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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys.

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Presentation on theme: "© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys."— Presentation transcript:

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2 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Effective Utilization of RTO with APC, Planning and Scheduling - Asia Experience Session Name: SimSci-Esscor Solutions Session ID #: PBSS311 Junichi Watanabe Nov./10/2011

3 Slide 3 Agenda APAC RTO Projects Experience in last 10 years Some case studies of RTO (CDU, RFCC, CCR) Difficulties of Development and maintaining Utilization for RTO RTO with Production Planning/Scheduling

4 Slide 4 Invensys Enterprise Control Offerings Manufacturing / Production Operations Corporate Integration and Collaboration Platform Automation Invensys and Third Party Software Applications Invensys and Third Party Enterprise Control System IT Platform Corporate Systems

5 Slide 5 Integration & Collaboration Platform Enterprise Integration Workflow Open Device Integration Web Portal Application Toolkit Historian Third-Party Offerings Software Applications Execution Manufacturing Execution Systems Batch Enterprise Asset Management Mobile Workforce Management Performance Enterprise Manufacturing Intelligence Performance Measurement and Reporting VisualizationQuality Asset Performance Optimization Operator Training Design Advanced Process Control Simulation / Optimization Control DCSPACSCADAHMI Safety Safety Instrumented Systems General Purpose Safety Turbomachinery Control Measurement & Instrumentation Controllers Recorders Automation Software Applications Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System

6 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. APAC RTO Projects Experience in last 10 years

7 Slide 7 APAC Optimization Project Experience 40 Actual ROMeo Projects have been implemented in Asia since 2000 (Excluding feasibility study projects) Closed Loop : 18 Projects Open Loop : 13 Projects Planning : 3 Projects Performance Monitoring, Others : 6 Projects Total 10 engineers are RTO engineers in APAC (Japan, Korea, India, China, Thailand and Singapore)

8 Slide 8 RTO/Performance Monitoring Implemented in Japan Since Y2000 Idemitsu Chiba:Site Wide JX,Negishi: CDU, RFCC Idemitus Aichi: Utility, H2 JX Chita: H2 Management OPC : Ethylene JX Mizushima: Utility,CDU3,CDU2 Asahi Chemical : Ethylene Idemitsu Tokuyama : CDU, FCC Ethylene Idemitsu Hokkaido : H2 Management Showa Denko : Ethylene Refinery : 13 PetroChemical : 7

9 Slide 9 Real-Time Optimization (ROMeo, ARPM) Business in APAC Korea : HDO, SK, STC China : Petrochina Taiwan : FPCC Thailand : Thai Oil BCP,PTTGSP Malaysia : Petronas Singapore : SRC India : Reliance ASEAN India

10 Slide 10 APAC Optimization Project Experience 94% projects come from Refineries, Utility, Ethylene projects

11 Slide 11 APAC Optimization Project Experience CDU/VDU, FCC, Reformers, H2 management are majorities from Refineries projects

12 Slide 12 APAC Optimization Project Experience Closed loop projects are nearly half

13 Slide 13 APAC Optimization Project Experience ROMeo doesnt rely on APC package.

14 Slide 14 APAC Optimization Project Experience ROMeo dont rely on RTDBS

15 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Case Study CDU RTO SAT: 2007 Jun Closed Loop with DMC+

16 Slide 16 Heater Outlet Temp. No.3 Side Reflux flow Kero Stripping Steam Ratio kg/KL KL/H PV RTO Target APC controls to OPT targets Change of Optimization Variables (Independent Variables)

17 Slide 17 Cold Reflux Flow LGO Draw Flow Heater Inlet Temp. KL/H PV Predict All CVs move as predicted Change of Optimization Variables (Dependent Variables)

18 Slide 18 Time Benefit Crude Change APC Start Start RTO Set the base point when RTO started RTO Benefit After RTO Time Benefit Crude Change APC Start Before RTO Set the base point when APC made stable operation PI Data is used for evaluation How to Evaluate Benefit

19 Slide 19 Change of Benefit before/after RTO Before RTO (+287K Yen/day)After RTO (+2,362K Yen/day) After RTO, every case shows increasing benefit and above base

20 Slide 20 Change of Benefit before/after RTO Before RTO (+287K Yen/day) After RTO (+2,362K Yen/day After RTO, every case shows increasing benefit and above base Yearly Benefit = 493MYen/Year (2, )KYen/Day×0.72 Run Time %

21 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Case Study RFCC RTO SAT: 2010 Jun Closed Loop with RMPCT

22 Slide 22 RFCC Feed Modeling

23 Slide 23 RFCC Modeling (Rx/Rg)

24 Slide 24 RFCC Optimization Variables

25 Slide 25 Test Data: (MVPC + RTO) Vs MVPC Only June 2010

26 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Case Study CCR/BTX RTO SAT: 2008 May Closed Loop with SMOC

