How analysers are managed in the Oil& Gas and Petrochemical industry

Transcription

1 How analysers are managed in the Oil& Gas and Petrochemical industry Hans Cusell Senior Metering & Allocation Consultant One step beyond your imagination 10 October 2011

2 Who am I Curriculum Vitae Personal data Name Hans Cusell hcusell@hint.nl Date of birth 13 November 1947 Nationality Dutch Marital status married, two children Formal education and training HTS Amsterdam, measurement and control (applicatie cursus meet en regeltechniek) Hogere Polytechnsiche School,Rotterdam mechanical engineering Experience Hint Since 2010 Senior Metering and Allocation consultant Shell, various companies Company: Shell Global Solutions Upstream, Rijswijk Position: Metering and allocation engineer Content: Research implementation multiphase flow meters Consultancy, study and design of hydrocarbon allocation systems, fiscal metering, analyser systems, metering systems and instrumentation for environmental systems (GHG). Subject matter expert analysers systems in upstream production systems Design and implementation of internal engineering standards Conducting training Company: Shell Egypt Position: Project engineer Project management (expansion of production facilities of a gas processing plant) Company: Shell IT, Leidschendam Position: System Analist Development, design and roll out of Maintenance Management Systems

3 Who am I Company: Shell Development Company, Nigeria Position: Senior instrument engineer Commissioning and start up of the Bonny LNG plant. Plant maintenance with prime responsibility for on-line analyser systems, fiscal metering systems, fire and gas systems, laboratory equipment and medical systems (hospital) Company: Shell Internationale Petroleum Maatschappij, Den Haag Position: Senior instrument engineer Consultancy instrumentation with the focus on on-line analyser systems, fire and gas systems and fiscal metering systems Company: Nederlandse Aaardolie Maatschappij Position: Senior instrument engineer System integrity of instrumentation with the focus on analyser systems, metering systems and fire and gas systems. Liaison Gasunie concerning fiscal (gas) metering Company: Woodside, Australia Position: Instrument engineer Commissioning and start up of the Karratha LNG plant. Plant maintenance with prime responsibility for on-line analyser systems, fiscal metering systems, fire and gas systems, laboratory equipment Company: Brunei Shell Position: Instrument engineer Maintenance of analyser systems, metering systems and gas and fire systems. Plant engineering instrumentation Shell Nederland, Pernis Refinery Position: Instrument engineer Plant engineering instrumentation Consultancy, design and implementation of on-line analyser systems Project engineering Company: Shell Internationale Petroleum Maatschappij, Den Haag Position: Junior instrument engineer Various projects IBM Nederland, Amsterdam Position: Assembly engineer Design and optimization of assembly lines

4 PAT (Process Analytical Technology) Benefits: Immediate action if quality is not met Better process control and understanding Less uncontrolled variation and less production waste Better and more stable products Data collection and improved historical knowledge Quote out article from Process Analytical Technology (PAT) : Boon to Pharmaceutical Industry

5 Areas of application Process control e.g. to monitor quality of distillation in a distiller Product quality and custody transfer e.g. to measure energy content of sales gas at a custody transfer point Fiscal metering for taxation purposes Allocation purposes in upstream production systems; the process to assign to the shareholders equitable shares in the sales of a joint venture based on the value of their contribution Plant and Personnel Safety systems e.g. to measure air pollution and toxicity of ambient surroundings

6 Analysers in the oil industry (examples) 1.Oil analysers ( the dinosaurs ) Distillation Flashpoint Cloud point Kinetic vapour pressure Reid vapour pressure Octane rating engines

7 2. Product characterisation Gas chromatography PONA five main types: paraffin, olefin, naphthene, aromatics ASTM distillation. Temperature programmed distillation in order to simulate the distillation curve of an oil product FTNIR feed stock to refinery NMR

8 2. Product quality Gas chromatography Component analyses in natural gas up C6+ for the calculation of compressibility, density, heating value etc. Trace component in environmental applications; e.g. EO and PO in surrounding air FTNIR octane number of gasoline

9 2. Product quality (cont d) Water content and moisture analysers Oxygen analysers Total sulphur Mercury in gas How analysers are managed in the Oil & Gas Gas and liquid density analysers NDIR analysers for e.g. CO2

10 3. Water - en boiler plant applications ph conductivity turbidity free residual chlorine dissolved oxygen total organic carbon oil in water

11 4. Combustion CO CO2 Oxygen Nitrogen oxides 5. Personal and Environmental Safety Oil in water (water overboard) GC toxicity (chemical plants) Toxicity sensors (refineries, e.g. H2S) Explosiveness (refineries, explosion meters)

12 Analysers in the pharmaceutical industry Tell the man in front!

13 TRADITIONAL PROCESS INSTRUMENTATION LIKE TEMPERATURE-, PRESSURE-, LEVEL- AND FLOW TRANSMITTERS Weather proof Robust design suitable for harsh weather conditions. Can be readily installed outdoors Explosion proof either Exd or Exi a/b. Can be readily installed in a hazardous area Simple to connectable to the process. Long-term calibration properties; sometimes for life. Requires occasionally zero adjustment Install and forget Replace on failure Low OPEX COMPLEX ON-LINE ANALYSER SYSTEMS LIKE PROCESS GAS CHROMATOGRAPHS, SPECTROMETERS, FTNIR Delicate design Not weatherproof Narrow environmental conditions w.r.t temperature and humidity Need for a protective environment like an analyser house general purpose design Requires either ex-proofing or installation in a analyser house with over pressure protection Requires intricate sample transport and sample handling systems. Unstable measurement platform which requires regular validation. High level of specialisation in maintenance Refurbish High OPEX

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19 RULES OF INTERVENTION (instantaneous) 1.A single point plots outside the Control Limits; 2.Two out of three consecutive points plot outside the Warning Limit on the same side of the centreline; 3.Four out of five results points plot outside the a value equal to half the Warning Limit on the same side of the centreline; 4.Eight consecutive results plot on one side of the centreline. 5.Eight consecutive points increase or decrease in magnitude.

20 STATISTICAL INFERENCE (periodical) Analytical performance Test on non-randomness Patterns in the distribution may cause either under or overestimation of variability. Test on systematic error Systematic errors may lead to give away. Test on Warning Limits Limits too wide: loss of control over the process, undue errors Limits too tight: strained control and undue maintenance intervention. Test on reproducibility rate Score significantly lower than 95%: common indicator for bad performer Test on bi-directional adjustment Unbalanced adjustment may indicate e.g. fouling or ageing.

21 AVAILABILITY PERFORMANCE AND MAINTAINABILITY Keep track of equipment unavailability due to: 1.not required by operations 2.preventive maintenance and validation 3.breakdown

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23 System architecture and cyber security

24 HINT Human Interest in New Technology Thank you for your Attention Any Questions? Architects in Metering & Allocation, from Engineering to Billing One step beyond your imagination