Claients
Juice Concentration Plant – Control Loops Tuning
Juice Concentration Plant – Control Loops Tuning
Fuel Gas HDS Plant – Control Loops Tuning
Fuel Gas HDS Plant – Control Loops Tuning
The Fuel Gas HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.
Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning
Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..
The control performance is calculated and presented using two indices:
1. Process value Standard Deviation (STD)
and
2. Process Value Travel Index (Process travel)
Benefits:
Significant improvements were observed in the Standard Deviation of the control loops (>12 fold) and in the control valve travel (>175 fold!).
Economic indexes were not calculated.
Kerosene HDS Plant – Control Loops Tuning
Kerosene HDS Plant – Control Loops Tuning
The Kerosene HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.
Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning
Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..
The control performance is calculated and presented using two indices:
1. Process value Standard Deviation (STD)
and
2. Process Value Travel Index (Process travel)
Among other things:
- Top Reflux valve was identified as “Sticky” and had been mended.
- Instrumentation ranges changed to give true and effective ranges of operation.
- Change logic of Reflux operation to “Reflux Ratio” to better follow changes in plants throughput.
Gasoline HDS Plant – Control Loops Tuning
Gasoline HDS Plant – Control Loops Tuning
The Gasoline HDS plant control loops were re-tuned as part of re-tuning all the control loops in the HDS plants.
Loops were tuned to get the best performance to their duty and efforts were done to compare it’s functioning prior and after the tuning
Tuning was done by “Ziegler Nichols” approach – namely – finding the ultimate process gain and ultimate process dynamics and setting the controller’s parameters accordingly – bearing in mind the controller duty and the characteristics of the expected behavior..
The control performance is calculated and presented using two indices:
1. Process value Standard Deviation (STD)
and
2. Process Value Travel Index (Process travel)
Economical Benefits:
The improvement of temperature control in the column TOP TEMP only, brought savings of nearly 1 Million $/Year by reducing product RVP and savings in steam due to better temperature control and reduction in the reflux.
Project Documentation
Methanol – Fuel Oil Blending System
Methanol – Fuel Oil Blending System
Design of the system to enable Fuel Oil users switch to more environmental friendly and more economical energy source.
Number of approached were offered.
Client decided to abort project due to high cost of implementation.
Blending device was designed by Mr. David Livschitz.
Energy Survey – Metal Machining Plant
Energy Survey – Metal Machining Plant
Energy Survey – Metal Machining Plant (May 2015) indicated significant potential saving:
SUBJECT | %of total energy consumption |
Lighting | 5.0 % |
Compressed Air | 2.5 % |
Improved monitoring and control | 2.0 % |
Ventilation and Air Conditioning | 1.5 % |
Water Warming | 1.0 % |
Total | 12.0 % |
Steam Saving in a Turbo Compressor Operation
Steam Saving in a Turbo Compressor Operation
In the process of performance checking for a refinery we came across a turbo compressor that, apparently, operated in a very un economically way.
Careful checking was needed to assure our first observation until the decision was taken to change the machine setting which was made when the plant was commissioned by the vendor rep. some years before.
Keeping the same rate of production, the steam consumption dropped to less than 3/4 from is previous one and the machine speed dropped more than 5%.
The immediate savings from steam only, at the project time, estimated in more than 1.5 MM$/Year.
Sulphuric Acid Process and Process Control Improvements
Sulphuric Acid Process and Process Control Improvements
Customer is operating a Sulphuric Acid plant.
Instability in the waste heat recovery – Steam production brought the need to stabilize the process and let the system operate more efficiently.
Using the existing process instrumentation, changing some of the configurations (Adding some cascade levels and feed forward compensations) made the plant manager happy.
Stabilize Cooling Water Make-Up
Stabilize Cooling Water Make-Up
Customer is operating a steam generation plant.
Instability in the make-up water streams reduces the overall plant throughput.
Based on the existing instrumentation, addition of one controller – the performance of the existing controllers was orchestrated to give smooth operation to the whole steam production operation.