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optimizationof production processes

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Syed Farukh

1) The document discusses optimization of production processes through condition based management and integration of intelligent process instrumentation and analytic technologies. 2) Key topics include life cycle management, asset management, process efficiency, and reducing unplanned downtime through predictive maintenance. 3) Various process automation and instrumentation solutions are presented for applications in industries like oil and gas, chemicals, and biofuels production.

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ISA Saudi Section 2013 Optimization of Production Processes and Life Cycle Management by Integration of Intelligent Process Instrumentation and Analytic Technologies © Siemens AG 2010. Alle Rechte vorbehalten. Analytic Technologies
Industrial Automation Delhi November 2012 New Trends in Process Automation Life Cycle Management Asset Management Condition Based ManagementCondition Based Management Process / Energy Efficiency Plant and Production OptimizationPlant and Production Optimization Reduction of unscheduled Down Time by Preventive / Predictive Maintenance ConceptsMaintenance Concepts
Life Cycle Management – Single Source for Services A t ti I t t ti El t i l d PAutomation, Instrumentation, Electrical and Power Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail Become a substantial t f th t ' Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail part of the customer's operations team for entire scope of delivery PLC Automation & OTN Multi Vendor Services Operation of the maintenance concept Planning Value Added Services Remote assistance & diagnostics Condition based Product Related Services Keeping specialists – readiness for 24/7 hotline support and Telemetry Scheduling Performance Improving services focused on Key Performance Indicators Reliability guarantees on demand Condition based monitoring Modernization & Migrations Shut Dows Services Consultation for Energy Saving, Project 24/7 hotline support and On-site fault elimination Software & Hardware updates Maintenance & uptime Services Includes third party equipment y g Management and Maintenance ProcessIncludes third party equipment
Life Cycle Management Concept f f O C biliti f j t d l t I l t ti d ti The whole Lifecycle of Plant Operation S t T t Capabilities for project development, Implementation and operation Assembly/ Erection System Test Putting into operation Delivery/Shipment engineering Project- management Delivery/Shipment Documentation Lifecycle Management HW, SW Engineering - Product Related and Value Added Services - Operation Related Services (Frame Agreement) Modernization / Migration Services Studies / Planning - Modernization / Migration Services - Total Cost of Ownership / Plant Availability
Production Efficiency Process Optimization with intelligent Analytics androcess Optimization with intelligent Analytics and Instrumentation Solutions with advanced DiagnosticInstrumentation Solutions with advanced Diagnostic functionalities in order to improve Plant / Energy Efficiencyfunctionalities in order to improve Plant / Energy Efficiency
From Condition based Monitoring to C diti M tCondition Management Condition based Monitoring / Management is a major process in order toCondition based Monitoring / Management is a major process in order to optimize production processes concerning facility operation, efficiency , production quality, quantity and to achieve production repeatability particular d i th i d tiduring the running production process. A major step is to identify the actual requirements, demands and future trends in various industries in all international regions part of this process is thevarious industries in all international regions, part of this process is the development and establishment of the competence concerning detailed segmentation of industries by total solutions, partial solutions as well as single components applications and supportcomponents, applications and support. In order to improve the achievement of business results, a reactive and preventive maintenance process of production facilities has to be turned into ap p p predictive concept .
S l ti C it i / R i t SSelection Criterias / Requirement Specs Physical Measurements Technology-Selectiongy Industry-Segments Solutions Application Database Product-Selection Solutions
From Upstream to Downstream F R fi i S i l Ch i lFrom Refineries to Special Chemicals LNG Oil&Gas Pipeline LNG Offshore Drilling TankfarmCompression Gas Storage G Onshore Oil&Gas Fields Refinery Compression Chemical Industry Gas Treatment Injection HPI Petrochemicals Basic Chemicals (e.g. Fertilizers) HPI Air Separation Fibers/Foils Specialty Chemicals Bio Fine Chemicals (e.g. pharmaceutical pre- products) (e.g. Nylon) Specialty Chemicals (e.g. Oil additives) Chemicals (e.g. Bio-Ethanol) products)
optimizationof production processes
Process Optimization as part of Asset ManagementProcess Optimization as part of Asset Management
Advanced Automation for Emergency Shut down Systems and Solutionstions in order to avoidSystems and Solutionstions in order to avoid Blow Outs and Oil & Gas Leaks
Leak Detection and LocationLeak Detection and Location
Advanced Automation for Emergency Shut down Systems and Solutions in order to avoid CatastrophiesSystems and Solutions in order to avoid Catastrophies in Tank Terminals Ethanol tank farm on fire in Australia Barton Solvents tank farm fire in Kansas, 2007 Chemical tank farm accident
Competence in Level Technologies and Solutions Advanced Overspill ProtectionAdvanced Overspill Protection
Condition Based Management - Process Efficiency Asset and Condition Management Condition Monitoring and Process Optimization using Process Automation and Analytic Technologiesusing Process Automation and Analytic Technologies with intelligent Diagnostics and Condition Based Monitoring Functionalitiesin in order to improve Plant Efficiency / Energy Efficiency
Major Market Trends in Process AutomationMajor Market Trends in Process Automation Goal: Asset Goal: Reduction of unscheduled down-time, protection of equipment improvements on P Management equipment, improvements on safety and reduction of maintenance. Process Analytical PAT Security Wireless Communication M2M Communication Industrial Ethernet Intelligent Field RFID Wireless Machine Field Devices RFID Sensors Vision
P / E Effi iProcess / Energy Efficiency The topic of energy efficiency has come to dominate the field of industryThe topic of energy efficiency has come to dominate the field of industry. This is set to continue into the future as a result of political requirements and concern about the environment and climate. The opportunity to gain cost and competitive advantages through the more efficient use of energy will also ensure that the topic does not lose itsefficient use of energy will also ensure that the topic does not lose its importance. Although efforts have been made in the area of energy efficiency in the past, there is still significant room for improvement in the various industrial sectors.
