Refining

• CENTUM CS 3000 plays key role in Malaysian waste oil to diesel project.
• Yokogawa proposed to provide its systems and services as the main instrument vendor.

Yokogawa provided a Dynamic Real-Time Optimizer (RT-OP) to optimize the operations of the hydrocracker unit at Aramco Riyadh Refinery.
By dynamically calculating optimal setpoints, the RT-OP optimizes operations beyond the APC system.

• To replace the existing CENTUM XL control station with the latest Yokogawa CS 3000 hardware and upgrade the control network.
• The plan was to minimize plant downtime by doing a hot cutover from the old to the new control system.

• This has considerably improved the safety, quality, and efficiency of off-site operations.
• Yokogawa was the clear choice for installation of the OMS.

• Smooth and safe switchover to the new system
• Easy-to-use, easy-to-engineer system, plus various post-installation enhancements
• Tuned controllers for smooth plant operation and better traceability of process upsets
• Various other improvements thanks to advanced process control and MVC implementation

• Exapilot was introduced to maximize operational efficiency at an experimental refining facility.
• To prevent operator errors, it was essential to standardize operating procedures.

• Flawless refinery start-up assured by operator training simulator.
• The virtual test function of the OmegaLand simulator created the same environments as CENTUM CS 3000.

• Computerized Maintenance Management System by PRM and SAP Schedules Field Instrumentation Maintenance.
• The frame applications and DTMs support the preventive maintenance strategy with self-diagnostic and condition monitoring.

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.

• To decrease downtime and maintenance costs, the decision was made to introduce Yokogawa's CENTUM DCS.
• With well-experienced MAC approach, Yokogawa replaced successfully legacy DCS.

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.

• Successful migration of in-line blending distributed control and oil movement systems.
• To minimize operator intervention and to keep the product properties on specification.

• Smooth project execution with no schedule and/minimal safety incidents.
• Easy to use, easy to reconfigure interface that has resulted in numerous post-installation enhancements.
• Minimizing day-to-day plant operation problems including reducing the alarming factor.

• The project goals emphasized schedule, quality, cost and safety.
• More than 40 sub-system interface cards are utilized for b14 partners company7s system integrated with CENTUM CS 3000.

• Integrated CENTUM VP and ProSafe-RS Systems Ensure Nonstop Operation of ADU/DKU Processes.
• "This is a real VigilantPlant! We will continue to improve our production efficiency."

• Exapilot contributes to safety, reduces cost, and retains operational know-how.

• Using the CENTUM CS 3000 system, many kinds of plant key performance indexes are calculated and analyzed to produce further improvements.
• During plant start-up, PRM helps the customer's engineers perform all the loop checks.

• The AR1 refinery recently replaced its legacy DCS with Yokogawa's CENTUM CS 3000.
• Achieving an Intelligent Oil Management System.

• Exapilot smoothly starts up and shuts down the world's biggest experimental distillation unit.
• Data visualization is the key, giving operators a complete understanding of what is is going on in the process, in real time.

• HMEL selected an integrated solution from Yokogawa
• Yokogawa India oversaw and implemented the engineering, installation, and commissioning of the refinery

BASF Schwarzheide GmbH selected Yokogawa's Cavitation Detection System to detect pump cavitation at an early stage.
The Cavitation Detection System catches minute pressure fluctuations generated by low cavitation; problems are recognized before vibration occurs.

• This is the first project in which Shell Global Solutions US has used a contractor outside of Shell for its Advanced Process Control implementation
• The post implementation study shows that the overall Delayed Coker APC controller returns a benefit which is almost three times the original promise.

• CACT Offshore platform reduces unplanned downtime by migrating from Legacy PLC System to reliable CENTUM CS 3000.
• It is possible for CACT engineers to modify the system configuration, download software updates, and hot-swap I/O cards while the process control system is online.

• The Advanced Process Control application on the GOHT unit helped control the plant with less variation during Coker drum switch and with less operator interactions and minimized giveaway.
• A post-implementation study estimated that the overall GOHT Unit APC controller returns a savings about 198% greater than the originally estimated.

