Operational Excellence by Asset Maximization, Utilizing Yokogawa's DCS, SIS, Analyzers, and Field Instruments

Map Ta Phut Olefins Company Limited logo
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Executive Summary

Map Ta Phut Olefins Company Limited, Rayong, Thailand
Map Ta Phut Olefins Co. Ltd., Rayong, Thailand

Map Ta Phut Olefins Company Limited (MOC), SCG Chemicals's subsidiary, operates a newly completed petrochemical complex at the Map Ta Phut Industrial Estate in Thailand's Rayong province. The complex produces 900,000 tpa of ethylene and 800,000 tpa of propylene, which is used in downstream plants to produce 400,000 tpa of high density polyethylene (HDPE) and 400,000 tpa of polypropylene.

Functioning for the first time as a main automation contractor (MAC), Yokogawa Thailand worked closely with the EPC contractor to deliver a comprehensive control and instrumentation solution for this greenfield project. This included the CENTUM VP production control system (PCS); the ProSafe-RS safety instrumented system (SIS); process gas chromatographs; analyzers; an advanced analytical instrument management system (AAIMS™); HART differential pressure transmitters, temperature transmitters, and flowmeters; InsightSuite AE asset excellence services; an Exaplog event analysis package for alarm reduction; and the Exasmoc advanced process control package.

main automation contractor

The Challenges and the Solutions

1. Project execution
In such a large greenfield project, it is important to start engineering and determine the basic specifications at an early stage. As the MAC, Yokogawa Thailand proceeded from front end engineering design (FEED) to the engineering phase, then undertook configuration & implementation, staging, and startup & commissioning. By executing this project as the MAC, Yokogawa Thailand was able to effectively manage the overall project schedule and reduce maintenance costs by maintaining consistency in the specifications.

2. Safety and efficiency
The CENTUM VP PCS and ProSafe-RS SIS were integrated using the same engineering environment. This reduced the overall engineering costs and resulted in a system that operates smoothly and efficiently. The PCS and SIS faceplates have the same look & feel, and security measures are in place that restrict access to the SIS faceplate.

The ethylene plant has multiple crackers and decoking is essential to maintaining efficient ethylene production. The InsightSuite AE analysis package calculates an optimum decoking algorithm that is used to optimize steam consumption, for greater efficiency and improved plant safety.

3. Asset maximization
To manage the more than 5,000 Yokogawa field instruments installed throughout this large complex, MOC opted for a remote monitoring solution based on Yokogawa's PRM plant asset management package that reduces the maintenance workload for field technicians and generates summary reports for future reference. This is backed by InsightSuite AE services that work 24/7 to identify issues and implement corrections that improve both availability and performance rate and reduce maintenance costs over the entire plant lifecycle.

The olefins plant has approximately 20 critical safety valves that are rated for SIL levels 1, 2, and 3, and they need to be checked periodically to determine that they are in correct working order. PRM's partial stroke test (PST) function allows these tests to be run from the control room, eliminating the need for technicians to go to each device to manually check its operation. This reduces workload and ensures safety.

4. Analyzer maintenance and data acquisition
Nearly 60 gas chromatographs and a large number of other types of analyzers in several analyzer houses are utilized throughout this petrochemical complex. An AAIMS is used to monitor, evaluate, and improve the performance of these on-line analyzers in a cost-effective manner. An AAIMS executes statistical analyses for analyzer validation; calculates validation KPIs such as availability rate, breakdown rate, checking rate, reproduction rate, and standard deviation; and generates SQC validation, maintenance, and key performance reports. An AAIMS has the following benefits:

  1. A flexible and reliable tool that centralizes the monitoring and management of analyzers
  2. Automates the collection of analyzer data in real time from the PCS, through an OPC server
  3. Automates the analyzer validation process

Working at an AAIMS workstation, operators, QMI personnel, and maintenance personnel can also manually enter and edit data like sample test results and maintenance records.

