Remote & Automated Coke Cutting
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1 Product Management Remote & Automated Coke Cutting Andrew Worley Product Manager Coke Cutting Flowserve FSG
2 Product Management Agenda Flowserve Overview System Overview Process Benefits Remote Cutting Requirments Automation Requirements Required Equipment Drum Monitoring Automation Process Lessons Learned
3 Simplified 2 Drum System
4 The Goal is transition from
5 To. modern systems 2013 Flowserve Corporation Company Confidential
6 Remote Coke Cutting Move operator from the cutting deck to a remote location Benefits Increased Safety Personnel no longer exposed to: High-pressure water Hot spots or steam eruptions Fire and mechanical hazards Hydrogen sulfide vapors Noxious vapors Improved Operator Information
7 Automated Benefits Improved cutting personnel safety Automated cutting system integrated with PLC interlocks Minimize probability of operator mistake Eliminates shortcuts sometimes taken by cutting personnel Standardized cutting procedures reduce risk of aggressive cutting practices Improved equipment reliability Process efficiency and consistency Advance program and cutting tool as soon as possible Consistent cutting times with standardized cutting procedure Data recording for process optimization or troubleshooting Cycle Time Optimization Ability to access data for troubleshooting in case of event
8 Remote Coke Cutting Requirements Information required for the Operator Data sent remotely to operator Cutting tool position and rotational speed Cable tension and AutoShift mode Drum status Equipment required Unheading valve AutoShift cutting tool Remote operator shelter or location Automated tool enclosure and drill stem guide Remote winch and rotary joint operation Vibration/acoustic/video drum monitoring
9 Automation Coke Cutting Requirements Equipment required Unheading valve AutoShift cutting tool Remote operator shelter or location Automated tool enclosure and drill stem guide Remote winch and rotary joint operation Vibration drum monitoring
10 Flowserve Product Management Innovation Remote Winch & Rotary Joint Operation
11 Drive Options introduced by Flowserve in 1994 Higher Initial installed cost Low maintenance during operation Can combine with unheading valve HPU for cost savings. Best option for remote & automated cutting with electric actuation E-motor (with VFD) In operation since 2008 Approximately same initial cost as hydraulic Low maintenance during operation Requires electrical installation in tower by contractor. Best option for remote & automated cutting with hydraulic actuation Air piston motor Original power option Lower initial installed cost Requires frequent repair if lubrication is not maintained frequently or dry, clean air is not used. Suitable for remote & automated cutting
12 Why Air Motors? Main technical reason (1938): No problems for operation in hazardous areas (Ex zones) Cons: Dependence on plant air (potential low pressure issues) Air quality (moisture problems in freezing temperatures) Low equipment control precision Noise and oil mist Intensive maintenance required
13 Motors in 1994 Main technical reasons (1994): Improve general working conditions for operation personnel (handling, safety) Eliminate operation issues in very cold climate Precision control of equipment for operator Cons: Space for Power Unit on the deck Intensive piping (3 lines from HPU to each motor) Cleanness of the hydraulic oil is key for trouble free operation
14 Why Electric Motors? Main technical reasons (2008): Proven technology is available and affordable Reduces installation and maintenance efforts Cons: Space for electric motors
15 Electric Motor Design Features E-motor, flameproof (Ex de ) Low voltage squirrel cage induction motor Winch: 30 kw Rotary Joint: 11 kw Winding temperature 3x PTC Internal shaft encoder (for winch) Forced ventilation by separate fan motor Rated Stall capability for 10 min (tested for 35 minutes)
16 Comparison Of Actuators AIR HYDR. ELECTR. Physical Prop. Operation Commercial Space Requirements (Cutting Deck) Driver Weight Speed-Torque Characteristics Control/Response Characteristics Environmental Issues Maintainance Requirements MTBR Spare Parts Availability Initial Investment Installation Cost Maintenance Cost TOTAL SCORE
17 Flowserve Product Management Innovation Drum Monitoring Audio, Video & Vibration
18 Operator feedback for Cutting progress Personal Cutting Style & Experience Visual Feedback Audio Feedback by his ears by his eyes by his personality 18
19 Confusing Environment is an extremely NOISY service: Refinery machinery and coke cutting equipment Winches / Crossheads Weather / Wind Area surrounding high noise activities Equipment : pumps/motors Trains / Skip loaders / Cranes Steam / air / process noise Alarms / Sirens/
20 Challenging Layouts & Situations is also a LOW VISIBILITY service: Outdoor unsheltered area Inclement weather fog / rain / snow / storms Process produces steam,vapors & explosions Area surrounding has visual obstructions Piping / structural beams/ wiring/ equipment
21 Solutions: Provide Same or Improved Information To Remote Locations Provide reasonable reproduction of the Sounds o Remote Audio Provide reasonable duplication of the Sights o Remote Camera Provide additional detailed information on the process activity to manage better decisions. o Remote Drum monitoring information
22 Ver-003 : Remote Drum Monitoring Audio Offering Updated & Simplified Audio system Compact/simple arrangement Area rated Operator Cabin Mic PLC Speaker
23 Video Design Equipment Challenges Video Camera Standard Camera Issues Corrosion Coke Fine Accumulation Self Cleaning Pan Tilt Zoom when necessary Area Certification Engineered Placement Cutting Deck Winches Pit
24 Automation System Architecture HMI IPS APEX Serial Modbus communication Control System Coker Drums Vibration Sensors
25 Cutting Overview on HMI Vibration Strip Charts Instantaneous Vibrations
26 Cutting Overview on HMI Push Button Controls Field Information
27 Cutting Overview on HMI Drum Cleanliness Will Be Indicated Here
28 Flowserve Product Management Innovation Automation
29 History - Pre-programmed cutting First used in early 1980s PLC programmed to operate equipment at pre-defined parameters Limited feedback signals about cutting progress Program is customized based on the established best practices of the operators Operator interface required
30 Automated Flexibility Cutting Style Options Coke Type Options Multiple Backup Options Start/Stop/Pause Operator Control Exception Handling Coke Bed Collapses Slack Cable Reliable Clean Drum Sensing Auto-calibration
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Absorption Chillers TGG, TBG, TEG, TUG, 3.9 TBS, Gene-Link series Stable Chilled Water Outlet Temperature PID control is applied to maintain constant chilled water outlet temperature. When the cooling