Hydrocarbon Processing - August 2021 - 76

Digitalization
reduce cost with improved process control, tighter integration
among systems and better data handling-key enablers of speed
to market, higher performance and more sustainable operations.
Better core process control. Performance and sustainability
go together, so organizations are turning to advanced process automation
technologies to simultaneously improve both.
Loop issues often occur in the plant units consuming the
most energy. The author's company has found nearly two-thirds
of core control loops are underperforming in typical plants-often
occurring in high-energy units such as distillation columns,
boilers and reactors. Many plants, particularly those focused on
carbon capture practices, are moving toward fully automated
monitoring. Automating monitoring makes it far less likely that
busy plant personnel will overlook the asset performance issues
that lead to poor loop operation and reduced performance.
In addition, organizations are using advanced process control
software to optimize operations through added efficiencies,
driving minute-to-minute performance improvement. Modeling
and predictive control are combined with advanced control
logic to identify best practices, capture them as control logic and
embed them in the process through automation for consistent
increases in throughput and quality.
Taking advantage of state based control (SBC) software can
also optimize processes for improved performance. SBC automates
control logic into production lines, helping individual
process units communicate and coordinate with each other.
Operators are responsible for state transitions and act as process
managers, intervening only when prompted by the system. Each
stage of the process is aware of variables from other process units
and can automatically adjust production accordingly to eliminate
risks and waste from production processes.
The emergence of simulation. Simulation software is another
key lever for delivering more sustainable operations. Often,
organizations must adjust production to optimize efficiency and
reduce environmental impact through tighter control. However,
testing a new control strategy often creates risk due to lost production
while systems are in reduced capacity for testing, along
with the increased likelihood of safety or environmental incidents
if newly implemented controls do not operate as expected
on live equipment.
Using a digital twin simulation, plants can test new process
configurations on a virtual replica of the plant, seeing how
changes cascade across the system and identifying any faults in
execution without creating risk to safety or environmental incidents.
If a change does not yield the right outcome, the team
simply reverts the digital twin back to its initial state and tries a
different solution until they get the results they are looking for,
with no operational risk whatsoever.
Moreover, the flexibility of a simulated plant environment
offers a wide range of opportunities to test scenarios that may
be unlikely but could still impact production or cause a plant to
exceed regulations. Service interruptions, unexpected bubbles of
demand, supply-chain disruptions, equipment failure and other
issues can all be tested safely, and solutions can be designed to
mitigate even the rarest 'what if' scenarios.
Outside of operations, digital twin simulations also provide
operators a safe place to train and upskill, enabling them to gain
real world experience with zero risk, even in complex scenarios
that they are only likely to face a handful of times over their entire
career. Advanced simulations can be used to replicate these
rare situations-plant trips, process excursions, equipment failure
and more-and help operators quickly gain the skills to reduce
emissions and safety risks to an absolute minimum.
Better data coverage translated into actionable insights
through contextualization. Timely delivery of quality data is
not only critical to the operational excellence of a plant, but also
essential to enable smaller groups of workers to deliver more
product with improved sustainably. Fortunately, advances in
automation are enabling organizations to not only access more
data than ever before, but also to easily put the data in context
and quickly deliver it to the right people at the right time (FIG. 2).
This improved, on-demand access to data helps drive improvements
from the plant floor up through the enterprise.
Key components for improving efficiency are reducing operator
load and providing personnel with tools to help make better
decisions. Alarm systems have always been critical to helping
operators stay ahead of the issues reducing performance and
impacting sustainability. Many staff- and resource-limited organizations
are relying more heavily on alarm management, with
some organizations centralizing alarm systems to reduce maintenance,
while making these systems easier to update, maintain
and scale consistently across multiple sites.
In combination with more powerful alarm management, the
Industrial Internet of Things (IIoT) has made it possible for a
plant to move away from maintenance routes. With increasing
options for smaller, simple-to-install IIoT measurement points,
it is now easy and affordable to add automated monitoring to
the majority of a plant's assets.
Fully automated monitoring provides important benefits
for organizations working with small staff numbers. Personnel
can be freed from maintenance rounds to perform more critical
tasks to improve operations performance and product quality.
In addition, plants with assets in hard to reach, remote or
hazardous areas can improve visibility without increasing the
expense, time, environmental impact and safety risk of travel.
FIG. 2. Secure remote monitoring provides plant personnel with
timely data, enabling them to make better decisions quickly.
76 AUGUST 2021 | HydrocarbonProcessing.com
Expanding sustainability beyond the local perimeter.
Better performance through improved data is also enabled by expanded
access to cloud technologies. Organizations can centralize
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Hydrocarbon Processing - August 2021

Table of Contents for the Digital Edition of Hydrocarbon Processing - August 2021

