Effect of automation projects on reliability r3

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Improving Automation Projects through Reliability Ömer Haluk Yılmaz Tüpraş İzmir Refinery Reliability Champion

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2 HELLO, from Aliaga-Turkey!

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RELIABILITY and AUTOMATION Reliability: On spec operational continuity Automation: Self controlled operation Project: Theory vs Practice Essentials of Automation Projects EXAMPLES and CONCLUSION Reliability implications of control behaviour Examples Reliability implications of automation Multidisciplinary knowledge Epilogue Orchestration Presentation Plan

Statement of the presentation: : 

Statement of the presentation: Automation Projects can improve Operational Reliability 4

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A refinery may seem a very peaceful place, when things go straight. ..but it’s not always the case that things go straight. There may be a voltage sag, a compressor trip, an exchanger leak etc. ...and you never know if it’s day or night, summer or winter. How can automation contribute to risk control? Reliability: On spec operational continuity

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The pyramid of operational continuity 6 Reliability and Integrity Process Control Production Planning Operation Mgt Operational Continuity Operational Continuity

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Automation is self controlled operation. We can build an automation on reliable equipments only, and automation helps keeping these equipment stay reliable in return. ...but, automation is not the job of automation engineer only. Multidisciplinary knowledge makes automation work. Do we always integrate this multidisciplinary knowledge into our automation projects? Automation: Self controlled operation

Project: Theory vs Practice : 

Project: Theory vs Practice An automation project is a candidate for success, if and only if the ultimate goal the process all the equipments operation and maintenance strategy cultural habits the risks are well understood, and the project accordingly developed. Do we always reach the right target?

Project: Theory vs Practice : 

Project: Theory vs Practice 9 COMMUNICATION FAILURE!

Essentials of automation projects : 

Understanding the subject of automation covers, almost always understanding the multidimensional fact which lies behind. Understanding the multidimensional fact, is only possible via the coordination of multidisciplinary knowledge. 10 Essentials of automation projects

Reliability implications of control behaviour : 

Reliability implications of control behaviour 11

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Instrument Air Compressor failure Propane pump seal fire HC Reactor temperature control Emergency Power Automation revamp CCR Emergency Power Suppply Antisurge control CCR recycle gas compressor 12 Examples

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It was reported that the speed control of the running compressor was oscillatory and change of running compressor with the spare caused overspeed trip. Instrument technician, and then the engineers ran to explore the cause, and fix the problem. Not being able to propose a solution to the mechanical engineers, instrumentation guys readjusted the reset rate of the speed controller from 5 to 2 r/min. The problem was apparently solved for a WHILE! ..but, what was the ROOT CAUSE? 13 Examples- Instrument Air Compressor failure

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Instrument Air Compressor failure When the system behavior changes, the need of change in the controller tuning parameters, may tell you to investigate deeper into the problem. Problem: Speed oscillation High pressure between compressor stages Fouling in the air side of aftercooler Corrosion Condensation CW circulation during std by causes T<Td Why? Why? Why? Why? Why? 1 2 3 4 5 Root cause Solution: Revise operation procedure Root Cause

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15 Instrument Air Compressor – aftercooler fouling

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Examples- Pump seal fire 1- LIC had too responsive PID parameters 2- Low flow from T-1202. P-1203 pumps lower than minimum flow Propane De-asphalting Plant High Pressure pump Operation not possible because of seal leak and consequent fire. WHY?

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17 Examples- HC Reactor temperature control 284 mm ID 54 mm actual Spec: 114mm 260 mm 82TE047 14’’ Pipe Sch 160 OD= 356mm ID = 284mm T = 36mm Actual Installation The Reactor inlet temperature controller 82TIC047 has not functioned well in cascade mode since the unit start-up. Hence, the Quench Gas flow to Reactor inlet 82FIC010 has been operated in automatic with local set point...and WHY?

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During commissioning it was found out that there were two mistakes built in the project: 1- Low CW pressure trip. 2- The CW pump was subject to blackout, and could not pump during a black out. The emergency power system was revamped after 23 years for HC load, although its historical performance was not brilliant. Examples- Emergency Power Automation revamp

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19 ‘Ready to take load’ signal was ’1’ only after speed up (13 secs.)&no voltage condition , which then triggered close command to supply CB’s. Never forget that a contactor will drop below say U*60% in a cycle! Examples- CCR Emergency Power Suppply The beautiful emergency power supply system didn’t function if the power loss or dip lasted for a short period, i.e. A few seconds.

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20 Examples- Antisurge control CCR recycle gas compressor Surges if HV-022 (red valve) mech. stop not maintained and the valve closes. ('Fail close valve') The main risk is the antisurge control valve itself! Install a fail open valve bypassing HV-022.

Reliability implications of automation : 

Reliability implications of automation The need of changing tuning parameters of the controller may tell you that the system behavior has changed, and a deeper investigation into the problem is needed. Wishfull thinking is not the best method for automation projects. Automation projects fail according to Murphy’s rules, if we can not integrate multidisciplinary knowledge into the project. ... and the well known motto: If you can not measure you cannot control. 21

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Maintenance They know how it fails.

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23 Operations They know what the consequence will be.

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Multidisciplinary Knowledge Especially the reinstrumentation projects are great opportunities to dig the experiences and imbed multidisciplinary knowledge into the operation system. Automation Projects can improve Operational Reliability!

Epilogue : 

Epilogue Take the necessary time to develop the IDEA. Discuss, challenge and test it. (Is there an equally good way of doing it without automation?) Build the idea into the project realistically. Don’t assume that what you cannot solve at the table, can be solved at the field. Exercise ‘what if’ querries with experienced process engineer, operator, maintenance engineer etc. Be systematic with alarm management. Develop self diagnostic procedures for the application, in addition to system diagnostics. Develop the documentation in parallel, with clarity. Perform a satisfactory FAT. Encourage the project team for professional satisfaction. 25

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26 Orchestration Thanks! Questions please?