E Effi i Studies show that from the energy source to the consumer up to 80 % of Energy Efficiency Studies show that, from the energy source to the consumer, up to 80 % of the energy currently used in the various production, transmission and conversion stages can be lost. Source ZVEI
E Effi iEnergy Efficiency Source ZVEI
Totally Integrated Automation: S l I t ti f Fi ld t MESSeamless Integration from Field to MES Automation Hierarchy Products and SystemsMES PAMSManagement level Control level Host computer Monitoring & control systemsMSOS PAMS systems Programmable logic controllers MSOS Field level Sensors, actuators, drives, field instrumentsCMCM CM CM CM CM CM CM CM CM Detectors, switches
Definition of Plant Asset ManagementDefinition of Plant Asset Management Pl A MPlant Asset Management Therapy / Maintenance Proposals and support Operation Communication Communication of the below Information Provision Operation Prediction / Prognosis Forecast and Archiving Maintenance Diagnosis Prognosis Evaluation -> Cause -> Di i fi di Evaluation Analysis Processing Engineering Condition M it i Signal -> Characteristic -> Diagnosis finding Distribution Business admin. Monitoring Analysis
Integrated Plant Asset Management – M it i & O tiMonitoring & Operating OS Clients with accessOS Clients with access to maintenance area (pictures, messages, faceplates) Maintenance Station has additionally direct online C1 Cn ... OS OS MSOS MS Maintenance Station integrated into the additionally direct online access to PDM and hardware engineering ... AS1 AS2 ASn Sn AS – Automation System C – Client S1 ... ... AS1 AS2 ASn integrated into the Operator Station MS – Maintenance Station OS – Operator Station S – Server Maintenance pictures All diagnostic capable SIMATIC PCS 7 components + „non-intelligent“ assets + Common and unified symbols for representing the status of all assets + Good Announcement of request f i t (l ) Request for maintenance k / t ti t d Simulation Function Request for maintenance (medium) for maintenance (low) Maintenance alert (hi h) unknown/not activated Request for maintenance activated Request for maintenance icontrol/ local (high) in process
Automation Interface I t lli t S S t i t ith th A t ti S tIntelligent Sensor Systems communicate with the Automation System f IntelligentIntelligent SensorsSensors Flexibility Start up Parameter Set Function Request Information Digital Value Data Validation Control Loop functionsFunction Request Functions Upgrade Software Download Control Loop functions Diagnosis Information Asset Management Information Field device Integration wired or wireless is crucial
Automation Interface Intelligent Sensor Systems communicate with the Automation System DistributionPROFIBUS DP PROFIBUS PA Ethernet PROFIBUS PA Foundation Fieldbus 4…20mA with HART
optimizationof production processes
Improvement on Production Efficiency Condition Based Management and Energy Efficiency From 1st to 2nd Generation – Bioethanol Production YeastEnzymes Methylation Petrolium spirit Dehydration Delivery Storage Milling Liquefaction Saccharification Fermentation Distillation Storage Water Yeast Co2 Distillation Enzymes Fraction ation Methylation Superheated steam Bioethanol Destiller‘s wash Cooling tower/cooling plant Syrup Concentration Separation Drying DDGS DGS Bioethanol Syrup Storage / Loading
Production Process Optimization with advanced P A t ti I t t ti d A l tiProcess Automation, Instrumentation and Analytics YeastEnzymes Methylation Petrolium spirit Dehydration Delivery Storage Milling Liquefaction Saccharification Fermentation Distillation Storage Water Co2 Distillation Fractionat ion Superheated steam Bioethanol Destiller‘s wash Cooling tower/cooling plant Separation Drying DDGS Destiller s wash Bioethanol Syrup Concentration DDGS DGS Storage / Loading
T t ll I t t d A t ti Operator Workstations Totally Integrated Automation Engineering Workstation Maintenance Workstation Redundant Controller Storage and Load Out InterfacesRedundant Fiber Optic PROFIBUS DP Area 1 Area 2 Area 3 Distributed I/O Distributed I/O Distributed I/O PROFIBUS PA Devices PROFIBUS PA DevicesPROFIBUS PA Devices SMART MCC SMART MCC SMART MCC Typical Application of a Digital Bus Network in an Ethanol Production Facility
Process Optimization with advanced Diagnostic FunctionalitiesDiagnostic Functionalities Evaluation of Frequencies / Frequency Shift / Phase Shift / differiential Frequencies/ Frequency Attenuation
