Major Emerson Cat Cracker project at BP Whiting Refinery

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A view of the BP Whiting Refinery, photo courtesy of BP

Emerson Process Management is providing process automation technologies and services to help British Petroleum (BP) further enhance the safety, reliability, and performance of its Whiting refinery in Northwest Indiana, USA – without the costly downtime often required for such projects.

The project to upgrade the process control system of two fluid catalytic cracking units is part of a strategic BP-Emerson automation upgrade programme. It follows BP’s earlier multi-billion-dollar Whiting Refinery Modernisation Project, which was one of the largest investments in BP history. Emerson also provided process automation for that massive upgrade, which helped BP boost its heavy-crude capacity more than four-fold.

The Whiting refinery is BP’s largest and a major supplier to the Midwest and other parts of the United States. One of the key benefits that Emerson brings is its experience managing “hot cutover” projects – upgrading units while the operation continues running, which helps BP maintain a secure supply of fuel for its customers. Catalytic crackers are primarily used to produce high octane gasoline in the refining process.

Emerson has already provided upgraded automation technologies for one of the cat crackers, implementing a new DeltaV distributed control system. Diagnostics available in the DeltaV system can help BP detect problems well before an unintended loss of operation, saving money and improving efficiency.

For the second cat cracker, Emerson will provide a DeltaV control system and integrated DeltaV SIS safety system. The integrated control and safety system will provide a common operations and engineering environment and access to extensive diagnostics across the unit. The complete automation upgrade also includes Emerson’s Fisher control valves and Rosemount measurement instruments.

“The ability to use our resources and experience from one stage of the upgrade programme on another stage helps BP manage project cost and schedule risks,” said Steve Sonnenberg, president of Emerson Process Management. “Our commissioning and start-up expertise developed in previous projects also helps BP safely and reliably improve performance without unexpected downtime, providing significant benefits to its customers that rely on a predictable supply of gasoline.”

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Further Yokogawa CCGT and Desalination business in Qatar

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The QEWC Ras Abu Fontas plant

A press release this week from Yokogawa announces that the Yokogawa South Korean engineering operation has won another major contract from Samsung C&T for Centum VP control and ProSafe-RS safety systems for a 2.4GW Combined Cycle gas turbine power and desalination plant. The plant is to be built in Qatar, using local natural gas as the fuel, and will make up an important part of the future Qatari infra-structure: it will be located 20km south of Doha. It will be operated by Umm Al Houl Power, a joint venture consortium which includes Mitsubishi/Tokyo Electric Power and Qatar Petroleum, the Qatar Foundation, and the Qatar Electricity and Water Company (QEWC).

Another order from Acciona Agua covers the supply of an associated Yokogawa Centum VP control system for a reverse osmosis water desalination plant to be created as a part of the power plant. Separately, Yokogawa received an order placed by Hitachi Zosen Corporation for a Centum VP control system on a further multi-stage flash desalination plant. Combined, the two desalination plants will produce 590,000 cubic meters of water per day.

Yokogawa will be responsible for the engineering of these interlinked systems, which will be able to monitor and control the operations of all three plants: plus they will provide support for installation and commissioning.

Yokogawa Experience

Yokogawa in South Korea has developed extensive expertise in working alongside Korean and Japanese power plant contractors, and claims a solid global track record in executing large CCGT projects, based on over 100 systems for combined cycle power plants. This capability was demonstrated in Qatar on a previous desalination plant for QEWC, known as the Ras Abu Fontas A2 project, and previous CCGT projects alongside Samsung C&T have included a 2.1GW plant at Rabigh on Saudi Arabia’s Red Sea coast.

Yokogawa anticipates major growth in demand for CCGT plants worldwide, particularly where there is access to local supplies of natural gas. However, some recent projects have been more unconventional, with a recent installation in Ireland using a high speed controller to manage a fly-wheel energy storage system for smoothing the output power from wind farms! Another project in Cornwall, UK, will use Centum VP and ProSafe-RS to control the boilers and auxiliary systems on a waste to energy plant, their fourth such installation in the UK.

(c) Nick Denbow:  www.ProcessingTalk.info

@Processingtalk

New methanol plant automation

Yokogawa has received an order from Orascom E&C USA to deliver control and safety systems for the Natgasoline LLC methanol plant, which will be one of the largest methanol plants in the World. Currently under construction in Beaumont, Texas, this facility will have a capacity of approximately 1.75 million metric tons per year when it starts production in 2017.

