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Revision History
Revision
Date
Prepared
Checked
Approved
0.0
15 Dec 13
Anjan K Datta
Seyed Masood A
Rohit Ravichandran
Anjan K Datta
Anil Dutt
1.0
30 Dec 13
Anjan K Datta
Seyed Masood A
Rohit Ravichandran
Anjan K Datta
Anil Dutt
2.0
15 Apr 14
Anjan K Datta
Seyed Masood A
Rohit Ravichandran
Anjan K Datta
Anil Dutt
3.0
12 May 14
Anjan K Datta
Seyed Masood A
Anjan K Datta
Anil Dutt
Confidential
Contents
1.0
2.0
3.0
3.1
3.2
3.3
DHT ................................................................................................................................... 8
3.4
3.5
3.6
4.0
Confidential
5.3.6 EXCESS AIR MINIMIZATION IN HCR FRACTIONATOR HEATER & DHT REBOILER
FURNACES (WITHIN ALLOWABLE RANGE) ................................................................................... 23
5.3.7 CONTROL & OPTIMIZATION OF GAS-TO-OIL RATIO IN HCR 1ST STAGE (WITHIN
ALLOWABLE RANGE) .................................................................................................................... 24
5.4 TOTAL EXPECTED APC BENEFIT ........................................................................................... 26
5.4.1 TOTAL EXPECTED APC BENEFIT IN HCR-DHT SECTION .................................................. 26
8.2
8.3
PRETEST ........................................................................................................................... 34
8.4
STEPTEST .......................................................................................................................... 35
8.5
ENGINEERING ................................................................................................................... 35
8.6
COMMISSIONING .............................................................................................................. 36
8.7
8.8
POST-AUDIT ..................................................................................................................... 36
9.0
10.0
Confidential
1.0
The Scoping Study was carried out with the objective of finding various benefits
that can be derived by application of APC technology, hardware and software
requirement for APC implementation, and additional instrumentation and hardware
requirement in order to get the projected benefits from APC. In this connection,
YIL engineers visited BORLs Bina Refinery from 15th November to 23rd
November of 2013. BORL presented the description, operational strategies and
control objectives of both the process. Operating manuals, DCS Screenshots, and
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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Page 1
PFD/P&ID were provided and opportunity was given to know the present state of
the basic regulatory control system. In addition to the Process and Instrumentation
Review, a detailed analysis of Process and Laboratory data over the period of 1st
June 2013 to 30th October 2013 was conducted to establish a baseline performance
of existing process control system and estimate the performance improvement
benefit that can be expected from APC.
Acknowledgements:
We express our sincere thanks to the excellent support extended by BORLs
Managers, Engineers and Technicians in providing the inputs required for this
study. Their contribution and commitment has helped us gain the understanding
necessary for preparing this Report within the stipulated period. Special thanks to
the Technical Services Group for arranging the meetings with Process and
Operations groups which has enabled us to understand the process and operating
constraints.
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2.0
Executive Summary
YIL is pleased to present the Scoping Study report to BORL describing in detail the
benefits of implementing Advance Process Control in the HCU, DHT units,
including the hardware and software requirements. Through this study, it has been
found that these two units are prime candidates for APC implementation. APC can
not only stabilize the plant operation but also result in an increase in the yields of
valuable products and decrease in the energy costs.
Although the scope of the study initially included only HCU, the HCU & DHT
units at BORL-Bina are highly interlinked. The lighter and Naphtha products from
both units are combined before separation into OFF gas, LPG, Light Naphtha and
Heavy Naphtha in a common Light End Recovery section. Similarly, KERO
products of HCU & DHT are combined, and HCU Diesel is further blended with
part of the common KERO and Heavy Naphtha streams. The light gases from both
units feed single recycle gas compressor and a PSA unit. The compressed recycle
gas and make-up gas header is also connected to both units. If we consider Gas-toOil Ratio control or optimization in HCU, then Gas-to-Oil Ratio in DHT is to be
considered as constraint. Hence, this report presents benefits achievable for HCU &
DHT together.
Many different areas where APC can result in more stable plant operation,
increased yields of valuable products or enhance energy savings were identified. At
the same time, required changes in hardware, addition of instruments or some
existing process problems have also been identified and provided inside this Report.
These are to be attended before APC implementation. A brief highlight of the
present study is as follows:
APC will consistently maintain the RCAT (or Volume Average Bed
Temperature of each reactor) and STGCAT (Volume Average Bed Temperature
of a Stage) in HCR 1st & 2nd Stage reactors. Apart from this, APC will maintain
Maximum Bed Temperature and Delta Bed Temperature of each bed and Outlet
Temperature for all the reactors.
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Yields of valuable products such as Liquefied Petroleum Gas (LPG) and Diesel
(both HCR & DHT Diesel) will be increased while yields of Naphtha and
Kerosene will be decreased by APC through adjustments of product cuts and
other operating conditions in the HCR & DHT Strippers & Fractionators,
Deethanizer, Sponge Absorber and Debutanizer columns so that quality
giveaway is minimized. In order to realize these product yield benefits,
daily-basis Density & ASTM distillation data of Diesel & KERO and Flash
Point data of KERO at the HCR & DHT Fractionator product ends (before
any mixing) will be needed (in addition to the existing data of final
products). Furthermore, the VFD AC fans at the top of HCR & DHT
Strippers and DHT Fractionator are to be made available for manipulation
by APC, and flow meters (preferably with Flow Control Valves) are to be
provided in HN & KERO line to HCR Blend.