Flow Technologies Fl V l D it C t ti d M fl tFlow, Volume,Density, Concentration and Massflowmeters Open Channel, non-filled pipes Solids Flow/ Impact Flow Belt Scales Mass Dynamics Flowmeter t l Venturi US Flow Magn. ind. Flowmeters Closed pipes Impact Flow Mass Dynamics rectangle-, triangle weir Volume- meters Volume- flowmeters applicable Mass- flowmeters Non Pipe Ultrasonic Flowmeters Coriolis omega / bent tube Vortex flowmeterCoriolis parallel Rotary piston meter Intrusive Oval wheel meter restricted applicable non applicable Single Beam Multi Beam Single Beam Multi Beam Spool Piece Intrusive (Clamp on) Variable Area- flowmeters Effective Pressure Technology parallel tubes A li ti Twist flow- meter Turbometer, Positiv- displacement Coriolis single straight tube Comparison Beam BeamBeam Beam Transit Time Transit Time Doppler Magn. Ind. flowmeters Pulsed AC ACPulsed DC Applications meter, Woltman- meter Thermal Wide Beam Narrow Beam (Shear Mode) Transit Time Doppler TransitTime Narrow Beam (Shear Mode) Beam (Shear Mode)(Shear Mode)
Technology Comparison, e.g. Detection of Flow, V l D it C t ti MVolume, Density, Concentration, Mass
Magnetic Flowmeter Condition Monitoring Metal Particles in MediaMetal Particles in Media Metal particles in media
Reduction on waste of Natural Sources Environmental Cleaning Costs > 1 Mio € Leak Detection / Leak Location as part of Condition Based Monitoring Condition Monitoring on Gas and Liquids Flow Lines in order to reduce the waste on natural Environmental Cleaning Costs > 1 Mio € order to reduce the waste on natural resources and optimize Energy Efficiency on Pumps, Compressors, Filters and Shut Down Time for claening purposes
Differential Pressure Condition Monitoring Fouling of Impulse Lineg p Impulse Line
L l M t T h l iLevel Measurement Technologies Electronic Overfill Mechanical Electronic Point LevelContinous Interface contact Protection Mechanical Non contact Servo Displacer Oscillating Vibrating Capacitance Servo TDR Optical Capacitance Servo Displacer Capacitance Ultrasonic Interface Ultrasonic Sense Disc Float Magneto- strictive TDR Conductive Laser Nucleonic Static weighing Capacitance Conductive Nucleonic Capacitance TDR Static Weighingstrictive weighing Hydrostatic Optical Laser Radar S b ibl Hydrostatic Weighing Hydrostatic Delta P P lChi Radar Ultrasonic Radar TDR FMCW CW Reflectometer Low / High F Absolute Bubble System Submersible P K b d Delta P PulsChirp TDRCW FrequencyPressure Keyboard
L l M t T h l iLevel Measurement Technologies Sitrans LG Sitrans LU Sitrans LR Sitrans LR Sitrans LR Sitrans LCSitrans LG Guided Wave Radar / TDR Sitrans LU Ultrasonic Sitrans LR 2 wire Pulse Radar Sitrans LR 4 wire Pulse Radar Sitrans LR 4 wire FMCW Radar Sitrans LC Capacitance LEVEL I t f Technology ApplicationLEVEL TECHNOLOGIES Interface Technology Description Application Simulation
Simulation of Process Conditions / ApplicationsSimulation of Process Conditions / Applications Pulse 6 GHz Radar Sitrans LR 200/300 Pressure Sitrans P FMCW/Pulse 24 GHz Radar Sitrans LR 400/460/250 Capacitance Sitrans LC500 Ultrasonic Sitrans LU Guided Wave Radar Sitrans LG200
Process Optimization in Petrochemical Production Processes
Customized Solution in Synthol Production Processes Optimization of Separation Process with advanced GAS WATER & OIL SEPARATOR p p Interface Detection GAS, WATER, & OIL SEPARATOR Process Details and Requirements DE-MISTER PADS HEAT EXCHANGERS1. Measurement section determines transmitter oscillator frequency Gas intake GAS oscillator frequency. 2. Driver circuit applies same frequency to active shield. 3 Electrical potential between DP TX for Oil Level OILWATER / INTERFACE MEASUREMENT OIL INTERFACE OIL OUTLETOIL 3. Electrical potential between shield and measurement section is zero. Result: WATER WATER OUTLET Ignores dust, vapor, and material deposits on the active shield portion of the electrodeelectrode.
Capacitance vs. TDR Interface MeasurementCapacitance vs. TDR Interface Measurement Sitrans LC 500 Sitrans LG200Sitrans LC 500 Capacitance Sitrans LG200 TDR Max Span: 20 mA – 59 pF 100 % Water Min Span: 4 mA – 6 pF Referenz: 12 mA – 44 pF 50 % Water / 50 % Test Benzine Min Span: 4 mA – 6 pF 100 % Test Benzine
Process Optimization in Chemical Production Processes ZUARI
Safety Requirements (Burst Conditions) Operation on Styrene / Styrol ProcessesOperation on Styrene / Styrol Processes Design related to Burst Safety Requirements 300 deg C at 40 bars
Maintenance optimization with advanced Instrumentation Technologies Safety Check during Operation of the ReactorTechnologies Safety Check during Operation of the Reactor without Shut Down of Production 10dB D t Level Radar Dust Vapour Steam ConstructionConstruction Obstacles Tubings Interference Foam Turbulent Product surface Votex 30dB Agitator Heating Coils Reduction of unscheduled Down Time
Process Optimization in the Chemical Production Processes C t i d S l ti i th F tili I d t S tCustomized Solutions in the Fertilizer Industry Segment The fertilizer plant produces both simple (classic) and composed fertilizers. The process which is at concern here goes about the basic fertilizers and comprises several reactors in line, where mainly acids t li d ith iare neutralized with ammonia, which is a known basic component for fertilizers.