For the process control and safety of the Lurgi MegaMethanol process technology and auxiliary facilities throughout this plant, Yokogawa will supply their Centum VP integrated production control system, ProSafe-RS safety instrumented system, Exaquantum plant information management system, and Plant Resource Manager (PRM) software package. The Yokogawa Corporation of America will be responsible for the engineering and delivery of these systems, and will provide support with installation and commissioning.

Yokogawa entered the U.S. market in 1957 and has grown the business across diverse markets, but have had particular success in the oil and gas refining and offshore production, LNG liquefaction and chemical manufacturing areas. We are proud to win the first order for a new US-based grass roots methanol plant that exceeds a million metric tons per year. This project allows us to build on our already extensive track record in executing and maintaining methanol production in North America”, said Daniel Duncan, President and CEO of Yokogawa Corporation of America.

Though the chemical industry in the USA has long relied on imported methanol, the amount of methanol produced locally is steadily increasing, because of the ready availability of ethane produced from domestically sourced shale gas. Yokogawa won this order because of its excellent track record in completing projects, and its demonstrated ability to deliver comprehensive, integrated solutions that help optimize operations.

First UK Certified Profibus System Designers

The first group of engineers to pass the newly accredited UK Certified Profibus System Design course have graduated. The course was delivered by Verwer Training and Consultancy (VTC) at the extensive Endress+Hauser training centre in Manchester, where the picture below was taken.

profibus courseThe graduates include engineers from Endress+Hauser, Trant Engineering, CAT E&I and Control Specialists Ltd: Andy Verwer, of VTC, is on the left. The intensive course covered the detailed design of Profibus systems including methods for dealing with hazardous environments, various speed and performance requirements and solutions for high reliability and availability.  One of the core aims of this training is to cover the various methods of optimising control system design so that the impact of control system failures and maintenance on production is minimised.

The course is suitable for engineers who are involved in the specification, design and procurement of Profibus systems and covers many of the key concepts in achieving a reliable, repairable and maintainable system. The course is particularly valuable for companies involved in the UK water industry, where the WIMES standards apply.

The course can be cost effectively delivered on-site for between 4 and 20 people. See the Certified Profibus System Design course web page for more information. You can also call VTC to chat over your requirements.

2015 UK Profibus and Profinet Conference

This annual two-day conference is taking place in Stratford-on-Avon on 23 & 24 June in 2015. It includes two parallel streams of activities involving hands-on practical workshops and in-depth presentations by industry experts. The event will be covering the latest developments in Profibus and Profinet – it is also suitable for those who are new to the technology, who want to see the equipment working and talk to users who have installed systems already. Equipment manufacturers will show products and systems in an associated exhibition.

VTC will be represented by Andy Verwer who will be making a presentation on Profibus and Profinet system design and running a hands-on Profibus workshop. Peter Thomas, another of the VTC trainers, will be running a Profinet diagnostics workshop. Dennis van Booma, the CEO of ProCentec in the Netherlands, will be talking about network monitoring and diagnostics and presenting the latest ProCentec products for use on site.

See the conference programme for more details. If registering, please mention VTC in the comments box! VTC are offering two free places on the Certified Profibus Installer course and Certified Profibus System Designer course at the conference. Winners will be drawn from the conference attendees, during the event.

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Profinet gets the main attention from PI

In a separate news item, PI (Profibus and Profinet International) is celebrating its 25th Anniversary, and has released the latest node counts for installed systems: over 50 million Profibus and 10 million Profinet devices have been installed.

PI say that the growth in numbers of installed Profinet systems has been in line with the forecasts of an ARC market study of trends in Ethernet-based systems, which stated that the growth of Profinet was expected to exceed that of its competitors and the general Industrial Ethernet market. This PI claims is because Profinet is the only standard that combines the strict real-time requirements of high-performance machines (using higher-level systems such as MOM – Manufacturing Operation Management) with the necessary openness for IP communication.

Karsten Schneider, PI Chairman, commented “Users are won over by the integrated overall concept. For example, the combination of Profisafe and Profinet is an important deciding factor for the automotive industry. This is also reflected in the number of Profisafe nodes installed, which exceeded the 4 million mark this year. In 2014 alone, over 1 million new Profisafe nodes were installed, setting a new record. Outside of the automotive industry, Profisafe has been ensuring safety for the past 15 years in amusement rides, cable cars, passenger transportation, and in particular throughout the machine building sector as well as in many other applications.”

But what about Profibus, and Profisafe for that matter, in process industry applications?

PI does then talk about Profibus. They add: “Even though it has been on the market for a long time, Profibus continues to report impressive market growth. At the end of 2014, nearly 51 million Profibus devices were installed in industrial plants worldwide, about 3.6 million more than the previous year. This number shows that user confidence in Profibus is as high as ever. Profibus PA is also recording steady growth. Around 9 million PA devices are now installed in the process automation sector, around 800,000 more than in 2013. This sector will receive special attention at PI in the Achema year. Accordingly, PI is currently working closely with users to address the specific requirements of process automation in Profinet.”