The information on gas chromatographs and other types of analyzers that is gathered with this system can play an important role in maximizing the efficiency of plant operations.

Customer Satisfaction

Witoon Pradubsripetch, the olefins production manager at the MOC complex, said, "We are striving to operate this plant safely and efficiently, and to make maximum effective use of all assets. That's why we are using field digital technology with FDT/DTM, PRM, and AAIMS. We have started using ISA 100 wireless devices at our raw material tank yard. All systems in this plant are integrated in the central control room. Our operators can clearly see everything that is happening in the plant. They know the status of each operation and have all the information they need to make correct and timely decisions. We appreciate the support given to us by Yokogawa Thailand."

Wireless transmitter

Wireless transmitter

Central control room

Central control room

 

업종

  • 석유화학

    석유화학 업종 고객사의 요구는 매우 다양합니다. 경쟁이 치열한 오늘날의 시장에서 앞서 나간다면, 생산자는 품질과 생산성을 향상시키기 위해 노력하고 있습니다. Yokogawa는 이 분야에서의 오랜 기간의 광범위한 경험을 바탕으로 이러한 요구에 맞는 맞춤 솔루션을 제공합니다.

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  • 화학

    화학 플랜트는 연속 및 Batch 생산 공정에 의존하며, 각각은 제어 시스템에 대한 다양한 요구 사항을 제시합니다. 연속 공정은 실패하지 않고 생산 라인을 중단시키는 견고하고 안정적인 제어 시스템을 필요로하는 반면, Batch 공정의 중요성은 수식, 절차 및 공정을 조정하는 데 있어 큰 유연성을 허용하는 제어 시스템을 갖추는 데 있습니다. 두 종류의 시스템 모두 제품의 사용 가능한 품질 내역에서 관리되어야 하며 비일상적인 작업을 수행할 수 있어야 합니다. Yokogawa는 광범위한 제품 포트폴리오, 숙련된 시스템 엔지니어 및 글로벌 영업 및 서비스 네트워크를 통해 모든 공장 공정에 대한 솔루션을 제공합니다.

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Related Products & Solutions

  • Alarm Analysis (Exaplog)

    새로운 Exaplog Event Analysis Package를 사용하면 DCS 이벤트 로그의 문제를 정량적으로 분석할 수 있습니다. 알람 설정 조정 및 작업 순서 조정으로 번갈아 분석함으로써 운영 효율성을 지속적으로 향상시킬 수 있습니다.

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  • CENTUM VP

    CENTUM VP는 HMI(Human Machine Interface), FCS(Field Control Stations), 제어 네트워크(Control Network)로 구성된 단순하고 일반적인 아키텍처를 가지고 있습니다.

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  • Plant Resource Manager (PRM)

    신뢰성 높고 안정적인 플랜트 운영을 위해 설비를 제대로 관리하고 계신가요? PRM은 플랜트 수명 주기 전반에 걸쳐 유지보수 계획의 품질을 개선하고 유지보수 비용을 최적화하는 데 기여합니다.

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  • SIS (Up to SIL 3) ProSafe-RS

    ProSafe-RS는 IEC 61508에 명시된 SIL(Safety Integrity Level) 3을 충족하는 것으로 독일 인증 기관(TÜV)의 인증을 받은 안전 계측 시스템입니다.

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  • 필드 업그레이드

    요꼬가와의 전문가들은 필드 업그레이드 과정의 모든 단계에서 경험이 있습니다. 요꼬가와는 컨설팅 서비스를 통해 최적의 마이그레이션 및 업그레이드 전략을 수립 할 수 있습니다.

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  • Safety Instrumented System (SIS)

    안전 계장 시스템(SIS)은 사람, 환경 및 자산을 보호합니다. Yokogawa의 SIS 및 관련 안전 솔루션은 비상 정지, 화재 및 가스, 버너 관리 및 HIPPS 애플리케이션에 널리 사용됩니다.

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