Monitoring of Deposit and Corrosion on Sensor Probe and Reactor in order to increase Production Efficiency and reductioneacto o de to c ease oduct o c e cy a d educt o on Maintenance Costs purging and coating of sensor probes highly adhesive endhighly adhesive end product hardens out very fast consistency of cementconsistency of cement existing solution inaccurate Coated Sensor Probes In the reactors this process causes aIn the reactors, this process causes a very erosive, abrasive and corrosive liquid which ends up as a solid final product This hardens out very fast and isproduct. This hardens out very fast and is then granulated. Reduction of unscheduled Down Time
Monitoring of Deposit on Sensor Probe and Reactor Condition in order to increase Production Efficiency and reduction on Application: Process requirements: Encrustation inside the in order to increase Production Efficiency and reduction on Maintenance Costs by controlled cleaning in place Process requirements: Measuring safe and maintenance free level- and volume detection Use of a integrated purge kit Raw materials antenna integrated purge kit Technologies: Process Radar Solution: 20mA Flushing in/out 20dB Solution: Condition Management By the comparison of the internal antenna reflection th i t t d fl hi Encrustation the integrated flushing system is activated and deactivated. The additional status and diagnosis information 4mA diagnosis information avoids production interruption Titan dioxide production Very dirty and sticky 30dB Production Operation Very dirty and sticky dioxide process reactor Reduction of unscheduled Down Time
Foam Layer Monitoring in order to avoid overspill of Foam, increase of Production Efficiency and reduction onincrease of Production Efficiency and reduction on Maintenance Costs Application:pp Resin production Foam during vacuum phase Process requirements: Vacuum Vacuum outlet Condensation filter Condition Monitoring Level control and reduction of foam layer Avoidance of pipe and filter 20mA Avoidance of pipe and filter blockages Technologies: Process Radar Instrumentation Resin 10cm Foam Solution:Condition Management Foam layer control by evaluation of attenuation of the microwave 4mA Resin products radiation while penetrating through the foam Start and stop of vacuum phase t ll d b fid h B ili ti l t d Production Operation 40dB controlled by confidence echo Boiling process stimulated by vacuum Reduction of unscheduled Down Time
Pressure Technologies Piezo resistive Capacitance Inductive Resonance B bbl t DiaphragmRemote seal Dry / ceramic cells VibrationCeramic cell Absolute pressure Submersible Bubble system air/nitrogen Injection Differential pressure Gauge pressure S b iblAb l t Bubble-LEVEL Differential SubmersibleAbsolute Bubble- system Air/ nitrogen Injection LEVEL e e t a pressure Differential with PLC FLOW Orifice Hydrostatic incl. density CLOSE Screen condition FLOW Orifice Gold-plated diaphragm Calibration CLOSE detection Venturi p g P300Steam Shock
Pressure Measurement d l f lCondition Monitoring - Fouling of Remote Seal Condition ManagementCondition Management Remote Seal Purge Kit
Advanced Diagnostics on Positioner Technologies Actuaters Electric Pneumatic Hydraulic RotaryLinearValves Perforated Plug Valves Linear Plug Valves Ball Valves Flame proof PS3 Enclosures Eccentric Plug Valves Bray Butterfly Valve Sliding Gate Valves Turn Plug Valves Gate Valves Stainless Steel Plastic Damper Drive Positioners Pneumatic Electro Pneumatic Electro Pneumatic Digital Intelligent Single Acting Intelligent Double Acting CLOSE Double Acting Configuration SimulationExploded view Diagnostics 3D PDF
Kompetenz in Lösungen mit Stellungsreglern Asset Management / TCO / Condition ManagementAsset Management / TCO / Condition Management Optimization on Configurations of Valves and Positioners
Competence in Valve Positioner Technologies Asset Management / TCO / Condition Management Shaft Stopfbuchse Spindel g g Valve and Positioner Configuration Optimization Stopfbuchse Ventilsitz Valve
Condition Monitoring and Managementon Valves and Flow Lines in order to optimize Plant Operation and SafetyFlow Lines in order to optimize Plant Operation and Safety Partial Stroke Test, Leak Detection, Valve Wear and Deposit
Energie Savings with advanced Condition Based Monitoring 500 000€/a Energy Savings on Motors Drives Condition Monitoring on Valves and Pumps Wirtschaftlichkeitsvergleich Monitoring 500.000€/a Energy Savings on Motors, Drives, Pumps of 137.000€/a Condition Monitoring on Valves and Pumps Optimization of Energy Efficiency, Production Efficiency and Operation Costs with intelligent Prozess Sensors and Analytical Technologies andsetzung) g einer Schlauch-Membran-Kolbenpumpe mit und ohne Online-Ventildiagnosesystem 300.000 € 400.000 € 500.000 € andsetzung) 300.000 € 400.000 € 500.000 € Kosten(InvestitionundInsta 0 5 10 15 20 25 30 0 € 100.000 € 200.000 € Jahre Kosten(InvestitionundInsta 0 5 10 15 20 25 30 0 € 100.000 € 200.000 € Jahre
Process Optimization with advanced Process Analytic Technologies Solutions and Applications Oxygen UV Single or few components Stack Emissions Monitoring Continuous Gas Analyzers yg FID Hydrogen Combustion Control Incinerator Measurement StandardGas Chromotagraphy y g Infrared Multi Component H2O/Trace H2O Standard Miniature Gas Chromotagraphy Laser Spectrometry Multi Component Complex Gas Streams Single or few components Spectrometry Laser Spectrometry Mass Spectrometry AOTF Single or few components Stack Emissions Monitoring Combustion ControlAOTF FTIR/FTNIR Combustion Control Incinerator Measurement H2O/T H2O E-box SibenchExhaust Gas Analysers H2O/Trace H2O
Recovery of Hydrocarbons with an Energy E i l f 7 i Lit f C d OilEquivalence of 7 mio Liter of Crude Oil per year
The Cooperation as part of Customer Relationship C t d i f diff t j t h b id tifi dCost drivers for different project phases can be identified CAPEX OPEXPre CAPEX Modernisation/ Decommissioning Advanced automation and instrumentation technology knowhow made it possible to find flexible solutions for various harsch applications,p pp based on the creativity of the customers and supplier. Optimization on configurations and application knowledge opens doors in industry segments for reliable and cost saving solutions.doors in industry segments for reliable and cost saving solutions. The cooperation between industries and suppliers very close, the support and testing are done within a framework of consequent partnershippartnership.
Safety Requirements Regional Requirementsg q Approvals, Certificates, Declarations, Typ Testing
Chemical Companies A id t & C t t hAccidents & Catastrophes Algeria 2007: The explosion in the industrial town of Blida killed 5 people and wounded 10 others
Chemical Companies A id t & C t t hAccidents & Catastrophes Texas, 2005
Condition based Monitoring / Management Health & SafetyHealth & Safety The goal and target is competent support starting with the planning process ofThe goal and target is competent support starting with the planning process of production facilities until the commissioning and start up as well as support and consultancy over the whole facility life cycle in order to reduce follow up costs as part of Total Costs of Ownership and Down Time and avoid additional unexpected modifications to optimize production volume and quality. The key tasks for the increase of efficiency during the implementation of condition management are: Reduction of unexpected down timeReduction of unexpected down time Production quality Production quantity Production effectivity and repeatabilityy p y Protection equipment and components Increase of safety Reduction of non useful preventive maintenance Up to 50% of preventive maintenance investments are not necessary, these expenses can increase up to 20% of the total maintenance costs. This conclusion is a clear statement and fact to change from preventive to predictive i imaintenance strategies.