So the PI emphasis seems to be on developing Profinet into the process automation industry, possibly even displacing Profibus.

MTL and Yokogawa launch Universal I/O for Hazardous Areas.

In the INSIDER for November this year, it was reported how Honeywell have used the Universal I/S interface module from P+F, and that MTL were happy to remain with the dedicated function units. Well now a new PR from MTL – as you know part of Cooper Crouse Hinds, part of Eaton, who say they are a ‘Power management company’ – so that has got their corporate rubbish out of the way. MTL announced today that it has been supporting Yokogawa in the development of their next generation integrated production control system, Centum VP R6.01.  This is also reported on in the November INSIDER.

However, Yokogawa wanted to design a new system with an intrinsically safe universal input/output (I/O) module for greater efficiency in system configuration and engineering: so they approached MTL, for its expertise in intrinsic safety devices for hazardous area and general process control applications.

“We have a long standing relationship with Yokogawa, having worked together globally for more than 20 years on various projects, so we were delighted once again to partner with them on the Centum VP R6.01,” said Riccardo Codega, MTL marketing director.  “We worked closely with them to understand their requirements for a universal I/O module and recommended our MTL4500 intrinsic safety isolators, which have been adapted to work in a universal environment.  The backplane mounting series is designed with systems vendors in mind and is perfect for DCS applications such as this.”

Yokogawa, a leading manufacturer of process control instrumentation, distributed control systems (DCS) and test and measurement instruments, launched its first version of Centum in 1975, and the company has continued to improve the platform by applying the latest technologies. Recognising the challenges faced by today’s manufacturing plants for increased flexibility as well as improved process efficiencies, with the need to maintain safe operations, Yokogawa wanted to develop an intrinsically safe universal I/O module that would allow its customers to reduce the time required for installing and configuring a control system.

“We chose to work with Eaton MTL for its credibility and expertise in intrinsic safety,” said Nobuaki Konishi, vp of the Yokogawa Industrial Automation Platform Business. “The company is recognised in the industry as being a key supplier and we were confident we could rely on them to provide a high quality and safe solution.”

Now for the required PR paragraphs, first, from MTL:

“As part of the Centum VP R6.01, Yokogawa has expanded its range of I/O devices, which are critical control system components, and a key feature is a new N-IO field I/O device with an I/O module that can easily handle multiple types of I/O signals.  As such, it eliminates the need for I/O modules to be replaced according to the signal they convey, which reduces rewiring, footprint and the time spent on installation and associated costs.

MTL product specialists added additional diagnostic features and functionality so line fault detection is integrated into the Yokogawa system.  Now, there are channel level diagnostics in the control system that help users avoid downtime and increase plant productivity.

A key benefit of the MTL4500 Series isolators is that the base plate does not require intrinsic safety certification. The field connection is on top of the module, so it does not need any additional accreditations and it is accessible to all regions worldwide.  As a result, the approval process into a plant is simplified in virtually any application.

The MTL4500 isolators are a compact integrated solution for flexible cabinet layout.  Incorporating advanced circuit design, a common set of components and innovative isolating transformer construction, the isolators achieve a significant reduction in power consumption while increasing channel packing densities. The 16mm wide design reduces weight and gives exceptionally high packing density.

MTL4500 isolators are plug-and-play with easy commissioning and set up, therefore simplifying project engineering and reducing installation and maintenance costs.  The design is based on existing, proven technologies and provides a reliable solution for manufacturing plants and process industries including oil and gas, petrochemicals, chemicals and pharmaceuticals.

Eaton continues to work closely with Yokogawa in its development of control systems that will provide customers with an improved operating environment by increasing the safety and efficiency of their operations and achieving greater synergy between their control system and field devices.  In addition to improving production efficiency, this will allow the optimisation of maintenance of the production control system, safety instrumented system, programmable controllers, all field devices, and other components, thereby reducing costs and ensuring the long-term stability of operations.”

Second, a precis of the Yokogawa PR:

Yokogawa launched the new version of Centum VP, the Series 6, this month. Centum was launched in 1975 as the World’s first DCS system, and Yokogawa are proud to claim progressive compatibility and upgradability across all Centum systems over these 40 years. Over 25,000 Centum systems have been installed worldwide in this time, with 88% of these concentrated in Europe and Asia.

