SimSci APC and Offsites Updates Rujun Li SimSci by Schneider Electric
SimSci APC SimSci APC is the next-gen APC to replace Connoisseur Updated, intuitive UI Streamlined workflow New functions and features SimSci APC release history 2014 2015 Will be released every 9-12 months
Director IronPython based script language Automation of control actions and tasks Pre- and post-process the data going in and out of the controller Turn on and off controller Switch controller modelset during transition
Subcontroller Improved operator ease of use while switching in & out of control point groups
Enhanced Trending Ability to deal with large gaps in data Improved ease of use due to synchronizing all trends during analysis Faster analysis by allowing complete flexibility of intermixed process variables and modeling residuals Enhanced future prediction
Easier and Faster Data Selection Model data selector Zooming and dragging data slice edge for fine tuning of the start/end point
Enhanced Import and Export Can import multiple and export Connoisseur and SimSci APC data files Can export tag data to csv files Can import and export controller modelsets Can import and export Connoisseur and SimSci APC controller files
SimSci APC Crude/Vacuum Unit APC Tom Kinney, Schneider Electric
Crude Unit Description & Operation Mid-continent US refinery 60,000 BPD Unit produces naphtha, kerosene, diesel, AGO/LVGO, and HVGO Operators face challenges keeping the unit stable with products on spec due to crude switches, and especially addition of various slop oils as charge every few days Atmospheric tower overhead condenser duty frequently limited Control engineering staff is limited to 2 engineers covering the entire refinery, which includes an FCC and a hydrocracker
Day 1 Diesel Control
Before and After: Naphtha 450 Lab Naphtha Endpoint 430 410 390 370 Deg F 350 330 Before After 310 290 270 250 25-Feb-15 7-Mar-15 17-Mar-15 27-Mar-15 6-Apr-15 16-Apr-15 26-Apr-15 6-May-15 16-May-15 26-May-15 5-Jun-15
Product Improvements Before Commission Benefit is about $875K per year After Commission Change Naphtha Lab EP (F) 347.5 366.2 N/A Std Dev (F) 8.5 6.3-26% Kero Lab Freeze Pt (F) -57.4-56.9 +0.5 Std Dev (%) 4.84 4.07-16% Diesel Lab T90 (F) 645.5 645.7 Std Dev (F) 4.4 3.4-23% Diesel Yield (%) 6.01 6.75 +0.74% Std Dev (%) 0.82 0.71-13%
Total Refinery Antwerp Upgrade Refinery Off-sites Cor Swart, Schneider Electric
Estimate Sizing of the TRA Tank Farm TANKS 200 Motor Operated Valves (MOV) 1500 Hand Operated Valves (with feedback) (OZV) 400 Hand Operated Valves (HOV) 5000 Control Valves 200 PUMPS 200 LINES 3200 LINE SEGMENTS 12000 LOADING ARMs (shiploading) 20 PIPELINES (External movements) 3
Off-sites Application at TRA 1 Oil Movement Management; 3000 Source/destinations, 30,000 line-ups and 200 movements active 2 Movement Automation System including TRA functions 3 Thermal Relieve and Anti-Contamination 4 Non-registered movements in the field 5 Key valve selection 6 Pump protection valve (PBV) 7 Dynamic isolation 8 Line-up generation and management 9 Blenders control (10 blenders : 2 crude, 2 gasoline, 2 Diesel, 1 fuel 3 Bitumen) 10 Jetty loading control 11 Tank Information System 12 Aspentech/Infoplus interface (bitumen blender and supervisory control for other blenders) 13 OPC with DCS 14 ODBC with ROMSS 15 Hand Held Terminal system interface 16 Business application interface (MPRO, SAP, ROLLS) 17 Order handling 18 Inventory control 19 Equipment management and traceability 20 Line-up maintenance
Reason to Execute Project Legacy Yokogawa not supported anymore Legacy system had no expansion capabilities anymore for near future refinery expansion DCS and off-sites were integrated and therefore both to be upgraded Requirement to have the migration to future system during normal operations with minimum disturbance Request for upgrade was put on the market Project awarded to SimSci by Schneider Electric in summer 2011
End Results System startup was smooth, without unexpected impact on the operation of the refinery Target of change over one day achieved Operators are happy with the delivered functionality, which is better than the previous system.