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optimizationof production processes

  • 1. ISA Saudi Section 2013 Optimization of Production Processes and Life Cycle Management by Integration of Intelligent Process Instrumentation and Analytic Technologies © Siemens AG 2010. Alle Rechte vorbehalten. Analytic Technologies
  • 2. Industrial Automation Delhi November 2012 New Trends in Process Automation Life Cycle Management Asset Management Condition Based ManagementCondition Based Management Process / Energy Efficiency Plant and Production OptimizationPlant and Production Optimization Reduction of unscheduled Down Time by Preventive / Predictive Maintenance ConceptsMaintenance Concepts
  • 3. Life Cycle Management – Single Source for Services A t ti I t t ti El t i l d PAutomation, Instrumentation, Electrical and Power Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail Become a substantial t f th t ' Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail part of the customer's operations team for entire scope of delivery PLC Automation & OTN Multi Vendor Services Operation of the maintenance concept Planning Value Added Services Remote assistance & diagnostics Condition based Product Related Services Keeping specialists – readiness for 24/7 hotline support and Telemetry Scheduling Performance Improving services focused on Key Performance Indicators Reliability guarantees on demand Condition based monitoring Modernization & Migrations Shut Dows Services Consultation for Energy Saving, Project 24/7 hotline support and On-site fault elimination Software & Hardware updates Maintenance & uptime Services Includes third party equipment y g Management and Maintenance ProcessIncludes third party equipment
  • 4. Life Cycle Management Concept f f O C biliti f j t d l t I l t ti d ti The whole Lifecycle of Plant Operation S t T t Capabilities for project development, Implementation and operation Assembly/ Erection System Test Putting into operation Delivery/Shipment engineering Project- management Delivery/Shipment Documentation Lifecycle Management HW, SW Engineering - Product Related and Value Added Services - Operation Related Services (Frame Agreement) Modernization / Migration Services Studies / Planning - Modernization / Migration Services - Total Cost of Ownership / Plant Availability
  • 5. Production Efficiency Process Optimization with intelligent Analytics androcess Optimization with intelligent Analytics and Instrumentation Solutions with advanced DiagnosticInstrumentation Solutions with advanced Diagnostic functionalities in order to improve Plant / Energy Efficiencyfunctionalities in order to improve Plant / Energy Efficiency
  • 6. From Condition based Monitoring to C diti M tCondition Management Condition based Monitoring / Management is a major process in order toCondition based Monitoring / Management is a major process in order to optimize production processes concerning facility operation, efficiency , production quality, quantity and to achieve production repeatability particular d i th i d tiduring the running production process. A major step is to identify the actual requirements, demands and future trends in various industries in all international regions part of this process is thevarious industries in all international regions, part of this process is the development and establishment of the competence concerning detailed segmentation of industries by total solutions, partial solutions as well as single components applications and supportcomponents, applications and support. In order to improve the achievement of business results, a reactive and preventive maintenance process of production facilities has to be turned into ap p p predictive concept .
  • 7. S l ti C it i / R i t SSelection Criterias / Requirement Specs Physical Measurements Technology-Selectiongy Industry-Segments Solutions Application Database Product-Selection Solutions
  • 8. From Upstream to Downstream F R fi i S i l Ch i lFrom Refineries to Special Chemicals LNG Oil&Gas Pipeline LNG Offshore Drilling TankfarmCompression Gas Storage G Onshore Oil&Gas Fields Refinery Compression Chemical Industry Gas Treatment Injection HPI Petrochemicals Basic Chemicals (e.g. Fertilizers) HPI Air Separation Fibers/Foils Specialty Chemicals Bio Fine Chemicals (e.g. pharmaceutical pre- products) (e.g. Nylon) Specialty Chemicals (e.g. Oil additives) Chemicals (e.g. Bio-Ethanol) products)
  • 10. Process Optimization as part of Asset ManagementProcess Optimization as part of Asset Management
  • 11. Advanced Automation for Emergency Shut down Systems and Solutionstions in order to avoidSystems and Solutionstions in order to avoid Blow Outs and Oil & Gas Leaks
  • 12. Leak Detection and LocationLeak Detection and Location
  • 13. Advanced Automation for Emergency Shut down Systems and Solutions in order to avoid CatastrophiesSystems and Solutions in order to avoid Catastrophies in Tank Terminals Ethanol tank farm on fire in Australia Barton Solvents tank farm fire in Kansas, 2007 Chemical tank farm accident
  • 14. Competence in Level Technologies and Solutions Advanced Overspill ProtectionAdvanced Overspill Protection
  • 15. Condition Based Management - Process Efficiency Asset and Condition Management Condition Monitoring and Process Optimization using Process Automation and Analytic Technologiesusing Process Automation and Analytic Technologies with intelligent Diagnostics and Condition Based Monitoring Functionalitiesin in order to improve Plant Efficiency / Energy Efficiency
  • 16. Major Market Trends in Process AutomationMajor Market Trends in Process Automation Goal: Asset Goal: Reduction of unscheduled down-time, protection of equipment improvements on P Management equipment, improvements on safety and reduction of maintenance. Process Analytical PAT Security Wireless Communication M2M Communication Industrial Ethernet Intelligent Field RFID Wireless Machine Field Devices RFID Sensors Vision
  • 17. P / E Effi iProcess / Energy Efficiency The topic of energy efficiency has come to dominate the field of industryThe topic of energy efficiency has come to dominate the field of industry. This is set to continue into the future as a result of political requirements and concern about the environment and climate. The opportunity to gain cost and competitive advantages through the more efficient use of energy will also ensure that the topic does not lose itsefficient use of energy will also ensure that the topic does not lose its importance. Although efforts have been made in the area of energy efficiency in the past, there is still significant room for improvement in the various industrial sectors.