APC will manipulate the heavy Diesel Pump-Around circuit return temperature
in order to maximize MP steam generation that happens in the same PumpAround circuit.
APC will manipulate the FD fan inlet damper opening and cold air dampers to
HCR Fractionator Heater and DHT Reboiler Furnaces in order to minimize
Excess Air within allowable ranges.
APC will maintain HCR 1st & 2nd Stage HCR Reactors Furnace Heater
temperature difference while trying to increase in the heat recovery in the
Feed/Effluent exchangers. However, F/E Heat Recovery will be considered
unrealizable unless the ranges of Furnace temperature differences under
APC control are set around the average values under DCS control.
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For the HCU & DHT units, the minimum expected total APC benefit at the
average total throughput of 475 MT/hr or 538 m3/hr is estimated as:
o 2.49 Crore Rs/Yr or 1.53 Cent/Barrel (When F/E Heat Recovery is not
realized)
o 2.78 Crore Rs/Yr or 1.71 Cent/Barrel (When F/E Heat Recovery is
realized)
The tangible APC benefit would be much more since the increases in the LPG yield
by pulling from Light Naphtha could not be added to the above benefit figure.
Similarly, increase of HCR & DHT Diesel by pulling from Kerosene cannot be
added to the above benefit figure.
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3.0
then in a natural convection Furnace (FF101). Then, it passes through three reactors.
Reactor 1 (RB101) has two beds with Quench gas injection in between the beds. Reactors 2
& 3 (RB102 & RB103) has two beds each with Quench gas injections at inlet and in
between the beds. 1st Stage Reactor effluent releases heat subsequently to DHT Feed
(EE107), HCR 1st Stage Feed (EE105), HCR Stripper Bottom (EE108) and an MP steam
Generator (EE109).
Reactor effluent then flashes in HCR 1st Stage HHPS (VV102). Liquid from HCR 1st Stage
HHPS passes through pressure reducing valves and joins with HCR 2nd Stage HHPS liquid.
This is then flashed in HCR HLPS (VV103). Liquid from HCR HLPS and HCR CLPS
goes to HCR Stripper (CC501) that uses MP stripping steam. HCR Stripper bottom is
finally heated in a Furnace (FF501) and fed to the HCR Fractionator (CC502), which
produces Naphtha at top. KERO (Kerosene), LD (Light Diesel) and HD (Heavy Diesel) are
withdrawn as side products through respective side strippers. The Fractionator uses LP
stripping steam at bottom and two pump-around loops (e.g., LD & HD pump-around
loops). HD pump around is used to generate MP steam in EE512.
3.2 HCR 2nd Stage
HCR Fractionator bottom is fed to the HCR 2nd Stage Feed Surge Drum, from where it is
pumped out and mixed with 2nd Stage Feed Gas coming from Recycle Gas Header. The
combined feed is heated in the 2nd Stage F/E Exchanger and then in a natural convection
Furnace (FF201). Then, it passes through two reactors. Reactor 1 (RB201) has two beds
with Quench gas injection in between the beds. Reactor 2 (RB202) has only one bed with
Quench gas injections at inlet. 1st Stage Reactor effluent releases heat subsequently to HCR
2nd Stage Feed (EE201) and HCR Stripper Bottom (EE202A/B).
Reactor effluent then flashes in HCR 2nd Stage HHPS (VV202). Liquid from HCR 2nd
Stage HHPS passes through pressure reducing valves and joins with HCR 1st Stage HHPS
liquid before being flashed in HCR HLPS (VV103).
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3.3 DHT
The feed after preheating in Process Heat Exchangers is sent to DHT Feed Surge Drum,
from where it is pumped out and mixed with the DHT Feed gas coming from 2nd Stage
HHPS (VV202). The combined feed is heated in the DHT F/E Exchanger (EE304A/B) and
then in 1st Stage Reactor Effluent / DHT Feed Exchanger (EE107). Then, it passes through
the single Reactor (RB301) that has three beds with Quench gas injection at inlet and in
between the beds. DHT Reactor effluent releases heat subsequently to DHT Feed
(EE304A/B) and feed gas to 2nd Stage (EE305).
Reactor effluent then flashes in DHT HHPS (VV302). Liquid from DHT HHPS passes
through pressure reducing valves and then flashed in DHT HLPS (VV303). Liquid from
DHT HLPS goes to DHT Stripper (CC701) that uses MP stripping steam. DHT Stripper
bottom is heated by the DHT Fractionator bottom (EE702) and fed to the DHT Fractionator
(CC702), which produces Naphtha at top. KERO (Kerosene) is withdrawn as side products
through a side stripper. Part of the Fractionator bottom is heated in a Furnace (FF701) and
sent back to the Fractionator column. The remaining part of DHT Fractionator bottom is
sent to storage via a LP steam generator (EE704) and cooler.
HCR Heavy Diesel combines with HCR Light Diesel. Small amount of KERO, HN &
UCO are also added to the HCR Diesel to maximize Diesel production with desired
specification. At present, there is no flow control valve in the HN & KERO streams being
blended to HCR Diesel.
