Heated, Smart & Modular Sample Handling System: Enabler for Closed Loop Process Control

Topics Introduction & Background Elements of Analyzer Reliability New Tools for Sample Handling System Reliability Field Results Conclusions

Introduction & Background Lanxess Born of Bayer AG strategic realignment in 2004 Produces Performance Chemicals, Chemical Intermediates, Engineering Plastics & Performance Rubber Sarnia, Ontario Plant: Butyl Rubber producer >60 years Moisture analysis & control is key Process Engineers & Plant Operators lacked confidence in analyzer results due to Sample Handling System (SHS) problems

“How to Trust Your Process Analyzer" Perhaps this Paper should be entitled: “How to Trust Your Process Analyzer"

Elements of Analyzer Reliability Adopt a “Mini-Process” mindset and methodology to definition of the analyzer sample handling system (SHS) Focus on 4 Key Elements: Training Preventative Maintenance Automation Performance Monitoring

Process Control Information Training Analyzer Technicians should have intimate knowledge of the entire analyzer system: Carrier & Cal Gas Delivery Sample Transport Sample Return Sample Extraction Sample Conditioning Analyzer Including: what the analysis does, why it is important to the plant, and its role in the DCS Process Control Information INTERNAL CUSTOMER!

Preventative Maintenance Analyzer MTBF must exceed unit shutdown schedules Perform PM On The Plant Shutdown Schedule… …Not On The Analyzer’s or SHS’s Schedule!

Preventative Maintenance Case Study: Early 2004 Analyzer PM had been properly completed Midnight callout from operations: “Your Analyzer Isn’t Working!” Analyzer Engineer twisted operations arm over the phone: “Act On The Analyzer’s Results!!!” Operations listened- and set a new production record that very day! Stage was set for deployment of new SHS tools

Automation Engage Process Engineering & Plant Operations (the internal customer) on “mini-process” SHS needs Monthly ISO driven manual validations/calibrations proved to be major source of variability Secondary standard integrity found to be inconsistent Technician val/cal performance also inconsistent Enablers for remote val/cal: Modular, remote actuation double block & bleed stream switching valve Modular flow indication

Performance Monitoring Scrape DCS for “mini-process” data; fed into networked Process Information (PI) system Correlations predict validation requirements Eliminating ISO validations- takes time to validate Benefits Reduced variations resulting from unnecessary P.M. and validations Parameters constantly monitored- deviations show up prior to problems being found

New Tools for SHS Reliability Robust, modular, remote actuation double block & bleed stream (DBB) switching valve

New Tools for SHS Reliability Differential pressure flow indication w/ integral relief function (I.S., 4-20mA output)

New Tools for SHS Reliability Smart, Proportional Heater & Purge Preheater

Field Results System Commissioned June 24, 2005

Field Results Remote validation available to Operators via DCS DBB Stream Switch Reference Gas Dryer

Field Results Remote analyzer and bypass flow indication available to operators via DCS Bypass Flow Indication Analyzer Flow Indication Reference Gas Flow (9min 25sec) Switching valve cycled Sample Gas Flow (9min 25sec) Cycles repeated during commissioning

Field Results Process Engineers & Operations TRUST THE ANALYZER Several analyzers in the Sarnia plant are running closed loop control Plant Shutdowns HAVE BEEN AVERTED 5 additional “smart” systems have since been commissioned in the Sarnia plant- more planned

Next Steps Incorporate Human Machine Interface (HMI) in field Provides local host for “Smart Shelters”

Conclusions Process Engineering & Operations early involvement created a team atmosphere for a win-win conclusion Team wins are very fulfilling Breaking free form “the way we’ve always done it” requires open-mindedness to determine the vision And single-mindedness to work through the inevitable hurdles

Thank You!