Advanced PRD Monitoring Systemscontent.4cmarketplace.com/presentations/Donnangelo... · Advanced PRD Monitoring Systems Advanced PRD Monitoring Systems This presentation discusses

02/24/2016 Page 1 Advanced PRD Monitoring Systems

Advanced PRD Monitoring Systems

Marcio Donnangelo Global Business Development HSSE Applications

Don Cramer Instrument Project Coordinator Texas City - Refining Division

Company logo here

Company logo here


Advanced PRD Monitoring Systems This presentation discusses new EPA regulations for pressure relief devices and the most cost-effective and non-intrusive solutions to comply by using PRV downstream acoustic monitoring. Marcio Donnangelo with Emerson will discuss how to continuously monitor PRV conditions, such as release, leakage and simmering; submit comprehensive data for better and faster electronic EPA filing; improve operator safety and efficiency. Don Cramer with Marathon Petroleum gives a real case example and PRV acoustic monitoring results. He discusses how Marathon complied with EPA and increased unit throughput at the same time!


Agenda • EPA key facts and challenges with compliance • Solution overview to overcome challenges with compliance • Challenges with PRDs: Leakage and Simmering • Case Study from Marathon Petroleum

• Solution • Overview • Project Description

• Results • Preliminary information • Collective approach – The game changer • The unexpected bonus • The final results

• Conclusions and Takeaways PRD Electronically Monitored


Emerson At-A-Glance


Through Five Business Platforms, Emerson Is Delivering on Our Brand Promise

Emerson Process Management

Emerson Industrial Automation

Emerson Power Network

Emerson Climate Technology

Emerson Commercial & Residential Solutions


Key Facts from EPA Regulation • Operators would install electronic monitors

on PRDs that vent to atmosphere to identify and record the time and duration of each pressure release

• Identify the source of release on the flare systems

• Corrective action required for any leakage of 500 ppm or greater

• Reporting emissions during startup and shutdown is now required

Monitoring of all PRDs handling Hazardous Air Pollutant (HAP)

must be completed within three years of signoff

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?


Challenges With Compliance • Manual monitoring – automated monitoring is

now a preferred option

• Traditional electronic monitoring technology is expensive due to complex installation and commissioning requirements

• Identifying time and duration of releases using process information requires extensive data interpretation, time and expertise

• Locating the source of release in your flare system requires even more complex analysis and can result in increased emissions or production slowdown

Cabling and trenching Process shut down

Hard to reach locations

Unit A

Unit B

Unit C

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$


Complete Real-Time PRD Monitoring Solution Addresses Your Key Challenges 1. Emerson’s non-intrusive and wireless solution enables lowest cost implementation 2. Technology designed for PRD application delivers the information you need for compliance

accessible through your existing host system or historian 3. Quickly and easily identify the source of release in your flare system

HSSE

WirelessHART®

Gateway

Rupture Disc Monitoring

Relief Valve and Rupture Disc Monitoring

Relief Valve Monitoring

1

2 3


Non-Intrusive Design Rosemount 708 Wireless Acoustic Transmitter Features • Strap-on Installation • WirelessHART® Data Communication

• Acoustic • Temperature - for pipe surface • Operating Temperature - electronic board) • Battery Charge

• Long Battery Life – 1 to 60 Second Updates • 5.8 years @ 8 Seconds • 10 years @ 32 Seconds

Probe with Acoustic and Temperature Sensors

The non-intrusive sensor clamps directly onto the PRD vent pipe surface.

It’s that simple!!! Install in just minutes.


WirelessHART Communications Benefits • Reduced Engineering

• Reduced Labor

• Reduced Materials

• Faster Installation

• Assured Reliability and Performance

Pervasive Sensing Solution

Relief Valve Monitoring

Traditional Method


CAPEX Savings with Pervasive Sensing Solution

Total compliance and operational improvement at fraction of the cost of traditional method

(1) Estimated costs include monitoring of the wireless system, tamperproof secure data, and engineered services (2) Cost range dependent on application: PRV only or PRV with Rupture Disc monitoring

Total Cost of Implementation(1)

200 x PRDs Traditional Method Pervasive Sensing Solution(2)

Total Project Cost ($K) $3,520 $464 - $1,088 Total Cost per PRD ($K) $18 $2.3 – $5.4

Savings - 69% - 87%

Field Installation Intrusive Non-Intrusive Cabling and Trenches Required Yes No Technology Wired Wireless