• CENTUM CS 3000 and Exaquantum PIMS improve production efficiency at Chinese synthetic rubber plant.
• Exaquantum provides data on long-term trends needed to make improvements to plant processes.

• Yokogawa successfully carried out the upgrade of off-site system in a 48 hour shutdown period with Seibu Oil.
• Control room design for HSE and smooth communication contributes to the operational efficiency and safety.

PhenoVista Biosciences is the leading provider of custom, imaging-based, phenotypic assay services. With a collaborative and scientifically driven project design and management approach, PhenoVista has a proven track record of delivering high-quality data from robust and scalable assays. PhenoVista’s key advantage lies in the ability of their industry-trained scientists to combine world-class understanding of diverse biological systems with cutting-edge quantitative imaging to deliver clear, actionable output data.

An in-situ TDLS8000 installed on a process leg or bypass stream provides a reliable and high-speed measurement that is representative of the process composition.

VOC (Volatile Organic Compounds) are compounds that evaporate easily at room temperature. They generate photochemical oxidants and cause soil and water pollution.
 

Conductivity measurement can be used as a reliable indicator of the real-time brine concentration. Using an online process analyzer removes the need for timely grab sample analysis. 

APPFs consist of various software components in which an autonomous controller can perform control functions without writing custom code. A true turnkey solution.

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.

Enhance the efficiency and safety of your vapor recovery systems and flare/vent headers with Yokogawa's cutting-edge Tunable Diode Laser Spectrometers – the TDLS8000 and TDLS8220. Elevate your oxygen measurement capabilities with our interference-free analyzers, providing direct measurements. Experience unparalleled reliability, ensuring minimal upkeep and secure operations without the need for system shutdowns.

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.

Ideal for various tank and vessel level measurements, diaphragm seal systems with compensating capillaries set a new standard for high performance, safety, and reliability.

The Yokogawa DTSX1 Fiber Optic Heat Detector protects your equipment against abnormal heat events while being more affordable than other heat detection solutions.

Fired heaters are used for various processes in oil refining and petrochemical plants.

Heat exchangers are devices that provide the flow of thermal energy between two or more fluids at different temperatures. Heat exchangers are used in a wide variety of applications. These include power production; process, chemical and food industries; electronics; environmental engineering; waste heat recovery; manufacturing industry; and air-conditioning, refrigeration, and space applications. Yokogawa offers a means to control heat exchanger leakage and prevent costly maintenance, repair and downtime with an easy-to-use, virtually maintenance-free condensate conductivity measurement method.

Storage tanks are used in a variety of industries ranging from holding crude oil to holding feedstock for vinyl chloride monomer (VCM).

Wireless temperature measurement solution makes modernizing operations and maintenance of delayed coker unit affordable.

Challenges

• The distance is not so long, but there are many pipes and tanks ("Pipe Jungle") in the field.
• Had to avoid the obstacles and take care multi path condition.  

Solution

Repeater is installed on high place between control room and monitor position. The extend cable is used for antenna of Gateway.

• Temperature Transmitter (YTA) x1, Pressure Transmitter (EJX) x2

Ion Exchange is a method for the exchange of ions between two electrolytes or between an electrolyte solution and a complex molecule. In most cases the term is used to denote the processes of purification, separation, and decontamination of aqueous and other ion-containing solutions with solid polymeric or mineralic ion exchangers.

Fast online gas chromatograph (GC) analysis for LPG distillation. The analytical upgrade project with process GCs was a complete success.

NH₃ injection lowers NOx in stack flue gas, boosts dust collection efficiency, and prevents erosion. Precise measurement and control of NH₃ are crucial to avoid excess use, which increases costs and causes odors. The TDLS8000 solves these issues with direct measurement for effective NH₃ management.

The U.S. refineries represent approximately 23 percent of the world's petroleum production, and the United States has the largest refining capacity in the world. Petroleum refining is an industry, which is undergoing intense amounts of scrutiny in the United States from regulatory agencies and environmental groups.

Yokogawa's Data Aquisition Temperature Uniformity Survey enable heat-treaters to produce accurate records of TUS, instrumentation and thermocouple calibration certificates.

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.

