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Www.circortech.com Complete, Modular, Ready Today 1 Discussions of Modular Sample System Implementation in S. California Refineries.

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Presentation on theme: "Www.circortech.com Complete, Modular, Ready Today 1 Discussions of Modular Sample System Implementation in S. California Refineries."— Presentation transcript:

1 www.circortech.com Complete, Modular, Ready Today 1 Discussions of Modular Sample System Implementation in S. California Refineries

2 www.circortech.com Complete, Modular, Ready Today 2 Current integration schemes with “GEN 1” systems

3 www.circortech.com Complete, Modular, Ready Today 3 Current “GEN 1.5” Integration

4 www.circortech.com Complete, Modular, Ready Today 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 www.circortech.com Complete, Modular, Ready Today 5 End User Benefits Today

6 www.circortech.com Complete, Modular, Ready 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 www.circortech.com Complete, Modular, Ready Today 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 www.circortech.com Complete, Modular, Ready Today 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 www.circortech.com Complete, Modular, Ready Today 9 The Future Modular in S. Cal. Refineries n NOT SHOWN: n PLC control and monitoring n Calibration standard and self- validation sample cylinders n Temp control of system and sample lines n Sample Pumps

10 www.circortech.com Complete, Modular, Ready Today 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 www.circortech.com Complete, Modular, Ready Today 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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