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

Map Ta Phut Olefins Company Limited logo
下載 (223 KB)

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

 

產業別

相關產品&解決方案

CENTUM VP

CENTUM VP有一個簡單而通用的結構,包括人機界面、現場控制站和控制網絡。

SIS (SIL3認證) ProSafe-RS

ProSafe-RS是獲得德國認證機構(TÜV)認證的安全儀表系統,符合IEC 61508中指定的安全完整性等級(SIL)3。它已經在2400多個項目中安裝使用,涵蓋從大型集成製程自動化項目到獨立解決方案等多種項目類型。

工廠資源管理系統(PRM)

工廠資源管理系統(PRM)是用於橫河電機資產卓越的一個關鍵平台。該平台旨在改進操作和維護,通製獲得更大的可預測性,使工廠資產的可靠性和可用性最大化。

警報分析(Exaplog)

新的Exaplog事件分析套裝軟體有助於定量分析DCS事件日誌中的問題。交替分析警報設定調整和操作序列調整,您可以不斷提高生產效率。

分散控制系統(DCS)

橫河電機的分散控制系統(DCS)實現了工業製程自動化控制,並增強了業務性能。超過10,000家工廠採用橫河DCS實現他們的生產目標。

安全儀表系統(SIS)

安全儀表系統(SIS)保護人員、環境和資產。橫河的安全管理系統及相關安全解決方案被廣泛應用於緊急停機、消防、燃氣和燃燒器管理及HIPPS系統中。

×

Have Questions?

Contact a Yokogawa Expert to learn how we can help you solve your challenges.

置頂