1


Technology Designed for PRD Applications 2


Acoustic Transmitter Provides Insight Into Your PRD Release Without Complex Data Analysis Traditional PRD Monitoring Process • Observe upstream pressure peaks and valleys

around the pressure limit Challenges of monitoring with process pressure • Difficult to determine when the PRD is actually

opened or closed

Emerson’s PRD Monitoring Solution • Observe downstream acoustic signature of

PRD installation Benefits of monitoring with acoustic signature • Time and duration of each release clearly shown • Valve simmering, chattering, leakages and

malfunctions also identifiable

PRD monitoring using process data analysis can take from hours to days

Acoustic Process Pressure

Easy to identify time and duration of each pressure release


Easily Access Your PRD Information

PRV Unit Monitoring PRV PRV Active PRV State Change PRV Acknowledged Transmitter HealthWind Direction South EastUnit 1 PRV-001-009 Yes Yes Yes GoodUnit 2 PRV-002-001 No NO No BadUnit 3 PRV-003-001 No Yes No GoodUnit 4 No No No Good

The Rosemount 708*

combines ultrasonic signatures and surface temperature measurement from the vent pipe surface

Gateway connects the information directly to operators host system or historian for notification and reporting

PRD information is sent to a Gateway through the WirelessHART® protocol • Acoustic magnitude • Pipe surface temperature • Battery Life

2

* Additional configuration options available. Consult your local sales person for details.


64 Seconds

…And Integrate PRD Alerting and Reporting into Your Host System or Historian

• Alert on threshold • Visually inspect trend

for verification

• Add location and contextual information

• Easily access and share results

2

An estimated 100 lbs.* of VOC was released with wind conditions south by south east. Release was acknowledged and recorded.

*Relief valve and process constants: Spring-loaded operating relief valve, set pressure = 90 psig, valve capacity = 268 SCFM (Square Cubic Feet Per Minute) and gas temperature = 212 ˚F.

Unit 1

64

Seconds


Identifying the Source of Release in Your Flare System

• Challenges

• Not all releases are audible to human detection even when the PRD is releasing to the atmosphere

• Using process information to identify where the release is coming from requires hours to days of expert data analysis and exposure to what may be a hazardous area

Unit A

Unit B

Unit C

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?

?

?

$

Every minute spent identifying which PRD is releasing leads to increasing emissions, regulatory

fines and lost production

3


Identifying the Source of Release in Your Flare System

• Solution • Comprehensive PRD monitoring for closed recovery and flare systems enables

immediate identification and response to source

Unit A

Unit B

Unit C

Eliminate the need to slow down production and ensure minimal emissions with clear visibility to

your full system

3


In Addition to Compliance, Fast Detection of Releases and Leakages Saves You Money

• Undetected PRD leakages happen quite often

• Even a small leak (0.1% from PRV flow area) can cause tens of thousands of dollars per year of material losses

unseated

valve

Leakages caused by PRD malfunctions can waste large amounts of valuable product, along with the energy required to produce these products.


OPEX Savings Possible with this Pervasive Sensing Solution

Potential Annual Savings = $3,200,000 Example based on a 250 bpd refinery


Summary of PRD Monitoring Solution Benefits • Simple and accurate EPA compliance

• Minimum capital expenditure

• Increased throughput

• Improved productivity and safety

• Greater insight into overall process

• Establishes infrastructure for future operational improvements using Pervasive Sensing solutions


Wireless Field-Proven Technology

Billions of hours of operating experience

Thousands of Smart Wireless field devices

Thousands of Wireless Field Networks


Marathon Petroleum Case Study


Marathon Petroleum, Canton – OH Facility Marathon Petroleum Company

• 1.7 million barrels per day • Fourth largest transportation fuels refiner in the nation • Seven-plant refining network strategically located to serve major markets.

The Canton refinery: • 180 acres and is approximately 60 miles southeast of Cleveland, Ohio. • 360 employees • 80,000 barrels of crude oil per day • Products: Gasoline, diesel fuels, kerosene, propane, sulfur, asphalt, roofing

flux, home heating oil, #6 industrial fuel oil, and low sulfur gasoline.


Relief Valve Challenges • Pressure relief valves are known to

experience problems re-seating • Small leaks are difficult to detect

• Continuous relief due to chattering

• RVs can also get “stuck” open, or break • Release for a duration equal to the

time it takes to pinpoint the correct valve.

There is a need for individual electronic RV monitoring.


Solution Overview • 15 x wired flowmeters on fifteen flare headers.

• Wireless acoustic transmitters were installed on 69 RV’s in high H2S service or high hydrocarbon flow.

• One non-invasive Rosemount 708 Wireless Acoustic Transmitter was attached directly to the outlet side of the process piping of each valve

Solution allows individual monitoring of RVs without a lot

of infrastructure and cost 300 ft.

Gateways location

Plant overview: Gateway and Relief Valve location


Wireless Acoustic Transmitter and Gateway Installation

Cable

Without any interruption to the process! 69 x acoustic transmitters were easily

installed in a month’s time

Pipe Clamps

1420 Gateway Extended Antenna

Detail


Mesh Network and PI Integration • Seamlessly integrated WirelessHART into

the PI system through Delta-V • Operators data access:

• Can graph any relief event • From the event onset until the event has

stopped. • Scan rate set at 4 seconds

• Expected delay between the wireless gateway and the PI system is 10 seconds.