  • 18. E Effi i Studies show that from the energy source to the consumer up to 80 % of Energy Efficiency Studies show that, from the energy source to the consumer, up to 80 % of the energy currently used in the various production, transmission and conversion stages can be lost. Source ZVEI
  • 19. E Effi iEnergy Efficiency Source ZVEI
  • 20. Totally Integrated Automation: S l I t ti f Fi ld t MESSeamless Integration from Field to MES Automation Hierarchy Products and SystemsMES PAMSManagement level Control level Host computer Monitoring & control systemsMSOS PAMS systems Programmable logic controllers MSOS Field level Sensors, actuators, drives, field instrumentsCMCM CM CM CM CM CM CM CM CM Detectors, switches
  • 21. Definition of Plant Asset ManagementDefinition of Plant Asset Management Pl A MPlant Asset Management Therapy / Maintenance Proposals and support Operation Communication Communication of the below Information Provision Operation Prediction / Prognosis Forecast and Archiving Maintenance Diagnosis Prognosis Evaluation -> Cause -> Di i fi di Evaluation Analysis Processing Engineering Condition M it i Signal -> Characteristic -> Diagnosis finding Distribution Business admin. Monitoring Analysis
  • 22. Integrated Plant Asset Management – M it i & O tiMonitoring & Operating OS Clients with accessOS Clients with access to maintenance area (pictures, messages, faceplates) Maintenance Station has additionally direct online C1 Cn ... OS OS MSOS MS Maintenance Station integrated into the additionally direct online access to PDM and hardware engineering ... AS1 AS2 ASn Sn AS – Automation System C – Client S1 ... ... AS1 AS2 ASn integrated into the Operator Station MS – Maintenance Station OS – Operator Station S – Server Maintenance pictures All diagnostic capable SIMATIC PCS 7 components + „non-intelligent“ assets + Common and unified symbols for representing the status of all assets + Good Announcement of request f i t (l ) Request for maintenance k / t ti t d Simulation Function Request for maintenance (medium) for maintenance (low) Maintenance alert (hi h) unknown/not activated Request for maintenance activated Request for maintenance icontrol/ local (high) in process
  • 23. Automation Interface I t lli t S S t i t ith th A t ti S tIntelligent Sensor Systems communicate with the Automation System f IntelligentIntelligent SensorsSensors Flexibility Start up Parameter Set Function Request Information Digital Value Data Validation Control Loop functionsFunction Request Functions Upgrade Software Download Control Loop functions Diagnosis Information Asset Management Information Field device Integration wired or wireless is crucial
  • 24. Automation Interface Intelligent Sensor Systems communicate with the Automation System DistributionPROFIBUS DP PROFIBUS PA Ethernet PROFIBUS PA Foundation Fieldbus 4…20mA with HART
  • 26. Improvement on Production Efficiency Condition Based Management and Energy Efficiency From 1st to 2nd Generation – Bioethanol Production YeastEnzymes Methylation Petrolium spirit Dehydration Delivery Storage Milling Liquefaction Saccharification Fermentation Distillation Storage Water Yeast Co2 Distillation Enzymes Fraction ation Methylation Superheated steam Bioethanol Destiller‘s wash Cooling tower/cooling plant Syrup Concentration Separation Drying DDGS DGS Bioethanol Syrup Storage / Loading
  • 27. Production Process Optimization with advanced P A t ti I t t ti d A l tiProcess Automation, Instrumentation and Analytics YeastEnzymes Methylation Petrolium spirit Dehydration Delivery Storage Milling Liquefaction Saccharification Fermentation Distillation Storage Water Co2 Distillation Fractionat ion Superheated steam Bioethanol Destiller‘s wash Cooling tower/cooling plant Separation Drying DDGS Destiller s wash Bioethanol Syrup Concentration DDGS DGS Storage / Loading
  • 28. T t ll I t t d A t ti Operator Workstations Totally Integrated Automation Engineering Workstation Maintenance Workstation Redundant Controller Storage and Load Out InterfacesRedundant Fiber Optic PROFIBUS DP Area 1 Area 2 Area 3 Distributed I/O Distributed I/O Distributed I/O PROFIBUS PA Devices PROFIBUS PA DevicesPROFIBUS PA Devices SMART MCC SMART MCC SMART MCC Typical Application of a Digital Bus Network in an Ethanol Production Facility
  • 29. Process Optimization with advanced Diagnostic FunctionalitiesDiagnostic Functionalities Evaluation of Frequencies / Frequency Shift / Phase Shift / differiential Frequencies/ Frequency Attenuation
  • 30. Flow Technologies Fl V l D it C t ti d M fl tFlow, Volume,Density, Concentration and Massflowmeters Open Channel, non-filled pipes Solids Flow/ Impact Flow Belt Scales Mass Dynamics Flowmeter t l Venturi US Flow Magn. ind. Flowmeters Closed pipes Impact Flow Mass Dynamics rectangle-, triangle weir Volume- meters Volume- flowmeters applicable Mass- flowmeters Non Pipe Ultrasonic Flowmeters Coriolis omega / bent tube Vortex flowmeterCoriolis parallel Rotary piston meter Intrusive Oval wheel meter restricted applicable non applicable Single Beam Multi Beam Single Beam Multi Beam Spool Piece Intrusive (Clamp on) Variable Area- flowmeters Effective Pressure Technology parallel tubes A li ti Twist flow- meter Turbometer, Positiv- displacement Coriolis single straight tube Comparison Beam BeamBeam Beam Transit Time Transit Time Doppler Magn. Ind. flowmeters Pulsed AC ACPulsed DC Applications meter, Woltman- meter Thermal Wide Beam Narrow Beam (Shear Mode) Transit Time Doppler TransitTime Narrow Beam (Shear Mode) Beam (Shear Mode)(Shear Mode)
  • 31. Technology Comparison, e.g. Detection of Flow, V l D it C t ti MVolume, Density, Concentration, Mass
  • 32. Magnetic Flowmeter Condition Monitoring Metal Particles in MediaMetal Particles in Media Metal particles in media