DHT Diesel flows out as separate Diesel product after mixing with small amount of KERO.
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The major portion of UCO (Unconverted Oil) from HCR Fractionator bottom is sent to 2nd
Stage HCR as feed. After sending small amount of UCO as warm-up oil and for HCR
Diesel blending, the rest is sent to storage.
Deethanizer bottom is separated into LPG and Stabilized Naphtha in the Debutanizer
column (CC603). Stabilized Naphtha from Debutanizer and the overhead Naphtha from
HCR & DHT Fractionator columns are separated into Light and Heavy Naphtha products
in the Naphtha Splitter column (CC604).
All reactor Quench flows are sourced from RGC outlet. RGC outlet joins with make-up
hydrogen from MUGC into a single header. The feed gas or recycle flows to HCR 1st Stage
& 2nd Stage reactor inlets are taken from this header. Due to variation in H2 consumption in
HCR & DHT reactors, MUGC inlet pressure can vary. The excess H2 pressure at MUGC
inlet is preferably flared through the controller 16PIC9601.
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The 1st stage GOR will be maintained within the desired range (around the design value)
by APC and will be minimized within this range. During site visit, YIL found that the
recycle gas flow available in the 2nd stage was limited by pressure drop to a value lower
than design. Hence, the 2nd stage GOR cannot be maintained within the desired range
(around the design value) by APC, instead it would be controlled within the achievable
range that might be below the design value. Because of this limitation as well as the
unavailability of any measurement for recycle gas flow to DHT, no benefit based on 2nd
stage GOR minimization has been estimated.
APC can control the Furnace temperature differences for the 1st and 2nd Stage HCR
reactors to maximize process heat recovery. However, F/E Heat Recovery will be
considered unrealizable unless the ranges of Furnace temperature differences under
APC control are set around the average values under DCS control.
Throughput control could also be included as an APC strategy. However, many instruments
and hardware are presently running close to their design limits. For example, YIL found
that HCR 1st stage feed pump and DHT feed pump amperage is reaching values very close
to design FLCs (Full Load Currents). Hence, throughput control with APC could be
included after all the hardware and process constraints related to throughput increment are
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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confirmed before APC design and all the related hardware / instrumentation issues (such
as, availability of constraint measurements) are resolved by BORL. Once feasibility of
throughput control is established, then throughput setpoints could be set so as to maximize
it without violating any constraint.
At present Density & ASTM distillation data of only Blended HCR Diesel, final DHT
Diesel and Combined KERO, and Flash Point of Combined KERO are taken. For product
optimizations using product draw rates and side stripper heat inputs in the
Fractionator columns, product Density & ASTM distillation data are needed for
column products like Heavy Naphtha, KERO, Diesel & UCO before any
mixing/blending (apart from the existing data for final products). There is flow meter
in the HN line going to the Diesel Blend, and no Flow Control Valves in the HN &
KERO lines going to the Diesel Blend. These are needed for accurate control of Diesel
blending.
Similarly, The VFD AC fans at the top of HCR & DHT Strippers and DHT
Fractionator have to be manipulated by APC in order to control product qualities and
yields.
Based on the confirmation by BORL that daily lab measurement of Density, Flash Point &
ASTM D95% of KERO at HCR & DHT Fractionator ends (before mixing with any other
streams) will be available during APC project; the same qualities in the Combined KERO
will be controlled. Similarly, based on the confirmation by BORL that daily lab
measurement of Density & ASTM D95% of Diesel & UCO at HCR Fractionator end
(before mixing with any other streams) will be available during APC project and that a
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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flow meter will be installed in the HN line blend; the same qualities in blended HCR Diesel
will be controlled. Similarly, based on the confirmation by BORL that DAILY lab
measurement of density & ASTM D95% of Diesel at DHT Fractionator end (before mixing
with any other streams) are available; the same qualities in blended DHT Diesel (after
mixing with Combined KERO) will be controlled.
In case of HCR Fractionator, pump around flows and TD (temperature difference) will also
be manipulated to control tray temperatures and product quality. At the same time, APC
will control the steam generation in the Heavy Diesel Pump-Around circuit.
Stripping Steam flows to the bottoms of HCR Stripper & Fractionator and DHT Stripper
could be minimized whenever possible without affecting product qualities. Similar
opportunistic minimization could also be done for DHT Fractionator Reboiler duty, and the
VFD AC fans' loading at the top of HCR & DHT Strippers and DHT Fractionator.
However, because of complex dynamics between product qualities and these variables, it is
not possible to quantify any benefit from such optimizations.
4.6
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APC can control the FD inlet damper opening and cold air damper inlet to HCR
Fractionator Heater & DHT Fractionator Reboiler Furnaces to maintain excess air.
2. At present, there is flow meter in the HN line going to the Diesel Blend, and no Flow
Control Valves in the HN & KERO lines going to the Diesel Blend. These are needed
for accurate control of Diesel blending.
3. The VFD AC fans at the top of HCR & DHT Strippers should be made available for
manipulation by APC in order to recover LPG.