In this eBook we explain how to improve fired heaters safety & efficiency by controlling combustion using TDLS technology. Download it now and learn:

• The 4 top industry challenges related to fired heaters
• How to efficiently and safely manage combustion
• How TDLS technology can improve operational excellence in fired heaters

Download this eBook and learn:

• The top challenges that drive reinstrumentation
• How to plan for and achieve a successful project
• Best practices in identifying your project scope
• 5 ways to improve operator effectiveness
• Different scenarios and best practices for updating, migrating or replacing process controls, safety systems, and instrumentation in plants

A Basic Guide to Accurate & Reliable Flow Measurement.

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.

Smart devices, like Yokogawa’s line of Total Insight transmitters and flowmeters contribute to Digital Transformation during operations and throughout the lifecycle of the instrument.

Rohm and Haas Company is one of the world's largest manufacturers of specialty materials, including adhesives, sealants, coatings, monomers, electronic materials, inorganic and specialty solutions, and ion exchange resins. Founded in 1909 by two German entrepreneurs, Rohm and Haas has grown to approximately $6 billion in annual revenues.

Alarm management is not just a project that has a start and end date; it's a continuous cycle. Once the alarm system has been reviewed and improvements have been identified, we must check that controls are in place to ensure the alarm system remains functional. The key is to ensure that the system is continuously monitored and any changes are fully documented. There are seven key steps for alarm management. Rationalization is one of those critical steps.

This paper shows how to improve distillation operations by focusing on procedure automation. It will review the importance of using procedures in distillation operations and highlights the collaboration work underway between Fractionation Research Inc. (FRI) and Yokogawa Corporation to improve procedural operations.

The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.

In ARC's view, customers need a compelling business value proposition to justify investment in any kind of automation. Vigilance and VigilantPlant were created with this in mind. Yokogawa's vision with VigilantPlant is to create an environment where plant personnel and operators are well informed, alert, and ready to take action. 

Environmental pollution caused by volatile organic compounds (VOCs) has become a global environment issue, including issues on effects upon health. This paper introduces a system based on detection and sampling technologies and developed for measuring goes in the global environment. Small amounts of VOCs are measured with a gas chromatograph or photoionization detector (PID). VOCs in water are sampled using a sparging method. A small quantity of VOC constituents of more than 20 different types can be measured with a gas chromatograph using a programmed temperature oven. The PID can detect a ppb level of VOCs that are ionized using a vacuum ultraviolet radiation lamp. We expect these devices will be useful for improving the global Environment.

With fired heaters, users hope to get greater efficiency and reduced emissions but often are disappointed. Given the number of fired heaters operating every day and their importance in the process industries, any improvements realized across the board will have huge impacts. More units can reach their potential with some simple changes in work practices and technology upgrades.

Migration of a refinery's DCS provided an opportunity to reconfigure and consolidate the control rooms and operational management system.

July 2011

Process plants are run according to operational procedures. These procedures consist of a set of tasks that are executed in a consistent manner to achieve a specific objective, such as starting up, shutting down or transitioning a unit as part of making a product. 

April/May 2007

A Yokogawa ProSafe-RS safety instrumented system (SIS) will be the nucleus of a new fire and gas safety system at Shell's Clyde (NSW) refinery. The contract includes the control system, system engineering and installation and supervision.

Process automation in oil refineries is undergoing major changes, driven by customers frustrated by what they consider to be slow and incremental advances from the main automation original equipment manufacturers (OEMs) in the industry. ExxonMobil has become a de facto industry representative and is driving vendors like Yokogawa and others to reevaluate how large-scale automation projects are implemented.

Using wireless technology for monitoring a variety of measuring points in Industrial Plants has becoming a very attractive choice for plant managers. Today, the plant manager is able to build a quick and cost effective network solution to enable flexible information acquisition and to improve maintenance efficiency and safety.

Vibrating element (VBE) type gas measurement devices measure refinery reformer stream compositions, power generator hydrogen purity, centripetal compressor gas inputs, process heater fuel gas quality, and others in multiple process control environments.

Visual MESA Systems empower improved operational efficiencies in real time

CONTROL, January 2013

Standard Automation Methodology Improves Operations and Prevents Incidents by Enabling the Sharing of Best Practices Among Operators.

