Rujun Li

SimSci by Schneider Electric

SimSci APC and OffsitesUpdates

●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

SimSci APC

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 APCCrude/Vacuum Unit APC

Tom Kinney, Schneider Electric

●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

Crude Unit Description & Operation

Day 1 Diesel Control

250

270

290

310

330

350

370

390

410

430

450

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

Deg

F

Lab Naphtha Endpoint

Before

After

Before and After: Naphtha

Benefit is about $875K per year

Product Improvements

Before Commission

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 AntwerpUpgrade Refinery Off-sites

Cor Swart, Schneider Electric

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

Estimate Sizing of the TRA Tank Farm

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

Off-sites Application at TRA

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.