The R6 version introduces N-IO, Network IO, which “fulfills the functions of universal I/O and a signal conditioner, enabling configurable software and flexible I/O assignment”. As discussed in the INSIDER report on the Honeywell HUG EMEA meeting in November, Yokogawa also have established agreements with P+F and MTL to enable intrinsically safe interfaces for the N-IO. A FieldMate Validator software tool is also available, enabling the field instrument and wiring loop to be checked before there is any connection to the control system.

The Centum VP R6 also includes an ‘Automation Design Suite’ that facilitates project execution, including program templates for heat exchangers, filters, and other types of equipment commonly used in the field. The database structure facilitates the reuse of valuable engineering knowhow, centrally manages the functional design documents needed, eliminates inconsistencies between the design information and the actual system, manages change, and supports the automation lifecycle, for example in maintenance and expansion phases.

The INSIDER Newsletter is a Spitzer and Boyes publication, which includes reports from Nick Denbow as a European Correspondent. See http://www.iainsider.co.uk

Emerson SIS burner management system for Sasol

Emerson Process Management has successfully completed a DeltaV SIS burner management system migration project for the Sasol integrated chemical plant in Sasolburg, South Africa.

Sasol is a global energy and chemical company that produces fuel, oil, gas, polymers, chemicals, and fertilisers. The company has a large market for waxes that are used for an array of applications including adhesives, construction boards, cosmetics, packaging, pharmaceuticals, polymer processing, rubber, and tyres.

A burner management system (BMS) is the last line of defence in preventing the catastrophic failure of boilers, fired heaters, and other industrial heating systems. In the wax work-up production process at the Sasol plant, the old burner management system for a distillation column furnace reached its end of life and had to be replaced. Running continuously with scheduled shutdowns occurring between two to five years apart, this furnace was very critical to the production and its failure would cause a production loss of up to $150k per day.

Sasol selected Emerson and its local business partner, Aveng Automation and Control Solutions (A&CS), to migrate the old system to the Emerson DeltaV SIS for Burner Management during the annual plant shutdown in 2014. The solution ensured that it would be integrated seamlessly into the plant DeltaV distributed control system, which Sasol adopted in 2012. Moreover, it fulfilled the Sasol objective, which was to be in full compliance with the South African National Standards (SANS) accreditation 329, which sets the safety standards for industrial thermo-processing equipment.

“Safety is a top priority and a core value at Sasol,” said Willie de Beer, Senior Control Technician from Sasol Wax. “Emerson demonstrated technology leadership and project expertise, and together with the excellent local support from Aveng, this ensured a smooth migration process that was completed quickly and ahead of schedule. Through their support, we were able to deploy an advanced system to protect our people and assets from burner hazards.”

The Emerson Burner Management application allows the furnace to go safely through all relevant states, from start-up, to operation and shutdown when needed. It comes with IEC 61508 TÜV certified function blocks that simplify logic configuration, testing, and troubleshooting. An intuitive, graphical control environment conveys critical information in a single glance so operators can understand furnace conditions in real-time, put burners and igniters in and out of service safely and fast, and initiate other timely actions to maintain safe operating conditions.

“We are very happy that we have been able to help Sasol achieve this state of the art burner management,” said Peter Zornio, chief strategic officer for Emerson. “This project demonstrates our DeltaV SIS system flexibility, which has been able to meet BMS needs, increase visibility to plant processes involving fired equipment, and reduce engineering and complexity in system planning, design, configuration, and testing.”

Sasol CEO to join ABB Board

ABB’s Board of Directors has unanimously proposed David Constable, ceo of Sasol, as a new member. The shareholders will vote on his nomination at the company’s next annual general meeting on April 30, 2015.

Constable is the President and CEO of Sasol Limited, a leading international integrated energy and chemicals company based in South Africa, and the former Group President of Operations of Fluor Corporation, where he served for more than 29 years in leadership positions. He is also a member of the WEF International Business Council and The Business Council in the United States. He is 52 and a Canadian national.

Since Constable’s appointment as President and CEO of Sasol, he has driven a comprehensive, group-wide change program, which has reset the organization’s strategies, priorities, culture, operating model, structures, systems and processes. Importantly, he has also shaped the group’s growth initiatives in southern Africa and North America, driving well-defined contracting strategies and world-class project execution.

“David Constable’s nomination to the board reflects ABB’s commitment to strengthen our expertise for EPC solutions and the process industries sector,” said Hubertus von Grünberg, Chairman of the Board. “His strong background and experience in a field where ABB recently faced challenges in the Power Systems division will further enrich our board. His strong link with Africa as an attractive region for ABB makes him a welcome new member of our board.”

Constable has extensive international experience. He has lived and worked in the United States, the Netherlands, Canada, Chile, Argentina and South Africa. He is married with two children.