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105
104
103
102
SPECIFICATION
CONSTRAINT
101
PERCENT OF LIMIT
99
98
97
96
95
94
93
Distribution of
92
Instantaneous values
91
90
ADVANCED
PERFORMANCE
Figure 5.1
The graph represents the variation of some important process variable relative to a
constraint over a certain operating period. These variations can be represented by the socalled normal Gaussian distribution as indicated in the right hand side of the above
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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The actual calculation of APC benefit is carried out through the following steps. As a first
step, data collected during major process upsets are first discarded. Then, the SD (Standard
Deviation) is calculated using the formula given in Microsoft Excel. For those data that
should always remain within a range, e.g., Laboratory data, data values that differ form the
average value by certain magnitude (e.g., 2*SD) are considered out-liars and excluded
from the data. Then, the SD shall be re-calculated. The amount that the process variable
can be pushed towards constraint by use of APC can be found by using the statistical
formula, namely The Same Limit Rule (Ref: Hydrocarbon Processing, June 1991, Pg.
69):
x = k * (S-Sc)
where,
x = distance / gap the process variable can be moved towards constraint.
S = SD of process variable without APC in line
Sc= SD of process variable with APC in line
K = factor depends on the frequency of violation of process variable
If the violations are allowed 20% of the time then k = 0.8
If the violations are allowed 10% of the time then k = 1.3
If the violations are allowed 5% of the time then k = 1.65
If the violations are allowed 2.3% of the time then k = 2.0
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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Experience shows that most of the commercially available control systems show constraint
violations up to 5% of the time if plant is running below its designed capacity. Therefore,
x = 1.65* (S Sc )
(1)
Once the improvement x in the value of parameter is found out as above, it can be
correlated to the economic driver attached to the improvement in parameter and we can
then quantify the APC benefit.
Since HCU & DHT plants are running close to 115% & 120% capacity respectively at
present, many process variables are at their operating constraints and the probability
of constraint violation is more. Apart from this, due to strong interactions between
controlled variables, product quality and operating constraints, the feasible reduction
in standard deviation will be less than predicted by the above equation. Benefits have
been calculated by taking these limitations into consideration.
Product
IFO
LPG
Light and Heavy Naphtha
Kerosene
HSD (Euro- III)
UCO
Steam
Fuel Gas
Electricity
Unit
Rs/ MT
Rs/ MT
Rs/ MT
Rs/ MT
Rs/ MT
Rs/ MT
Rs/ MT
Rs/ MT
Rs / Unit
Price
48061
50613.33
52804.67
57449.36
55383.27
48146.15
2373
57673.2
7.16
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Variable Name
Minm. HCR Diesel Density
Minm. DHT Diesel Density
Minm. Blended Diesel Density
Calorific Value of FG
Feed Sp. Heat
Latent Heat of Steam
Unit
MT/m3
MT/m3
MT/m3
Kcal / MT
Kcal /MT/ oC
Kcal / MT
Value
0.82
0.824
0.8225
12000000
687.5
570000
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While maximizing LPG, Naphtha has been minimized by extracting light components as
much as possible into the LPG stream. The decrease in Naphtha yield achievable is
calculated as follows:
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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Decrease in LN (Light Naphtha) volm. Flow (as calculated above) = 0.0542 m3/hr
Av. LN Density = 0.6858 MT/m3
Corresponding decrease in SN mass flow = 0.0542*0.6858 = 0.0372 MT/hr
Av. HCR+DHT Flow = 475.2827 MT/hr
Decrease in Naphtha Yield = 0.0372*100/475.2827 = 0.0078 %
5.3.2
APC will try to control and optimization Diesel production at the individual Fractionator
column of HCR. For implementation of this strategy, ASTM distillation data of HCR
Diesel & KERO at the HCR Fractionator product end are needed. At present ASTM
distillation data of only Blended HCR Diesel and combined KERO is taken. APC can also
try to maximize proportion of UCO, HN & KERO in Blended HCR Diesel. However, for
implementation of this strategy, flow control valve is needed in the HN and KERO
blending line. At present, flow control valve is present only for UCO blending line. An
estimate of the benefit, assuming these issues get resolved, is as follows:
HCR Diesel can be maximized by dropping heavy KERO components into Diesel and
lifting light UCO components into Diesel. The reliable method for estimating HCR Diesel
yield increase for these two cases under present circumstances is the use of HCR Diesel
ASTM curve at light & heavy ends. Since distillation data of only Blended HCR Diesel is
available, ASTM data of the later will be used as an approximation for HCR Diesel. In
order to keep critical process constraints like draw temperatures and product qualities
satisfied, and due to operating / hardware constraints, effective changes have been limited
to 25%. The calculation procedure would be as follows:
Std. Devn. in HCR Diesel D05 v% Point = 8.1596 C
Av. Slope between HCR Diesel IBP D10 v% Points = 2.7904 C / v%
Std. Devn. in HCR Diesel D95 v% Point = 4.0094 C
Av. Slope between HCR Diesel FBP - D90 v% Points = 1.8247 C / v%
Av. light HCR Diesel Flow = 83.7995 MT/hr
Av. heavy HCR Diesel Flow = 76.4826 MT/hr
Av HCR Diesel Flow = 83.7995+76.4826 = 160.2821 MT/hr
Av. KERO Density = 0.7842 MT/m3
Av. HCR Diesel Density = 0.8209 MT/m3
Av. HCR+DHT Feed Flow = 475.2827 MT/hr
Decrease in HCR Diesel D05 v% based on Std. Devn. = 0.25*1.65*(8.1596-0.75*8.1596) = 0.8415 C
Increase in HCR Diesel v% due to decrease in HCR Diesel D05 = 0.8415/2.7904 = 0.3016 v%
Decrease in HCR Diesel volm. Flow =(0.3016/100)*(160.2821/ 0.8209) = 0.5888 m3/hr
Corresponding influx of KERO into HCR Diesel = 0.5888 m3/hr
Corresponding KERO volm. Fracn. In HCR Diesel = 0.5888/((160.2821/0.8209)+ 0.5888) = 0.003
Corresponding HCR Diesel Density = (1-0.003)*0.8209+0.003*0.7842 = 0.8207 MT/m3
Minm. Specification of HCR Diesel Density = 0.82 MT/m3
Allowed Increase in HCR Diesel volm. Flow by KERO dropping = 0.5888 m3/hr
Corresponding increase in HCR Diesel mass flow = 0.5888*0.8209 = 0.4833 MT/hr
Increase in HCR Diesel Yield due to dropping KERO = 0.4833*100/475.2827 = 0.1017 %
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While maximizing HCR Diesel, Kerosene and UCO have been minimized above by
dropping heavy components of KERO and lifting light components of UCO respectively
into HCR Diesel. The decrease in KERO & UCO yields achievable is calculated as
follows:
Increase in HCR Diesel volm. Flow by KERO dropping (as calculated above) = 0.5888 m3/hr
Corresponding decrease in KERO volm. flow = 0.5888 m3/hr
Av. KERO Density = 0.7842 MT/m3
Corresponding decrease in KERO mass flow = 0.5888*0.7842 = 0.4618 MT/hr
Av. HCR+DHT Feed Flow = 475.2827 MT/hr
Decrease in KERO Yield due to dropping into HCR Diesel = 0.4618*100/475.2827 = 0.0972 %
Increase in HCR Diesel volm. Flow from UCO Lifting (as calculated above) = 0.4424 m3/hr
Corresponding decrease in UCO volm. Flow = 0.4424 m3/hr
Av UCO Density = 0.8382 MT/m3
Corresponding decrease in UCO mass flow = 0.4424*0.8382 = 0.3709 MT/hr
Av. HCR+DHT Feed Flow = 475.2827 MT/hr
Decrease in UCO Yield = 0.3709*100/475.2827 = 0.078 %
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5.3.3
APC will try to control and optimize Diesel production at the Fractionator column of DHT.
For implementation of this strategy, ASTM distillation data of DHT Diesel & KERO at the
DHT fractionator product end are needed. At present ASTM distillation data of only final
DHT Diesel and combined KERO is taken.
DHT Diesel can be maximized by dropping heavy DHT KERO components into Diesel.
The reliable method for estimating HCR Diesel yield increase under present circumstances
is the use of DHT Diesel ASTM curve at light end. In order to keep critical process
constraints like draw temperatures and product qualities satisfied, and due to operating /
hardware constraints, effective changes have been limited to 25%. The calculation
procedure would be as follows:
Std. Devn. in DHT Diesel D05 v% Point = 4.3119 C
Av. Slope between DHT Diesel D10 - IBP v% Points = 4.7014 C / v%
Av DHT Diesel Flow = 189.3609 MT/hr
Av. KERO Density = 0.7842 MT/m3
Av. DHT Diesel Density = 0.8243 MT/m3
Av. HCR+DHT Feed Flow = 475.2827 MT/hr
Increase in DHT Diesel D05 v% based on Std. Devn. = 0.25*1.65*(4.3119-0.75*4.3119) = 0.4447 C
Increase in DHT Diesel v% due to decrease in DHT Diesel D05 = 0.4447/4.7014 = 0.0946 v%
Increase in DHT Diesel volm. Flow = (0.0946/100)*(189.3609/0.8243) = 0.2173 m3/hr
Corresponding influx of KERO into DHT Diesel = 0.2173 m3/hr
Corresponding KERO volm. Fracn. In DHT Diesel = 0.2173/((189.3609/0.8243)+ 0.2173) = 0.0009
Corresponding DHT Diesel Density = (1-0.0009)*0.8243+0.0009*0.7842 = 0.8243 MT/m3
Minm. Specification of DHT Diesel Density = 0.824 MT/m3
Allowed Increase in DHT Diesel volm. Flow by KERO dropping = 0.2173 m3/hr
Corresponding increase in DHT Diesel mass flow = 0.2173*0.8243 = 0.1791 MT/hr
Increase in DHT Diesel Yield = 0.1791*100/475.2827 = 0.0377 %
Price of KERO = 57449.36 Rs/MT
Price of Diesel = 55383.27 Rs/MT
Differential Price (Diesel-KERO) = Negative
Working Hours = 8000 hr/yr
Benefit from KERO Dropping into DHT Diesel = Cannot be estimated due to negative differential
price
While maximizing DHT Diesel, Kerosene has been minimized by dropping its heavy
components as much as possible into DHT Diesel. The decrease in KERO yield achievable
is calculated as follows:
Increase in DHT Diesel volm. Flow by KERO dropping (as calculated above) = 0.2173 m3/hr
Corresponding decrease in KERO volm. flow = 0.2173 m3/hr
Corresponding decrease in KERO mass flow = 0.2173*0.7842 = 0.1704 MT/hr
Decrease in KERO Yield due to dropping into DHT Diesel = 0.1704*100/475.2827 = 0.0358 %
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Total Decrease in KERO Yield due to dropping in HCR & DHT Diesel = 0.0972+0.0358 = 0.133 %
5.3.4
The temperature controllers of the F/E Exchangers before the reactor furnaces (FF101 &
FF201) are to be set such that the temperature difference across Furnace is around 22oC on
average. However, there is some variation in this temperature difference. Since APC can
reduce such variations by consistently maintaining the Furnace temperature difference at a
fixed value, heat recovery can be maximized. Since this benefit is based on the DCS
control as reference, the range of Furnace temperature difference under APC has to
be around the average Furnace temperature difference under DCS control to realize
this benefit. For example, the available data indicates that the present average values of
Furnace temperature differences under DCS control are below 22oC. In such a case, if APC
ranges are set around the higher value of 22oC for operational reasons, then obviously
energy consumption will increase in Furnaces instead of decreasing. We can consider this
as an F/E Heat Recovery OFF case in which the following benefit calculation
calculations cannot be used. Hence, during Post-Audit, this benefit can be estimated
and added to the total benefit only for F/E Heat Recovery ON case in which the
ranges of Furnace temperature differences under APC control are set around the
average values under DCS control. Due to operating / hardware constraints, effective
changes have been limited to 25%. The calculation procedure would be as follows:
FF101 TDI (Temp. Diff., 16TDI1601.PV) Mean = 18.306 C
FF101 TDI STD = 2.3843 C
Decrease in FF101 TDI based on Std. Devn. = 0.25*1.65*(2.3843-0.75*2.3843) = 0.2459 C
Feed Liq to FF101 = 256.0477 T/hr
Feed Gas to FF101 = 30584.332 KG/hr
Total Feed to FF101 = 256.0477+30.5843 = 286.632 T/hr
Cp of Feed = 687.5 Kcal/T/ C
Heat Requirement Decrease in Feed to FF101= =286.632*687.5*0.2459 = 48453.18 Kcal / hr
Calorific Val. of FG = 12000000 Kcal /T
Decrease in FG to FF101 = 48453.18/12000000 = 0.004 T/hr
FF201 TDI (Temp. Diff., 16TDI2603.PV)Mean = 19.358 C
FF201 TDI STD = 1.7283 C
Decrease in FF201 TDI based on Std. Devn. = 0.25*1.65*(1.7283-0.75*1.7283) = 0.1782 C
Feed Liq to FF201 = 200.7894 T/hr
Feed Gas to FF201 = 18759.8633 KG/hr
Total Feed to FF201= 200.7894+18.7599 = 219.5493 T/hr
Cp of Feed = 687.5 Kcal/T/ C
Heat Requirement Decrease in Feed to FF201= =219.5493*687.5*0.1782 = 26902.2 Kcal / hr
Calorific Val. of FG = 12000000 Kcal /T
Decrease in FG to FF101 = 26902.2/12000000 = 0.0022 T/hr
Total Decrease in FG = 0.004+0.0022 = 0.0063 MT/hr
Price of FG = 57673.2 Rs/MT
Working Hours = 8000 hr/yr
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5.3.6 Excess Air Minimization in HCR Fractionator Heater & DHT Reboiler Furnaces
(Within Allowable Range)
APC can control the FD fan speed and cold air damper inlet to HCR Fractionator Heater &
DHT Fractionator Reboiler Furnaces to maintain excess air. Due to operating / hardware
constraints, effective changes have been limited to 25%. The calculation procedure would
be as follows:
Stoichiometric Coeff. w.r.t. FO in FF501 = 1.7258 M3/KG
Stoichiometric Coeff. w.r.t. FG in FF501 = 2.4798 M3/KG
Av. Excess O2 in FF501 = 3.2822 %
STD of Excess O2 in FF501 = 1.5134 %
Decrease in Excess O2 in FF501 based on STD = 0.25*1.65*(1.5134-0.75*1.5134) = 0.1561 %
Maxm. Allowed Decrease in Excess O2 in FF1501 (final Excess O2 > 2%) = 3.2822-2 =
1.2822 %
Decrease in Excess O2 in FF501 w APC = 0.1561 %
Av. FG flow in FF501 = 2415.2517 KG/hr
Av. FO flow in FF501 = 2527.5376 KG/hr
Av. Air flow in FF501 = 62002.1602 M3/hr
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5.3.7 Control & Optimization of Gas-to-Oil Ratio in HCR 1st Stage (Within Allowable
Range)
At present, GOR (Gas-to-Oil Ratio) of HCR 1st & 2nd Stages are monitored through DCS
display. GOR is important for maintaining required H2 partial pressure in the reactors to
serve the desired reaction kinetics. There are variations in these ratios. By maintaining it at
an optimum value within an allowable range, it is possible to minimize Recycle Gas
consumption and hence the consumption of HP steam used to drive the RGC. As
mentioned in Section 4.1, only the 1st stage GOR will be optimized to remain at an
optimum value. In other words, minimization of GOR is expected to be achieved indirectly
by keeping it at an optimum value within the range of its normal variations. Due to
operating / hardware constraints, process interactions and the optimization difficulty, the
effective change has been limited to 10%. The calculation procedure would be as follows:
HCR 1st Stg. GOR Mean = 966.375
HCR 1st Stg. GOR STD = 204.9201
Decrease in HCR 1st Stg. GOR based on STD = 0.1*1.65*(204.9201-0.75*204.9201) = 8.453
Gain between HCR 1st Stg. GOR DCS-display unit and Direct KG/T unit = 0.12433
Decrease in HCR 1st Stg. GOR in Direct Kg/T unit = 8.453*0.12433 = 1.051 KG/T
Av Value of HCR 1st Stg. HC Feed = 256.0477 T/hr
Feasible decrease in HCR 1st Stg. Recycle Gas = 256.0477*1.051 = 269.0948 KG/hr
Gain of Recycle Gas and HP Steam Consumption in RGC = 0.00027106 T/KG
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Benefit Area
LPG Maximization
Naphtha Minimization
Percentage
Yield
Change
(wherever
applicable)
0.0146 %
Increase
HCR Diesel
Maximization
0.0078 %
Decrease
0.1781 %
Increase
DHT Diesel
Maximization
0.0377 %
Increase
KERO Minimization
0.133%
Decrease
0.078 %
Decrease
UCO Minimization
Maximization of
Steam Generation in
Heavy Diesel PA
circuit
Excess Air
Minimization in HCR
Fractionator Heater &
DHT Reboiler
Furnaces
Optimization of 1st
Stage GOR
Total Benefit (F/E
Heat Recovery OFF)
Maximization of Heat
Recovery in F/E
Exchangers
Total Benefit (F/E
Heat Recovery ON)
Benefit Estimate
Rs Lakh / Yr
7.86
13.85
248.64
28.97
277.62
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2.78 Crore Rs/Yr or 1.71 Cent/Barrel (When F/E Heat Recovery is realized)
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This proposed ExaOPC Gateway shall cater to handling process data from the
HGU and HCR-DHT Units. It is recommended to deploy separate dedicated
ExaOPC Gateways to facilitate the APC-DCS Communication for the same.
With OPC, any third party system can acquire and define process data from CS3000
& and receive alarm events. It supports OPC standard interface functions
(DA/A&E/HDA) specified by OPC Foundation, and many other optional
functional such as browsing.
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problems, access from the client is restricted to avoid exceeding the maximum
accessible data. The OPC package provides the OPC client with an interface with
the following specifications:
OPC has passed the OPC DA2 Compliance Test. The ExaOPC Station being
supplied will be the latest version available and is DA3 Compliant.
ExaOPC is OPC server, which satisfies the OPC Standards; hence existing DCS
system becomes truly OPEN with any third party OPC client.
d. Data thru put is as high as 1000 data per second.
e.
Multiple clients can access the DCS data at their own interval.
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f.
Figure 6.1
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HARDWARE
Online APC Server
Type of Application
To be supplied by APC vendor
as per APC Application
To be supplied by APC vendor
as per APC Application
Qty.
1
1
HARDWARE
ExaOPC Gateway
Network Switch for APC
Computers
Type of Application
Proprietary to Yokogawa
Qty.
1
**Note:- This has already been accounted for in the HGU Scoping Study Report.
1. Specifications for Online APC Computer (Server Range) Qty. - 1No
Make: HP / DELL /IBM
S.No
Item
Processor
1
RAM
2
Hard Disk
3
Requirement
Dual Intel XeonTM Processor 3.4 GHz or faster.
4 GB, expandable to 8 GB minimum
5x 80 GB minimum RAID 5 w/online spare (6x1) hot
pluggable drive bays minimum
4
5
6
7
RAID Controller
Monitor
CD-ROM/DVD
Network Card
Operating
System
MS Office and
Antivirus
10
Comprehensive
support
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11
Supplies and
Accessories
Requirement
Intel Processor 2.4 GHz or faster
RAM
Hard Disk
3x80 GB minimum
Monitor
17 TFT Monitor
CD-ROM/DVD
Network Card
Operating
System
MS Office and
Antivirus
Comprehensive
support
Supplies and
Accessories
10
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SOFTWARE
MVPC and Robust Quality
Estimator Online
MVPC and Robust Quality
Estimator Offline
APC-DCS Interface
Development ***
Type of Application
To be supplied by APC vendor as
per APC Application
To be supplied by APC vendor as
per APC Application
Proprietary to Yokogawa
***Note: The APC-DCS Interface is imperative to the smooth and reliable operation of
APC Controllers. The Interface comprises of:1) supervisory and interlocks logic that need to be created in the DCS Controller
(FCS) for safe switchover from APC mode to DCS Control mode on account of any
emergency in Plant Operations or any other Operations requirement.
2) DCS Graphics to enable the Operator to perform APC Monitoring by entering the
MV Limits, CV Limits etc. to ensure smooth operation of the Plant
This would require additional resources to be created in the FCS (DCS Controller) and
engineering to be done to implement Interlock logics and also any ERC (Enhanced
Regulatory Control) strategies if required for better control.
