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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.