  • 33. Reduction on waste of Natural Sources Environmental Cleaning Costs > 1 Mio € Leak Detection / Leak Location as part of Condition Based Monitoring Condition Monitoring on Gas and Liquids Flow Lines in order to reduce the waste on natural Environmental Cleaning Costs > 1 Mio € order to reduce the waste on natural resources and optimize Energy Efficiency on Pumps, Compressors, Filters and Shut Down Time for claening purposes
  • 34. Differential Pressure Condition Monitoring Fouling of Impulse Lineg p Impulse Line
  • 35. L l M t T h l iLevel Measurement Technologies Electronic Overfill Mechanical Electronic Point LevelContinous Interface contact Protection Mechanical Non contact Servo Displacer Oscillating Vibrating Capacitance Servo TDR Optical Capacitance Servo Displacer Capacitance Ultrasonic Interface Ultrasonic Sense Disc Float Magneto- strictive TDR Conductive Laser Nucleonic Static weighing Capacitance Conductive Nucleonic Capacitance TDR Static Weighingstrictive weighing Hydrostatic Optical Laser Radar S b ibl Hydrostatic Weighing Hydrostatic Delta P P lChi Radar Ultrasonic Radar TDR FMCW CW Reflectometer Low / High F Absolute Bubble System Submersible P K b d Delta P PulsChirp TDRCW FrequencyPressure Keyboard
  • 36. L l M t T h l iLevel Measurement Technologies Sitrans LG Sitrans LU Sitrans LR Sitrans LR Sitrans LR Sitrans LCSitrans LG Guided Wave Radar / TDR Sitrans LU Ultrasonic Sitrans LR 2 wire Pulse Radar Sitrans LR 4 wire Pulse Radar Sitrans LR 4 wire FMCW Radar Sitrans LC Capacitance LEVEL I t f Technology ApplicationLEVEL TECHNOLOGIES Interface Technology Description Application Simulation
  • 37. Simulation of Process Conditions / ApplicationsSimulation of Process Conditions / Applications Pulse 6 GHz Radar Sitrans LR 200/300 Pressure Sitrans P FMCW/Pulse 24 GHz Radar Sitrans LR 400/460/250 Capacitance Sitrans LC500 Ultrasonic Sitrans LU Guided Wave Radar Sitrans LG200
  • 38. Process Optimization in Petrochemical Production Processes
  • 39. Customized Solution in Synthol Production Processes Optimization of Separation Process with advanced GAS WATER & OIL SEPARATOR p p Interface Detection GAS, WATER, & OIL SEPARATOR Process Details and Requirements DE-MISTER PADS HEAT EXCHANGERS1. Measurement section determines transmitter oscillator frequency Gas intake GAS oscillator frequency. 2. Driver circuit applies same frequency to active shield. 3 Electrical potential between DP TX for Oil Level OILWATER / INTERFACE MEASUREMENT OIL INTERFACE OIL OUTLETOIL 3. Electrical potential between shield and measurement section is zero. Result: WATER WATER OUTLET Ignores dust, vapor, and material deposits on the active shield portion of the electrodeelectrode.
  • 40. Capacitance vs. TDR Interface MeasurementCapacitance vs. TDR Interface Measurement Sitrans LC 500 Sitrans LG200Sitrans LC 500 Capacitance Sitrans LG200 TDR Max Span: 20 mA – 59 pF 100 % Water Min Span: 4 mA – 6 pF Referenz: 12 mA – 44 pF 50 % Water / 50 % Test Benzine Min Span: 4 mA – 6 pF 100 % Test Benzine
  • 41. Process Optimization in Chemical Production Processes ZUARI
  • 42. Safety Requirements (Burst Conditions) Operation on Styrene / Styrol ProcessesOperation on Styrene / Styrol Processes Design related to Burst Safety Requirements 300 deg C at 40 bars
  • 43. Maintenance optimization with advanced Instrumentation Technologies Safety Check during Operation of the ReactorTechnologies Safety Check during Operation of the Reactor without Shut Down of Production 10dB D t Level Radar Dust Vapour Steam ConstructionConstruction Obstacles Tubings Interference Foam Turbulent Product surface Votex 30dB Agitator Heating Coils Reduction of unscheduled Down Time
  • 44. Process Optimization in the Chemical Production Processes C t i d S l ti i th F tili I d t S tCustomized Solutions in the Fertilizer Industry Segment The fertilizer plant produces both simple (classic) and composed fertilizers. The process which is at concern here goes about the basic fertilizers and comprises several reactors in line, where mainly acids t li d ith iare neutralized with ammonia, which is a known basic component for fertilizers.
  • 45. Monitoring of Deposit and Corrosion on Sensor Probe and Reactor in order to increase Production Efficiency and reductioneacto o de to c ease oduct o c e cy a d educt o on Maintenance Costs purging and coating of sensor probes highly adhesive endhighly adhesive end product hardens out very fast consistency of cementconsistency of cement existing solution inaccurate Coated Sensor Probes In the reactors this process causes aIn the reactors, this process causes a very erosive, abrasive and corrosive liquid which ends up as a solid final product This hardens out very fast and isproduct. This hardens out very fast and is then granulated. Reduction of unscheduled Down Time
  • 46. Monitoring of Deposit on Sensor Probe and Reactor Condition in order to increase Production Efficiency and reduction on Application: Process requirements: Encrustation inside the in order to increase Production Efficiency and reduction on Maintenance Costs by controlled cleaning in place Process requirements: Measuring safe and maintenance free level- and volume detection Use of a integrated purge kit Raw materials antenna integrated purge kit Technologies: Process Radar Solution: 20mA Flushing in/out 20dB Solution: Condition Management By the comparison of the internal antenna reflection th i t t d fl hi Encrustation the integrated flushing system is activated and deactivated. The additional status and diagnosis information 4mA diagnosis information avoids production interruption Titan dioxide production Very dirty and sticky 30dB Production Operation Very dirty and sticky dioxide process reactor Reduction of unscheduled Down Time
  • 47. Foam Layer Monitoring in order to avoid overspill of Foam, increase of Production Efficiency and reduction onincrease of Production Efficiency and reduction on Maintenance Costs Application:pp Resin production Foam during vacuum phase Process requirements: Vacuum Vacuum outlet Condensation filter Condition Monitoring Level control and reduction of foam layer Avoidance of pipe and filter 20mA Avoidance of pipe and filter blockages Technologies: Process Radar Instrumentation Resin 10cm Foam Solution:Condition Management Foam layer control by evaluation of attenuation of the microwave 4mA Resin products radiation while penetrating through the foam Start and stop of vacuum phase t ll d b fid h B ili ti l t d Production Operation 40dB controlled by confidence echo Boiling process stimulated by vacuum Reduction of unscheduled Down Time
