation of the project, the controller structure and the main results obtained from the MPC.
Visual MESA© is a steam system optimization and management computer program that was originally developed at Chevron and now marketed by Nelson & Roseme, Inc. Visual MESA is currently used at refinery and chemical manufacturing sites to optimize the overall site steam system and the parts of the electrical system that economically trade off with the steam system.
This paper will explore significant optimization variables and constraints commonly encountered in refinery steam system optimization, the strategies Visual MESA uses to deal with them.
Hydrogen management can have a significant effect on refinery utility supply through the integration with the rest of the utilities. Real-time optimization of hydrogen production in conjunction with steam, power and fuels can yield significant savings opportunities for the refinery.
This paper describes the tasks performed to develop and implement real time, online models, to help with the three KNPC refineries energy cost minimization and energy management, which are scheduled to perform it automatically. They allow to clearly identify the different economic trade-offs that challenges the operation of the site wide energy systems at minimum cost while reducing the energy waste and, therefore, CO2 footprint. Recommendations given by the optimizers are taken into account by operations on a daily basis
In general, refineries exhibit a very good potential for real time monitoring and optimization using Visual MESA Energy Management System.
Based on our extensive experience, overall benefit in the range of 2% to 5% of the total energy cost can be achieved. Expected project payback is always less than one year.
This article describes the tasks performed to develop and implement a real time, online model for energy cost minimisation and energy management at KNPC's MAA refinery.
After a description of the main project implementation tasks, the Real Time Energy Management System's (RTEMS) functionalities are described and the optimisation implementation procedures are commented on. Finally, several obtained results are presented.
Utilities and energy systems are often the major source of SOx, NOx and CO2 emissions, therefore, emissions control and the management of credits and quotas are tightly interrelated with energy management.
In the case of refineries, chemical and petrochemical plants, energy represents the main cost (second to feedstock) and therefore its reduction has become a bottom line business decision. The energy systems at these sites are inherently complex, with the emissions cost analysis and limits compliance introducing an additional factor to the complexity of the energy costs reduction challenge.
Process plants use different type of fuels, they often operate cogeneration units, their steam networks consist of several pressure levels, there are different types of energy consumers and there are emission limits to be observed. Import or export of electricity in deregulated markets, which could also be traded off with more or less CO2 and other contaminant gaseous emissions, increase the optimization problem complexity.
The Repsol YPF Tarragona Refinery operates a large, complex steam system. Utilities Optimization has been performed with an on-line computer based steam management program (VISUAL MESA) in order to make the Refinery more energy efficient and reduce steam system operating costs.
VISUAL MESA allows operators and engineers to: