Advances in Abnormal Situation Prevention in Refineries and

Petrochemical Plants

Ahmad Hamad and Ravi Kant

Emerson Process Management
Eden Prairie, MN 55344

Abstract

Abnormal situation prevention is of high importance in the operation of

refineries and petrochemical plants. Abnormal situation may result from
equipment malfunction, process upsets, operator errors, etc. There have been
several approaches to deal with those situations. The proposed abnormal
situation prevention approach in this work targets the timely and early detection
of abnormal situations to prevent undesired upsets, shutdowns and catastrophic
consequences. The approach uses advanced statistical control techniques, smart
field devices, and multivariate analysis to analyze trends of process variable and
detect faults or deviations. The approach has three phases: learning, model
development, and monitoring. All these phases can be implemented online or by
using off line data. The capabilities of the proposed abnormal situation
prevention approach will enable refineries and petrochemical plants to run safer
and cleaner while achieving higher economic benefits.

Introduction

Abnormal situations can be defined as process disturbances, upsets, and

events that can cause the process to deviate from its normal operating state and
may lead to damaging consequences. Abnormal situations can vary in severity
and consequences from off-spec product to catastrophic failure of equipment.
Cost of abnormal situation consequences increases as the severity increases.
Marsh Risk Consulting (2001) identified 379 abnormal events in the Hydrocarbon
industries with individual losses exceeding $10 billion in the period from 1970 to
1999. Average annual losses were approximately $700 million with twenty-five
of these events having individual losses of $150 million or more. Unfortunately,
these economical losses are sometimes also accompanied by loss of lives and
environment incidents. Till now, the main approach for preventing damaging
consequences of abnormal situations is preventive maintenance. However, this
approach has major disadvantages. First, this approach is costly since
maintenance is done on regular basis regardless of the status of the process or
equipment. This approach may include unnecessary plant or unit shut down.
Second, this approach does not detect abnormal situations. This is a major
disadvantage because abnormal situation can occur between scheduled
maintenance periods. Another disadvantage includes the direct and complete
dependence on plant operators. To overcome these disadvantages, several
efforts have been done by various industries and researchers to come up with
diagnostic techniques to detect and prevent abnormal situations and reduce the
cost of maintenance. Roemer and Kacprzynski (2000) presented a real-time,
integrated health monitoring of gas turbine engines that can detect, classify, and
predict developing engine faults. Kubiak et al. (2004) introduced a hybrid fault
pattern approach for diagnosing gas turbine component degradation. Reising et
al. (2005) discuss how abnormal situation management (ASM) is used by plant
operators to recognize the presence of failures before alarms are issued.
Eryurek et al. (2005) discusses how smart field devices are used for abnormal
situation prevention. This paper presents a novel on-line methodology for
abnormal situations prevention in the process industries. The proposed
methodology builds-on several tools to come up with a novel abnormal situation
prevention structure that is robust and operator-friendly. The methodology is
embedded in Emersons Plantweb technology and relies on using smart devices,
high frequency transmitters, statistical-based analysis methods, on-line data
gathering and analysis, and on-line process automation using operating software
such as DeltaV. Examples of applying this approach to refineries and
petrochemical plants will be presented.

Process Control and Abnormal Situation Prevention

Before talking about the proposed abnormal situation prevention

methodology, it is important to differentiate between process control and
abnormal situation prevention. Abnormal situation prevention technology is
intended to provide early detection and timely corrective action. Consider Figure
(1) where abnormal event severity is presented as a function of time. The
severity of the abnormal situation increases as time progresses. It is traditional
ASM approach that when the value of the process variable reaches unacceptable
region an alarm is issued to alert the operator. The operator takes an action in
an attempt to return the process into the normal operation region. The operator
is doing process control in this case based on prior knowledge or rules. In many
instances this approach is ineffective because the detection is too late and may
lead to catastrophic situations or unplanned plant/equipment shutdown. In
addition, this approach fails in most cases to identify the source of faults. The
operator gets trapped in fixing the symptoms of the fault by manipulating
process variables. The main goal of the operator is to bring the process back to
operate within the acceptable region. The operator may fix the fault symptoms
but fails to identify and eliminate the fault that caused these symptoms.
 Early Detection Traditional Detection

Abnormal
Situation
Severity Emergency

Abnormal

response
Region of process control

Alarm

Normal Corrected
response situation
Region of Abnormal
Situation Prevention
Alarm
Corrected
situation

Time

Figure 1: Typical Response Diagram for Abnormal Situations

Process control in this situation may take the process variable back to a point in
the normal region that is not far from the abnormal situation. The proposed
abnormal situation prevention approach, on the other hand, identifies the
abnormal situation at an earlier time (Figure 1) and identifies the source of the
fault. The abnormal situation is identified as it starts to develop. The whole
diagnostic, detection, and corrective actions take place in the normal operating
region. How is this done? This is done by comparing the actual real time
operating conditions to the ideal base. Ideal base here refers to the normal
process operating conditions without any deviation or abnormal situation. The
proposed approach uses advanced pattern recognition technologies, signal
analysis, statistical process control, as well as expert system based solution with
the smart devices for improved process operation, and early abnormal situation
detection and prevention.

Technology Advances In Abnormal Situation Prevention

The Fluid Catalytic Cracker (FCC) unit is used to illustrate advances in

abnormal situation prevention technology development. Figure 2 presents the
cost of abnormal situation consequences
catalyst transfer lines of the FCC unit.
catalyst circulation (abnormal situation)
and regenerator. The abnormal situation
be as follows:
resulting from slide valve failure in the
Valve failure is due to irregularity in
in the transfer pipes between reactor
consequences in this case progress can

1. Stage 1: represents pressure irregularity due to catalyst erratic circulation

in transfer pipes
2. Stage 2: represents loss of production due to regenerator fouling
3. Stage 3: Valve malfunction because of catalyst build up in transfer pipes
4. Stage 4: FCC unit shut down due to pressure loss across transfer pipes
5. Stage 5: Plant shut down

As the stage order increases, the cost severity associated with the abnormal
situation increases and may result in major damaging consequences. Circle (A)
in Figure (2) represents two corrective approaches, preventive maintenance and
knowledge-based diagnostic and fault detection. The preventive maintenance
takes a corrective action with respect to physical entity such as cleaning the
valve or the transfer pipe. The knowledge-based diagnostic uses historian data
to develop a multivariate model to detect the behavior of the process. This
approach can get very complex. It uses low frequency filtered data and relies on
historian data. It does not have the capability to gather data on-line to update
the monitoring models. This approach fails to detect abnormal situations if the
abnormal situation is very fast or with a high frequency unless a damaging
consequence is evolved. Furthermore, this approach fails to predict health of
machinery, devices, and transmitters used in the process. It can, though, give a
good indication of process variable deviation from normal operation condition.
The response time domain for circle A is slow and can be too late.

Circle B represents the use of smart field devices and field instruments.
Eryurek et al. (2005) illustrates that improved process measurements and real
time analysis/detection could have prevented or at least substantially reduced
the damage of approximately 25-40% of reported abnormal situations. With
advances in computing and measurement device technologies and advances in
communication such as the digital Fieldbus technologies, todays smart field
devices and transmitters are capable of providing much more information
regarding the processes and its conditions. Smart field devices and instruments
manufactured by Emerson Process Management have built-in ASPTM blocks
(Figure 3) which captures high frequency process data (22 Hz) and have data
analysis capabilities. Abnormal situation prevention algorithm now can have
access to data that was lost with a low frequency analysis (Figure 4).
Abnormal
Situation Plant shut down
Cost A

FCC shut down

Valve malfunction
B

C Loss of production

Pressure changes

Time

Figure 2: Abnormal Situation Cost For Slide Valve in FCC Unit

Process PV for Regulatory Control

Sensor AI PID AO
Readings

Field Device ASP Data

ASP Alert
ASPTM Statistical Data
Block Frequency Data
Auto Regression Data
Wavelets Data

Figure 3: Schematic Representation of ASPTM Block in Field Devices and

Instruments
 Historian looks like this to a field
device.

What looks like this

to a historian Sampling
frequency is
22samples/sec

Sampling
frequency is
1-60 seconds

Figure 4: Data (Pressure, Temperature, etc.) Frequency Sampling

in Smart Field Transmitters

Embedded in
Emerson DeltaV (Ovation, ..)
Fieldbus

Device ASP
ASPTM
Block

Equipment/Process
ASP
. Abnormal Situation PlantWeb
Statistical Prevention Module Alerts
.
. Frequency (Data gathering,
Auto Regression analysis,
and monitoring)
Wavelets
TM
ASP
Block Other
Process
Data

Figure 5: Equipment and Process Abnormal Situation Prevention

Approach Using Plantweb Technology

This data could provide information about process performance and

abnormal situations. Smart devices and instruments can provide the operator
with an assessment of their own health by providing high frequency statistical
data such as the variance and mean. This methodology still cannot go to detect
abnormalities due to process equipment fouling or process-related abnormalities.
Circle (C) in Figure 2 represents the proposed equipment and process abnormal
situation prevention approach in this work (Figure 5). This approach utilizes the
benefits of knowledge-based, smart field devices and instruments, advanced
process control techniques, and other diagnostic techniques to detect and
prevent abnormal situation in early stages while the process is running in the
normal operation region (see Figure 1). The proposed abnormal situation
prevention approach extracts high frequency real time plant data using Plantweb
components and applies on-line diagnostic techniques to analyze this data and
identify any abnormal situation or behavior in the plant. Plantweb is a digital
plant architecture that delivers proven results, and the DeltaV system makes it
easy. Designed with this digital architecture in mind, the DeltaV system fully
integrates smart plant capabilities including HART, FOUNDATIONTM fieldbus,
high-speed discrete buses, embedded advanced control, and advanced unit and
batch management. Such tools can be used in the proposed approach to make
online analysis and data extraction easier and faster. The following section
illustrates the phases of the proposed ASP approach.

Phases of Abnormal Situation Prevention Approach

The proposed abnormal situation prevention approach has three phases to

detect faults and abnormal situations in the process industry. The phases
include learning, model development, and monitoring. In the learning phase, the
module collects data (input and output) as needed and applies various statistical
techniques to relate input (load variable) and output (monitored variable) data.
The models relating outputs and inputs can be as simple as variance with a
threshold, or linear, or polynomial, or any other form of interest. Multivariate
analysis techniques can also be employed to relate inputs and outputs. Selected
model type is user defined. During the learning phase, data are collected for
both input and output variables. Two time domains are important here and both
are user specified. The first domain is time interval between data collected. It
could range from fractions of seconds to minutes or hours. The shorter the
interval the more data is collected. The second domain is the length of the
learning phase. It could be hours, days, weeks, or months. It is recommended
to have a learning period long enough to capture all anticipated variances in
process operation. It is important to realize here, that the models developed
during a learning phase are good enough for the range of data used in the
regression process. If the process shifts to a new region of operation, then new
models are needed. This means that a new learning phase is needed. The
models are developed during the learning phase and then used in the monitor
phase to detect and prevent abnormal situations. Operator may monitor point or
pattern deviation of the process variable. Smart field devices and instruments
are necessary to have robust data gathering and analysis of process variables.
 Implementation of Abnormal Situation Prevention Approach

One major advantage of this approach is that it is easy to implement. The

developed abnormal situation prevention algorithms or modules can be
implemented in any of the following platforms:

1. Field Device Interface Module (e.g. Rosemount 3420)

2. Control System (e.g. DeltaV, Ovation)
3. Standalone software application

Various abnormal situation prevention modules can be developed which may

be process equipment based or process unit based. Operators or plant
engineers will have the flexibility to tailor ASP modules to fit the needs of their
process unit application.

Case Studies

Various case studies are presented below to illustrate the effectiveness of the
proposed abnormal situation prevention methodology.

1. Coke Detection in Refineries

The Delayed Coker is used in refineries to process the heavy residue (Coke)
from the vacuum distillation unit. Although there are many components to the
Coker unit, a component with great value to Abnormal Situation Prevention is the
Coker Heater. This fired heater takes the feedstock from the vacuum bottoms,
and heats it prior to sending it to the Coke Drums. The feed enters the unit at
the left, and is divided into multiple passes (number of passes is user defined).
A load-balancing control regulates the flow though each of the passes. One
problem that can occur in the Coker Heater is the build-up of coke on the inside
of one or more of the passes. When this happens, the performance of the
furnace begins to degrade, and the other passes need to take more loads, in
order to compensate. If coking continues to build up even more, eventually the
affected passes, or even the entire unit, will need to be shut down. Thus, it is
desirable to know when coke buildup begins to happen, in order that a corrective
action can be taken.

Module Summary
The Coker abnormal situation prevention algorithm monitors each pass in the
furnace of the Delayed Coker to check for high coking. Generally, a decrease in
either the flow or heat transfer rate for a given pass indicates that there is high
coking in that pass. During the learning phase, data is collected for each pass.
At the end of the learning phase, a regression model is developed which can
predict the value of each monitored variable as a function of the load variable.
The value predicted by the model is considered the normal operating condition
for that monitored variable. When the actual value differs from the predicted
value by more than a certain threshold, an abnormal situation (high coking) is
detected. This algorithm is implemented in DeltaV (Figure 6) and is used in
industrial trials.

2. Catalyst Circulation In FCC Units

Catalyst circulation in the FCC unit is extremely important. Without proper
catalyst circulation the FCC unit deteriorates significantly. Detecting circulation
problems requires good understanding of pressure balance around the reactor-
regenerator system. It is important to detect erratic circulation; otherwise FCC
unit may experience unscheduled and costly shutdowns.

Module Summary
A lower or higher differential pressure across the slide valve than normal
slide valve opening is a good indication of abnormal situation development in the
catalyst transfer pipe. Catalyst circulation can also be limited by mechanical
problems with the slide/plug valve. The abnormal situation prevention module
consists of two steps:

High Coking
Detected
Pass 1
Click Here for More
Information

Figure 6: High Coking Detection as Implemented in DeltaV

 a. Using smart field valves such as DVC6000f. This valve will keep operators
informed of the health of the valve to avoid any unplanned shut down.
b. Pressure balance (drop) across the valve will be monitored using smart
pressure transmitters to detect abnormality. With this information,
operators will be able to take corrective action early in the problem
development before reaching the abnormal situation failure (Figure 1).

3. Maltrays Detection in Crude Columns

One of the major problems that face crude columns and distillation columns in
general is maltrays. Maltray could result from flooding, foaming, lost trays, etc.
The major technology that is used currently for column diagnostics is Gamma
ray. This technology is not handy and is expensive to use. As an example of
maltrays, lets discuss column flooding. Flooding is excessive accumulation of
liquid inside the column. This accumulation is generally caused by various
mechanisms such as downcomer backup flooding, spray entrainment flooding,
etc. Flooding can be recognized by some symptoms including excessive column
differential pressure, loss of bottoms, loss of separation, etc.

Module Summary
The objective of this algorithm is to detect conditions in column operation
that lead to flooding or to predict flooding conditions as early as possible to avoid
entire column or tray flooding. Different algorithms can be developed to identify
flooding conditions depending on existing instrumentations and potential future
instrumentations.

4. Gas Turbines Abnormalities

One of the major problems in gas turbines (GT) is fuel supply and efficient
usage of fuel. Uncontrolled and/or unburned fuel in the combustor could lead to
various abnormal situations in gas turbines and could cause sudden shut downs.
Abnormal situations include loss of fuel efficiency, damaged blades (due to high
temperatures, localized explosions), and damaged nozzles (due to high
temperatures). The objectives of the proposed abnormal situation prevention
method in this work are:

1. Control and monitor fuel supply to prevent abnormal situations in GT

2. Detect abnormalities in fuel system to prevent abnormal situations in GT
3. Detect abnormalities in expander to prevent abnormal situations in GT and
prevent unscheduled shutdowns

Module Summary
In the learning phase, the method collects data and applies various modeling
techniques to relate input and output data. The models developed in the
learning phase are used in the monitor phase to identify abnormal situations.
Each model is assigned a region of confidence for operation. The region of
confidence is user specified.

Conclusion

Preventing abnormal situations in the manufacturing processes (refineries,

petrochemical plants, etc.) can lead to substantial operational, economic, safety
and environmental benefits. The proposed abnormal situation prevention
approach diagnoses and analyzes process variables to detect abnormal situations
as they start to evolve. This advantage gives plant operators/engineers the
opportunity to eliminate the source of the abnormal situation before it causes
process variables to deviate from the normal operating region. The proposed
abnormal situation prevention approach has three phases: learning, model
development, and monitoring. The developed modules can be implemented in
field devices, DeltaV, or stand alone software.

References

1. Eryurek, E. P. Sharpe, and D. White (2005), Abnormal Situation

Prevention through Smart Field Devices, presented at the NPRA 2005
Annual Meeting (AM-05-49), San Fransisco, CA
2. Kubiak, J. S., A. G. Garcia, G. B. Urquiza, and G. R. Gonzalez (April 2004),
Hybrid fault patterns for diagnosing gas turbine component degradation,
Hydrocarbon Processing, p. 71 74
3. Marsh Risk Consulting (Feb. 2001), Large Property Damage Losses in the
Hydrocarbon Industries, A Third Year Review
4. Reising, D., T. DeMaere, J. Errington, K. Harris, and P. Bullemer (October
2005), Establishing Operator Performance Improvements and Economic
Benefit for an ASM Operator Interface, presented NPRA Plant Automation
& Decision Support Conference, Grapevine, TX
5. Roemer, M. J., and G. J. Kacprzynski (May 2000), Advanced Diagnostics
and Prognostics for Gas Turbine Engine Risk Assessment, presented at
IGTI/ASME Turbo expo, Munich, Germany