Fuel Gas HDS Plant – Control Loops Tuning

Fuel Gas HDS Plant – Control Loops Tuning

The Fuel Gas HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.

Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning

Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..

The control performance is calculated and presented using two indices:

1.      Process value Standard Deviation (STD)

and

2. Process Value Travel Index (Process travel)

Benefits:
Significant improvements were observed in the Standard Deviation of the control loops (>12 fold) and in the control valve travel (>175 fold!).

Economic indexes were not calculated.

Kerosene HDS Plant – Control Loops Tuning

Kerosene HDS Plant – Control Loops Tuning

The Kerosene HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.

Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning

Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..

The control performance is calculated and presented using two indices:

1.      Process value Standard Deviation (STD)

and

2. Process Value Travel Index (Process travel)

Among other things:

  • Top Reflux valve was identified as “Sticky” and had been mended.
  • Instrumentation ranges changed to give true and effective ranges of operation.
  • Change logic of Reflux operation to “Reflux Ratio” to better follow changes in plants throughput.

Gasoline HDS Plant – Control Loops Tuning

Gasoline HDS Plant – Control Loops Tuning

The Gasoline HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.

Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning

Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..

The control performance is calculated and presented using two indices:

1.      Process value Standard Deviation (STD)

and

2. Process Value Travel Index (Process travel)

Economical Benefits:
The improvement of temperature control in the column TOP TEMP only, brought savings of nearly 1 Million $/Year by reducing product RVP and savings in steam due to better temperature control and reduction in the reflux.

Project Documentation

Gasoline HDS Plant – Control Loops Tuning

Gasoline HDS Tuning Report

Steam Saving in a Turbo Compressor Operation

Steam Saving in a Turbo Compressor Operation

In the process of performance checking for a refinery we came across a turbo compressor that, apparently, operated in a very un economically way.

Careful checking was needed to assure our first observation until the decision was taken to change the machine setting which was made when the plant was commissioned by the vendor rep. some years before.

Keeping the same rate of production, the steam consumption dropped to less than 3/4 from is previous one and the machine speed dropped more than 5%.

The immediate savings from steam only, at the project time, estimated in more than 1.5 MM$/Year.

PetroMetriX – NIR Analyzers Applications

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PetroMetriX – NIR Analyzers Applications

Process Design & Implementation of NIR Analysis Technology based on our experience with Real Time / In Line process analyzers.

Besides supporting design marketing and implementation we also participated in the systems’ running in.

Among our (mutual) clients were: Haifa Oil Refinery (ORL), Ashdod Oil Refinery, CaOl, Gadiv, PDVSA and Valcor (Venezuela).

 

Projects Documentation

Use Telecommunications for Real time Process Control
Use of NIR Technology as Applied to Steam Cracker Monitoring and Optimization

pH Control

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pH Control

pH control is considered by the majority of Process Control Experts as the most difficult one topic control job.

Careful study the unique situation in each project together with cautious implementation of advance process control techniques brings excellent results to the full satisfaction of the projects’ goals.

pH control is found in Processes, in effluent treatment plants in scrubbers and more.

Wet Scrubber Process Control

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Wet Scrubber Process Control

Wet Scrubbing plays important role in Gas Cleaning operations.

As such it is widely used where gases that are released to the atmosphere have to meet the environment standards.

In the DSW case we had to take care of the brine collected at the system bottom to meet the required pH values as well to be suitable to be released to the sewage.

In refining projects, sour gases were treated to reduce the sulfur content down to acceptable levels.