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Discussions of Modular Sample System Implementation in S. California Refineries

This discussion explores the current integration schemes and challenges faced in implementing modular sample systems in California refineries. The study highlights the benefits of integrating analyzers with sample systems through conventional analog instruments or PLCs. It also emphasizes the performance and cost-saving advantages of using modular valves compared to traditional tube and fitting systems. The future potential of modular systems in refinery operations is discussed, along with the need for proper design and component selection for optimal performance.

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Discussions of Modular Sample System Implementation in S. California Refineries

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  1. Discussions of Modular Sample System Implementation in S. California Refineries

  2. Current integration schemes with “GEN 1” systems

  3. Current “GEN 1.5” Integration

  4. Comments • There is a current inability to integration the sample system using multi-drop, plug and play digital-bus technology due to a lack of IS, digital-bus components in the modular, low-flow footprint • There have been no documented, IS-certified GEN2 systems installed to date • End users and OEM alike can still benefit from IMSS integration of analyzer to sample system or PLC to sample system thru conventional IS certified analog instruments • Automation, closed-loop control, remote alarm and monitoring, and some diagnostic functions can be performed today which will still bring performance and cost of ownership benefits to the end user.

  5. End User Benefits Today

  6. CEM COO Comments • Sample system downtime on CEM applications results in Missing Data Incidents • Have to either trade emission credits or pay fines if tonnage of emissions are over budget • There is a high probability that CEM analyzers will go down because of a sample system/ component issues or leak

  7. Hard COO Data • A traditional tube and fitting blending system was replaced with a modular type system • Traditional System required 16 hours to rebuild 8 valves every 6 months • 8 valves per system • Parts to Rebuild = $150 / valve (highly conservative) • Technician Rate was $50/hour • New modular type of valves has been in service for over two years with no rebuilds needed • 2 YEAR SAVINGS = (16 * 4 * $50) + ($150 * 4 * 8) = $8000 • COST SAVINGS PER VALVE/ YEAR = ($8000 ÷ 8 ÷ 2) = $500 • TIME SAVINGS PER VALVE/YEAR = 32 HOURS

  8. “Greenfield Extrapolation” • Take these numbers and assume a 10 year valve cycle life (1M cycles, 5min analysis cycle time) and a refinery scale implementation (1000 valves) • TOTAL SAVINGS = (1000 * $500 * 10) = $5M • TOTAL TIME SAVINGS = (32 * 10) = 3200 MAN-HOURS

  9. The Future Modular in S. Cal. Refineries • NOT SHOWN: • PLC control and monitoring • Calibration standard and self-validation sample cylinders • Temp control of system and sample lines • Sample Pumps

  10. The Future of IMSS in S. Cal. Refineries • Currently Implemented systems have the following capability • Both Modular and High Flow Tube and Fitting Interconnect Technology • Online Density and Mass Flow Measurement • Differential Pressure Monitoring of Filters with Redundancy and Auto Switch Over • Flow Control of Bypass, Analyzer, and Calibration Flows • In Situ Validation and Calibration using Certified Standards • Both Discreet Analog 4-20mA and Digital Outputs to the Analyzer Control Room • Complete Closed Loop or Open Loop Control of all Flow Controllers, Control Valves, Stream Select Valves, Heater Controls, and Sample Pumps • One of the major refiners has mentioned that modular will become a standard for all new sample systems due to field proven performance enhancements and lower overall COO

  11. Conclusion • Proper design and component selection is paramount in obtaining desired performance from Modular • Performance benefits have been proven at the refineries engaged in this study for Gen 1 and 1.5 type Modular implementation • Hard performance and COO data is scarce because this new data is considered proprietary; primarily due to the unique process and performance advantages that Modular Sample Systems are bringing • It will not be feasible to utilize modular in 100% of all applications; hence a hybrid modular / fitting approach and hybrid analog / digital approach will need to be adopted • End-users do not need to wait for a true digital bus implementation to benefit from IMSS systems today.

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