ARC believes that by implementing procedural automation, many process plants can minimize variability to help ensure smooth, efficient, and safe state transitions.

The global refining industry is constantly evolving and responding to new crude supplies and sources, more stringent fuel/product specifications, perpetually changing demand patterns and other global and regional trends. Increased competition from large, efficient refineries is forcing small- to mid-sized refiners to rethink their strategies to remain competitive.

Increasing oil prices are reducing the relative feedstock and energy costs advantages refiners and petrochemicals producers have recently enjoyed. Allied with the high cost and growing scarcity of skilled staff, a fundamental shift in mindset towards plant operations and maintenance is required to assure organizational resilience. Therefore, the desire to achieve enhanced cost structures through innovation in operating models and digitalization has intensified.

Adding process considerations improves energy savings and production performance.

Hydrocarbon Processing article discussing tunable diode laser (TDLS) gas analysis for combustion management in fired heaters | June 2015.

Optimizing the maintenance cycle is not always straightforward. In some cases, cleaning once a week is sufficient and other processes may require every 8 hours.

Select the correct pH glass and reference type to improve your pH sensor lifetime and you can limit or even eliminate the effects of temperature and pressure on especially the reference sensor.

The lifetime of a pH sensor has a significant impact on the overall annual costs of a pH measuring loop. Optimizing four key factors will decrease these costs and optimize process control and overall plant efficiency.

Learning these four lessons will help you improve your engineering skills and most importantly extend the life of your pH sensors.

The YSS1000 setting software (hereinafter referred to as the YSS1000) is package software to configure the functions of the YS1000 series (hereinafter referred to as the YS1000) devices. Writing and reading of parameters and user programs of the YS1000, and PID tuning and monitoring of user programs can be performed through the use of communication.

Yokogawa programs each oven to suit one or multiple process samples via its main components (sets of valves, columns, and detectors explicitly designed to the customer's application), and the combination of which is based on the chemical properties of all or some of the components in the specific gas mixture.

The GC8000 has an innovative predictive diagnostics; Virtual Tech, package built in to help keep the unit operating at peak performance. A number of Key Performance Indicators (KPI) are monitored during every analysis to verify the analyzer is operating within proper tolerances. The data monitored includes: Chromatogram Shape, Peak Data, Valve Data, Detector Data, Oven Performance Data

The GC8000 has a built-in 12-inch color touch screen display that dramatically simplifies maintenance. At the touch of the screen, the technician can access all of the analytical parameters and measurement results; displayed in easy-to-understand graphical color screens.

The GC8000 is a process analyzer that uses gas chromatography to measure the composition of multiple components in a stream. Engineered with reliable electronics and intelligently designed columns and valves, the GC8000 improves ease of maintenance while reducing operating costs. Its intuitive touchscreen HMI with system diagnostics reduces operation and maintenance headaches, maximizing measurement accuracy, reliability, and uptime. More Information

How much do you know about pressure transmitters? Are you accurately, quickly and reliably measuring pressure? Ultimately, the drive of any good pressure transmitter is to get an accurate, reliable pressure measurement to the data user quickly. This video gives you the answers to your basic questions about pressure and pressure transmitters.

Fired heaters are the largest energy consumer in the manufacturing sector and represent a tremendous opportunity for energy savings. However, energy efficiency is not the only concern for fired heaters. Compliance and safety are continuous challenges.

In this one-hour presentation, we will discuss:

• How to improve fired heater safety and efficiency by controlling combustion using Tunable Diode Laser Spectrometers (TDLS) technology
• The 4 top industry challenges related to fired heaters
• How to efficiently and safely manage combustion
• How TDLS technology can improve operational excellence in fired heaters

In this webinar, we will:

• Share best practices for monitoring, recording, and transferring data 
• Challenges in data acquisition and how Yokogawa can help
• Demonstrate GA10 Data Logging Software capabilities

Sample systems are a crucial component of and have a significant impact on the performance of a process gas chromatograph analyzer. When working on sample systems, you must have a constant awareness of time delays. This fundamentals webinar will take the mystery out of lag times.