Petrotel-LUKOIL Oil Refinery completed system implementation of advanced production control

On February 13, 2015 it became known of project completion of system implementation of advanced production control of Profit Controller from Honeywell company in production process of Petrotel-LUKOIL Oil Refinery.

Project Tasks

The plant raises important issues on optimization of operation of furnaces of heating of oil and a column of atmospheric distillation:

• increase in profitability of production of primary oil refining;
• observance of quality requirements of products and reduction of "stock on quality";
• possibility of flexible change of operation modes of installation depending on market conditions.;
• strict observance of limits of safe operation of technology equipment.

Petrotel-LUKOIL Oil Refinery, 2014

It was required to improve operation of the furnace of heating of fuel oil and a column of vacuum distillation for:

• optimization (or minimization) furnace outlet temperatures, in relation to technology conditions;

• observance of all technological limits in operation of the furnace;

• increases in an exit of vacuum gasoil (VGO) at observance of requirements for its quality;

• possibility of increase in production of vacuum diesel fuel according to requirements of commodity production

• decrease in an exit of tar;

• maintenance of a required temperature profile of a vacuum column, both at a normal operation mode, and when changing raw materials.

Prior to implementation of a system of advanced management ("APC system") it was required to stabilize installation by the correct setup of circuits of regulation and cascades. Besides, refining of the developed models of product quality required carrying out the special tests of installation for step influences (with additional samplings) approved with the diagram of change of raw materials. The strong noises destabilizing the technology mode are connected with sharp change of composition of the water given on oil refining and maintenance in it.

Project Progress

For automatic recognition and effective compensation of such perturbations special logical networks were created and connected to an APC system. Besides, for ensuring fast accustoming of operators of installation to a new system and its subsequent more effective use profound training of operational and technology personnel is provided and the output of the additional information about its work on special operator symbolic circuits of the distributed control system (DCS) is implemented.

The Honeywell company took part in the project.

The software^[1] of Honeywell corporation functions on the separate server and safely^[2] interacts with RSU DeltaV. For this purpose it was required to create the special program interface.

Project Results

Implementation of APC allowed to gain the calculated effect:

• fractionation improvement which was expressed in increase in an exit of VGO at the expense of tar;

• decrease in consumption of fuel gas;

• decrease in consumption of steam;

Additional benefits from implementation of APC:

• PID-regulation quality improvement – after implementation of APC all key circuits work in the automatic mode. (Regulators were recustomized using a program and algorithmic complex of automatic adjustment of circuits of Honeywell TaiJi PID).

• inclusion in work of cascades of PID-regulators according to requirements of the production technology;

• stabilization of the technology mode of atmospheric and vacuum blocks – reduction of number of violations on product quality and reduction of number of interventions of operators in technology process;

• increase in flexibility in management of work of the subsequent installations – an APC system provides the valuable operational information about product quality used for fine tuning of the mode of other installations is lower on a technology chain;

• stability augmentation of the mode when changing raw materials, more effective compensation of the external perturbations arriving on installation;

• installation retrofitting by additional resources of measurement and management within the project of creation of an APC system.

Notes