Keeping in mind the criticality of the Interface for reliable and safe operations and also
mitigate any risks/delays that may arise in the later stages of Project Execution due to
insufficient knowledge on Yokogawas Centum CS3000 DCS System by any other APC
Vendor it is recommended that Yokogawa carry out this activity.
SOFTWARE
ExaOPC Application Package
Type of Application
Proprietary to Yokogawa
**Note:- This has already been accounted for in the HGU Scoping Study Report.
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8.3 Pretest
Following Base Case Study, Pretest is to be completed. The scope of Pretest is
primarily to check all the applicable DCS level regulatory controls, to make sure
they are configured properly and controlling adequately for the application of the
Advanced Process Control. Thus, PID (Proportional Integral Derivative) controller
loops critical for APC performance are examined and re-tuned if necessary.
Malfunctioning of existing instruments and need for additional instruments, which
are critical for APC application, are identified. All the controlled, manipulated and
disturbance variables are identified.
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consultant submits for approval a Step Test plant, indicating how the Steptest will
be conducted.
On the other hand, the customer should rectify the malfunctioning instrument and
provide the additional instrumentation identified before Step Test can begin.
8.4 Steptest
Following Pretest, Steptest is to be completed. Steptest is required for developing
dynamic models for the SMOC applications. During Steptest, inputs to the process
will be changed several times in both direction and the response will be noted. Data
of Steptest will be collected using the data historian software.
8.5 Engineering
There will be a complete Engineering of the APC system following Pretest &
Steptest, involving the following activities at the APC Vendor site:
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8.6 Commissioning
After completing the activities above, APC commissioning activity at customer site
starts. During commissioning, APC loops are tuned online to make then work
satisfactorily. Any changes are incorporated in the final design document known as
DDS (Detailed Design Document) that is submitted after commissioning for
customer review.
8.8 Post-Audit
Post-Audit is scheduled following SAT. In this activity, APC run data are collected
over 7 days. These data are compared to the Base Case data and the APC benefit
achieved is calculated. A Post-Audit Report is submitted.
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FDS Report
0.5
Step Test
1.5
1.5
FAT
0.5
Interface Development
0.5
Commissioning
10
11 SAT
12
10
1
0.5
Figure 8.1
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9.0Training Requirement
True success of any APC project is possible through synergy between BORL and
APC engineers. Therefore training shall be completed as early as possible
(preferably, before Steptest, or at least during FAT activity) in order to enable
BORL engineers to appreciate and involve fully in all activities of APC
implementation. BORL console officers shall also be trained before the APC is put
online.
The Engineering Training should be a comprehensive one and should cover design
aspects of APC. There are several advantages of comprehensive Engineering
Training:
1. BORL engineers can exploit advanced features of APC available at APC server,
such as on-line APC tuning, changing priority among controlled variables.
2. BORL engineer can quickly restore the system after communication or power
failure.
3. It becomes easy for BORL to look after the APC system.
4. BORL engineers can use the design tools themselves and modify APC design if
necessary.
The Operator Training should focus on the APC operational aspects; so that console
officers can change the variables provided in the APC graphics and obtain the
desired results. It is also necessary to train the operators on the followings:
1. Which Manipulated Variables (MV) are used by APC to control each
Controlled Variable (CV).
2. Any specific requirement when switching between DCS and APC control.
3. What to do when CV or MV hit their limits.
A minimum of 6 engineers are given engineering training over a span of five days
and this training can be held at the APC vendors office. The operator training is
held prior to APC commissioning at site, and normally requires only a 2 hours
session. The console officers of the control room, where APC system has been
commissioned, are enrolled for the operator training.
Yokogawa India Limited, Bangalore
Doc. No: BORL-AB1-001
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10.0
The cost components in the HGU & HCR-DHT APC project are tabulated below in
Table 11.1 & 11.2. These are divided into proprietary and non-proprietary items.
Item
Quantity
1 Lot
1 Lot
1 Lot
APC Engineering
Base case preparation
Engineering
a. Pre-test
b. Step Test
c. RQE Model Development
d. SMOC Model Development
1 Lot
Training
1 Lot
Documentation
1 Lot
Site Commissioning
1 Lot
1 Lot
1 Lot
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The estimated cost for the APC systems are tabulated below.
Table 10.2 Estimated Costs of APC System for HCR-DHT (As per BOM Table
10.1)
S. No.
Item
Price
INR
1500000.00
Fifteen Lakhs
6000000.00
Sixty Lakhs
500000.00
Five Lakhs
3000000.00
Thirty Lakhs
APC-DCS Interface
1500000.00
Fifteen Lakhs
Development(Item No 4 of BOM)
*(Proprietary to Yokogawa)
Total
1000000.00
Ten Lakhs
1500000.00
Fifteen Lakhs
*Note: The price for the required EXAOPC Gateway and Network Switch for APCDCS communication is already furnished in the HCU Scoping Study Report. Since the
HCU-DHT and HGU Units shall have a common EXAOPC Gateway the prices are
given along with the HGU Scoping Study report and hence not explicitly mentioned in
this report.
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**Note: All the above prices for APC Hardware, APC Software, APC
Implementation, ExaOPC Hardware, Software and Implementation are exclusive of
taxes. The taxes applicable and terms & conditions of this proposal are indicated
below:Taxes
Excise Duty
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