• Best chance to see short, frequent releases

New OSI PI Connector enable native integration to WirelessHART

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCLur1eWGucgCFUtVPgodM4YHBg&url=http://www.glassdoor.com/Overview/Working-at-OSIsoft-EI_IE15323.11,18.htm&psig=AFQjCNE-fg8dZLWXkbE-cFuLJPBw46dKyg&ust=1444605977836485

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCJXerYSHucgCFcFzPgod9UkBag&url=http://appliedcontrolequipment.com/deltav-enhanced-application-for-virtualization-environment/&psig=AFQjCNH8Gbm9ck7Ro95wLJKjetGupeBDtQ&ust=1444606031957048


How the System Works • Validation that a RV has truly relieved by an increase in flow rate in the Unit’s

flare header • Pinpoint which valve is in alarm immediately after a flow alarm is generated • The temperature measurement (SV) on the 708 Acoustic Transmitter can be

used for part of the RV diagnosis • The operators for that Unit are called immediately:

• Problem diagnosed within an hour • The ability to pinpoint broken or stuck-open RV’s saves weeks and even months of

high flow releases • The ability to detect “undetectable” slow or intermittent releases is equally valuable

Overtime, all these actions combined, have a significant impact of reducing the total H2S and hydrocarbon flow to the Flare.


Process Book (PI) Screens

Acoustics in Alarm Sub-header 7

Flare System selection screen

Flow Header PI screen view

Sub-header detail

Quick identification of increased header

flow


Process Book (PI) Screens (Continued)

Quick identification of lifting relief valve

Sub-header 7 detail scree

Rosemount 708 – Battery Life


Process Book (PI) Graph

Leakage Releases Simmering

Acoustic

Temperature

Rosemount 708 Wireless Acoustic Transmitter


Process Book (PI) Graph

You can not always rely on pressure, temperature or flow to indicate if an RV is

releasing

Acoustic

Pressure

Acoustic and Pressure Graphic

Missing Pressure Data


Results from the 69 Acoustic Monitors • More then 200 lifts and reseating events over 15 month

• Inspection is required to fill out a RV Post Activation Report each time a RV lifts

• 20 Problems were identified and resolved


Business Results Achieved • Reduction in loss of hydrocarbon to the Flare System

• Capturing before-and-after data for duration of RV lifts

• Timely detection and intervention of faulty valves

• Improved operation of our process Units

• The acoustic data shows when we are operating outside of operation limits, and now we have more confidence to increase throughput of the units

• The project paid for itself within 5 months • Estimated ROI at 271% annualized over 20 years

• We plan to expand the use of acoustic monitoring for 80 more relief valves on smaller flows of H2S and hydrocarbon


The Unexpected Bonus • 216 lifts occurred in a 15 month period on 69 RVs, with potential high flow

and high H2S

• Expected and realized environmental benefits: • Tamper-proof environmental reporting

• Reduction in post-lift reports

• Time-stamps correlated with process conditions and timely intervention that enabled better environmental stewardship

“The increased throughput and revenue was an unexpected bonus”


The Flare System Team, Enabled by Pervasive Sensing Strategy, Achieved Same Challenging Results

• The amount of actionable information has grown thanks to Relief Valve Acoustic and Temperature monitoring, Header flow monitoring in addition to previous instrumentation implemented in the process, such as pressure, temperature, level, etc.

• PRV and Flare Header data information available and integrated into PI helps the flare system team develop targeted action plans: • Read-out Process Book (PI) alarms and Flare system activities

• Set process priorities

• Perform root cause analysis as part of continuous improvement plan to avoid the same release happening again


Plans for Pervasive Sensing Applications • Detroit Plant:

• Installing > 70 Acoustic Monitors

• 17 will be installed this year with the rest to be installed next year

• Texas City Plant: • 50 last year

• Canton Plant: • 69 installed

• Team is looking at adding more Acoustic Monitors

• Future plan: Galveston Bay, Robinson, Garyville and Catlettsburg.

• This project has enabled the Wireless HART backbone for the refinery to implement other application such as Safety Showers, Levels, Temperature and Pressure surveys, etc.


Additional Tips • Visit Emerson booth #28 on the tradeshow floor to see a live demo.

• http://www.emersonprocess.com/PRDWirelessMonitoring • For video, whitepaper, presentation and flyer.

• Additional resources: • http://www3.emersonprocess.com/rosemount/powermodulelifecalculator/default.aspx

• http://www3.emersonprocess.com/rosemount/SWirelessGCEstimator/Default.html

• http://www2.emersonprocess.com/en-us/brands/rosemount/documentation-and-drawings/pages/index.aspx

• http://www2.emersonprocess.com/en-us/plantweb/wireless/pervasive-sensing/pages/index.aspx


Thank you!

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Advanced PRD Monitoring Systemscontent.4cmarketplace.com/presentations/Donnangelo... · Advanced PRD Monitoring Systems Advanced PRD Monitoring Systems This presentation discusses