27 Slide 27 Real-Time Optimizer Scope Kerosene ( 113,000 T/Y) ( 364,000 T/Y) Propane Butane Naphtha B - C Crude #2 LER #2 C D U LPG Naph Kero Gas Oil Benzene P-Xylene #1 Naph AR to VDU/DCU AR #2 NHT Gas Oil #2 LMX #2 PLT BTX #1 KGHT #1 KHT #3 GHT ( 3%) ( 20%) ( 17%) ( 20%) ( 40%) #2 GHT #1 Gas oil

28 Slide 28 No.UnitDescriptionUOM 1 #2 NHT Naphtha Splitter Heavy Naphtha Dist.5% (RQE) DEG C 2 #2 NHT Naphtha Splitter Naphtha SPLITTER REFLUX FLOWM3/HR 3 #2 NHT Naphtha Splitter #2 NHT FEED FLOWM3/HR 4 #2 NHT Naphtha Splitter Naphtha Stripper REFLUX FLOWM3/HR 5 #2 PLAT Reactor #2 PLAT FEED FLOWM3/HR 6 #2 PLAT Reactor #2 PLAT REATOR WAITDEG C 7 #2 PLAT Reactor H2/HC Mole Ratio- * BTX section considered as constraints Optimization Points

29 Slide 29 BZ P-X NSP #2NHT BTX #2PLT #2CDU REF-SIM for PLT Reactor Model Use NIR data For Feed comp. Scope for Online model OFF NIR Only for Simulations Current Online model (using NIR for feeds)

30 Slide 30 BZ P-X NSP #2NHT BTX #2PLT #2CDU REF-SIM NIR OFF HN5% HN FEED T/N FEED RXWAIT R/N FEED FIXED SRN Feed L/N Main Benefit Points * Found extra space for BZ product with maximizing P-X Product

31 Slide 31 >> Decreasing 3.3% of Feed SRN [ Saving Operation cost ) >> Increasing 3% of BZ ( Fixed P-X Product ] Price Y2008Price Y2007Price Y2006 Average (Y2006-Y2008) Estimated Profit 1.2 Million1.7 Million1.0 Million1.3 Million Profit Estimation

32 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Difficulties of Development and Maintaining Utilization for RTO

33 Slide 33 Difficulties for CDU RTO Based on our Experience

34 Slide 34 Difficulties for RFCC and CCR/BTX RTO Based on our Experience

35 Slide 35 Importance for Utilization of RTO

36 Slide 36 Monitoring System Example Summary Screen Calculation Successful rate Optimization Status Optimization Variables Information Optimization Variables Information Economic Effects Reflection Rate Data handling Successful Rate Data REC Successful Rate Optimization Successful Rate Optimization Variables Names Study Low Limit High Limit Optimization Value Operation Value

37 Slide 37 Constraints Variables Screen Calculation Successful Rate Optimization Status Constraints Variable Information Constraints Variables Name The ratio of constraints hit Check Low Limit High Limit Optimization Value Operation Data

38 © 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. RTO with Production Planning/Scheduling The linkage between RTO and Planning/Scheduling is very important

39 Slide 39 Operation Cycle in Refinery Investment plan (Long term Plan) 3 Month Plan (Mid term) 1 Month Plan (Short term) Operation Guide/Instruction (Weekly) Control Logistics Control Tank Inventory RTO (ROMeo for Planning) Crude Selection Demand/Sales/Supply Exchange APC RTO (ROMeo) Performance Monitor Refinery Planning/Schedule HQ Planning/Sales Operation Process Design Improvement Bottle neck RTO (ROMeo for Analysis and case studies) Technical Product Storage Crude StorageCrude Tanker

40 Slide 40 Operation in Refinery One Month (Planning/Schedule (1)) 1 Month Plan (Short term) Operation Guide/Instruction (Weekly) Control Logistics Control Tank Inventory RTO (ROMeo for planning) Demand/Sales/Supply Exchange APC RTO (ROMeo) Performance Monitor Refinery Planning/Schedule HQ Planning/Sales Import Products Crude Storage Product Storage Crude schedule is already fixed Operation Export Products Blending and Shipping

41 Slide 41 Typical Production Planning/Scheduling Work 1 Month Plan (Short term) Operation Guide/Instruction (Weekly) Control Logistics Control Tank Inventory Demand/Sales/Supply Exchange Purchase/Sale Intermediate product Refinery Planning/Schedule HQ Planning/Sales Day A,B…: Crude Type One Month Operation plan is prepared by LP assuming one month mixed average Crude or Crude tank by tank with respecting Tank Inventory as constraint Scheduler decides Operation targets such as Cut point, Unit feed rate to meet the daily operation is as similar as One month planning by Daily bases Operation Instruction

42 Slide 42 Relation between RTO and Planning/Scheduling Day Planning/Scheduling Refinery Wide ROMeo RTO Unit RTO Shift Vector Opt. Yield Price Info Logistic Constraints Rigorous Marginal Price Continuously Maximizing Benefit

43 Slide 43 Thank You (

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