  • 48. Pressure Technologies Piezo resistive Capacitance Inductive Resonance B bbl t DiaphragmRemote seal Dry / ceramic cells VibrationCeramic cell Absolute pressure Submersible Bubble system air/nitrogen Injection Differential pressure Gauge pressure S b iblAb l t Bubble-LEVEL Differential SubmersibleAbsolute Bubble- system Air/ nitrogen Injection LEVEL e e t a pressure Differential with PLC FLOW Orifice Hydrostatic incl. density CLOSE Screen condition FLOW Orifice Gold-plated diaphragm Calibration CLOSE detection Venturi p g P300Steam Shock
  • 49. Pressure Measurement d l f lCondition Monitoring - Fouling of Remote Seal Condition ManagementCondition Management Remote Seal Purge Kit
  • 50. Advanced Diagnostics on Positioner Technologies Actuaters Electric Pneumatic Hydraulic RotaryLinearValves Perforated Plug Valves Linear Plug Valves Ball Valves Flame proof PS3 Enclosures Eccentric Plug Valves Bray Butterfly Valve Sliding Gate Valves Turn Plug Valves Gate Valves Stainless Steel Plastic Damper Drive Positioners Pneumatic Electro Pneumatic Electro Pneumatic Digital Intelligent Single Acting Intelligent Double Acting CLOSE Double Acting Configuration SimulationExploded view Diagnostics 3D PDF
  • 51. Kompetenz in Lösungen mit Stellungsreglern Asset Management / TCO / Condition ManagementAsset Management / TCO / Condition Management Optimization on Configurations of Valves and Positioners
  • 52. Competence in Valve Positioner Technologies Asset Management / TCO / Condition Management Shaft Stopfbuchse Spindel g g Valve and Positioner Configuration Optimization Stopfbuchse Ventilsitz Valve
  • 53. Condition Monitoring and Managementon Valves and Flow Lines in order to optimize Plant Operation and SafetyFlow Lines in order to optimize Plant Operation and Safety Partial Stroke Test, Leak Detection, Valve Wear and Deposit
  • 54. Energie Savings with advanced Condition Based Monitoring 500 000€/a Energy Savings on Motors Drives Condition Monitoring on Valves and Pumps Wirtschaftlichkeitsvergleich Monitoring 500.000€/a Energy Savings on Motors, Drives, Pumps of 137.000€/a Condition Monitoring on Valves and Pumps Optimization of Energy Efficiency, Production Efficiency and Operation Costs with intelligent Prozess Sensors and Analytical Technologies andsetzung) g einer Schlauch-Membran-Kolbenpumpe mit und ohne Online-Ventildiagnosesystem 300.000 € 400.000 € 500.000 € andsetzung) 300.000 € 400.000 € 500.000 € Kosten(InvestitionundInsta 0 5 10 15 20 25 30 0 € 100.000 € 200.000 € Jahre Kosten(InvestitionundInsta 0 5 10 15 20 25 30 0 € 100.000 € 200.000 € Jahre
  • 55. Process Optimization with advanced Process Analytic Technologies Solutions and Applications Oxygen UV Single or few components Stack Emissions Monitoring Continuous Gas Analyzers yg FID Hydrogen Combustion Control Incinerator Measurement StandardGas Chromotagraphy y g Infrared Multi Component H2O/Trace H2O Standard Miniature Gas Chromotagraphy Laser Spectrometry Multi Component Complex Gas Streams Single or few components Spectrometry Laser Spectrometry Mass Spectrometry AOTF Single or few components Stack Emissions Monitoring Combustion ControlAOTF FTIR/FTNIR Combustion Control Incinerator Measurement H2O/T H2O E-box SibenchExhaust Gas Analysers H2O/Trace H2O
  • 56. Recovery of Hydrocarbons with an Energy E i l f 7 i Lit f C d OilEquivalence of 7 mio Liter of Crude Oil per year
  • 57. The Cooperation as part of Customer Relationship C t d i f diff t j t h b id tifi dCost drivers for different project phases can be identified CAPEX OPEXPre CAPEX Modernisation/ Decommissioning Advanced automation and instrumentation technology knowhow made it possible to find flexible solutions for various harsch applications,p pp based on the creativity of the customers and supplier. Optimization on configurations and application knowledge opens doors in industry segments for reliable and cost saving solutions.doors in industry segments for reliable and cost saving solutions. The cooperation between industries and suppliers very close, the support and testing are done within a framework of consequent partnershippartnership.
  • 58. Safety Requirements Regional Requirementsg q Approvals, Certificates, Declarations, Typ Testing
  • 59. Chemical Companies A id t & C t t hAccidents & Catastrophes Algeria 2007: The explosion in the industrial town of Blida killed 5 people and wounded 10 others
  • 60. Chemical Companies A id t & C t t hAccidents & Catastrophes Texas, 2005
  • 61. Condition based Monitoring / Management Health & SafetyHealth & Safety The goal and target is competent support starting with the planning process ofThe goal and target is competent support starting with the planning process of production facilities until the commissioning and start up as well as support and consultancy over the whole facility life cycle in order to reduce follow up costs as part of Total Costs of Ownership and Down Time and avoid additional unexpected modifications to optimize production volume and quality. The key tasks for the increase of efficiency during the implementation of condition management are: Reduction of unexpected down timeReduction of unexpected down time Production quality Production quantity Production effectivity and repeatabilityy p y Protection equipment and components Increase of safety Reduction of non useful preventive maintenance Up to 50% of preventive maintenance investments are not necessary, these expenses can increase up to 20% of the total maintenance costs. This conclusion is a clear statement and fact to change from preventive to predictive i imaintenance strategies.