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Asset Management System for Gazprom Gas Treatment Plant in the Nord Stream Pipeline
The Asset Management System for the Gas Treatment Plant of GAZPROM at Portovaya has been released on the basis of the CPP-3 technology of Eascon.
The Portovaya Gas Treatment Plant (GTP) is the biggest plant in the world of its type and it is part of the Nord Stream Project, a multi billion euro international investment, and one of the key investments in Russia in 2011.
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The Operator Advisory System EAS in the IGCC power plant of Isab Energy

Isab Energy Services is the company charged to operate the IGCC power Plant on behalf of ERG Power & Gas.

 

The IGCC complex is made up of more than 20 units, 7 of which are classified "RIR", High level Risk Plants. Therefore Isab Energy Services, when  managing the plant, had to guarantee a safe and reliable conduction as well as a profitable one and in 2003 started a new project to improve both these aspects.

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The integrated Information System of Siirtec Nigi for Engineering, Procurement & Construction

Different technological solutions based on the ISO 15926 standard specification are now  available on the market to integrate the lifecycle of design, procurement, construction and operation of the process plants. Besides they allow the owner operators of the plant to trasform the old style hand over based on paper o PDF delieverables into a true delivery of a Digital Asset as well as the phisical one.

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APC in Sasol Italy Plants: a stepwise approach
On the basis of Eascon's experience, the main causes of failure of an advanced process control project are:
  • Discover only at end of the project that some instruments do not perform properly and there is no possibility to repair or substitute them until the next plant stop.
  • Do not give enough time to the control room operators to assimilatie the new process control strategies and become confident with them.

In both the cases the returns of investment may be very poor and far from the expected results.

For these reason, Eascon and Sasol Italy, agreed to follow a stepwise approach in the impementation of all the projects of Advanced Process Control

 

sasol_apc

 

This approach can be diveded into three main steps:

  1. A Robust Tuning of single loops controller of the plant is performed, in order to check the response of the instrumentation, reduce the oscillation index of the controllers and optimize thir response time.
  2. Than the "Standard Advanced Controllers" are configured directly on the DCS (i.e. ratio controllers, feed-forward dynamic controllers, single loop controllers with non linear compensation,... ) .
    These kind of advanced controllers are profitably used for separation column stabilisation, level non linear control of boilers and condenser, furnace pass balancing, reactor WABT control and so on.
    Generally speaking they have the effect of stabilising unit mass flows, energy flows and operating conditions; do not require large investments in hardware, software and engineering services and make the control rooms operators confident with "automatic" set adjustments.
  3. At last, after an accurate feasibility study, a Multivariable Predictive Control package (like DMC+) is applied on plant units with high interactive processes and complex dynamics in order to manage multiple control objectives without violating the process constraints


This stepwise approach has been successfully applied in different APC projects carried on by Eascon and Sasol Italy as summarized in the following table:


Year

Plant / Technology

Main Units.

Control Activities

Status

Service Factor

Contractual
Benefit

Achieved Benefit

2012

Alkylation Plant
[HF]

· 1 Reactor

· 1 Furnace

· 7 Distillation Columns

· Base Controllers Tuning & Instrumentation Check

· DCS Advanced Controls

· Multivariable Predictive Control

Completed

91%

6.5%

Fuel saving

9.0%

Fuel saving

2011

2102

Paraffine Plant
[ISOSIV]

· 1 Adsober train

· 3 Furnaces

· 2 Distillation Columns

· Base Controllers Tuning & Instrumentation Check

· DCS Advanced Controls

· Multivariable Predictive Control

Completed

95%

3%

Fuel saving

6.3%

Fuel saving

from 2011

Olefine Plant
[PACOL-OLEX]

· 2 Adsober Columnns

· 3 Distillation Columns

· 4 Furnaces

· Multivariable Predictive Control

Completed

98%

5.5%

Fuel saving

8.0%

Fuel saving

from 2011

Reforming Plant
[SELAS]

· 2 Reforming Furnaces

· Multivariable Predictive Control

Completed

99%

13%

Alcohol losses reduction

27%

Alcohol losses reduction

Alcohol Plant
[OXO]

· 3 Distillation trains

86%

2011

Paraffine Plant Complex
[HYDROBON
MOLEX
AROSAT
FRACTIONATION]

· 3 Reactors

· 2 Adsober Columnns

· 9 Furnaces

· 8 Distillation Columns

· Base Controllers Tuning & Instrumentation Check

Completed

-

-

-


 

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