Contents
Hydrocarbon Processing - August 2021 - Intro
Hydrocarbon Processing - August 2021 - Cover1
Hydrocarbon Processing - August 2021 - Cover2
Hydrocarbon Processing - August 2021 - Contents
Hydrocarbon Processing - August 2021 - 4
Hydrocarbon Processing - August 2021 - 5
Hydrocarbon Processing - August 2021 - 6
Hydrocarbon Processing - August 2021 - 7
Hydrocarbon Processing - August 2021 - 8
Hydrocarbon Processing - August 2021 - 9
Hydrocarbon Processing - August 2021 - 10
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Hydrocarbon Processing - August 2021 - 18
Hydrocarbon Processing - August 2021 - 19
Hydrocarbon Processing - August 2021 - 20
Hydrocarbon Processing - August 2021 - 21
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Hydrocarbon Processing - August 2021 - 26
Hydrocarbon Processing - August 2021 - 27
Hydrocarbon Processing - August 2021 - 28
Hydrocarbon Processing - August 2021 - 29
Hydrocarbon Processing - August 2021 - 30
Hydrocarbon Processing - August 2021 - 31
Hydrocarbon Processing - August 2021 - 32
Hydrocarbon Processing - August 2021 - 33
Hydrocarbon Processing - August 2021 - 34
Hydrocarbon Processing - August 2021 - 35
Hydrocarbon Processing - August 2021 - 36
Hydrocarbon Processing - August 2021 - 37
Hydrocarbon Processing - August 2021 - 38
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Hydrocarbon Processing - August 2021 - 40
Hydrocarbon Processing - August 2021 - 41
Hydrocarbon Processing - August 2021 - 42
Hydrocarbon Processing - August 2021 - 43
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Hydrocarbon Processing - August 2021 - 57
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Hydrocarbon Processing - August 2021 - 60
Hydrocarbon Processing - August 2021 - 61
Hydrocarbon Processing - August 2021 - 62
Hydrocarbon Processing - August 2021 - 63
Hydrocarbon Processing - August 2021 - 64
Hydrocarbon Processing - August 2021 - 65
Hydrocarbon Processing - August 2021 - 66
Hydrocarbon Processing - August 2021 - 67
Hydrocarbon Processing - August 2021 - 68
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Hydrocarbon Processing - August 2021 - 70
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Hydrocarbon Processing - August 2021 - 76
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Hydrocarbon Processing - August 2021 - 79
Hydrocarbon Processing - August 2021 - 80
Hydrocarbon Processing - August 2021 - 81
Hydrocarbon Processing - August 2021 - 82
Hydrocarbon Processing - August 2021 - Cover3
Hydrocarbon Processing - August 2021 - Cover4
Hydrocarbon Processing - August 2021 - GP-1
Hydrocarbon Processing - August 2021 - GP-2
Hydrocarbon Processing - August 2021 - GP-3
Hydrocarbon Processing - August 2021 - GP-4
Hydrocarbon Processing - August 2021 - GP-5
Hydrocarbon Processing - August 2021 - GP-6
Hydrocarbon Processing - August 2021 - GP-7
Hydrocarbon Processing - August 2021 - GP-8
Hydrocarbon Processing - August 2021 - GP-9
Hydrocarbon Processing - August 2021 - GP-10
Hydrocarbon Processing - August 2021 - GP-11
Hydrocarbon Processing - August 2021 - GP-12
Hydrocarbon Processing - August 2021 - GP-13
Hydrocarbon Processing - August 2021 - GP-14
Hydrocarbon Processing - August 2021 - GP-15
Hydrocarbon Processing - August 2021 - GP-16
Hydrocarbon Processing - August 2021 - GP-17
Hydrocarbon Processing - August 2021 - GP-18
Hydrocarbon Processing - August 2021 - GP-19
Hydrocarbon Processing - August 2021 - GP-20
Hydrocarbon Processing - August 2021 - GP-21
Hydrocarbon Processing - August 2021 - GP-22
Hydrocarbon Processing - August 2021 - GP-23
Hydrocarbon Processing - August 2021 - GP-24
Hydrocarbon Processing - August 2021 - GP-25
Hydrocarbon Processing - August 2021 - GP-26
Hydrocarbon Processing - August 2021 - GP-27
Hydrocarbon Processing - August 2021 - GP-28
Hydrocarbon Processing - August 2021 - GP-29
Hydrocarbon Processing - August 2021 - GP-30
Hydrocarbon Processing - August 2021 - GP-31
Hydrocarbon Processing - August 2021 - GP-32
Hydrocarbon Processing - August 2021 - GP-33
Hydrocarbon Processing - August 2021 - GP-34
Hydrocarbon Processing - August 2021 - GP-35
Hydrocarbon Processing - August 2021 - GP-36
Hydrocarbon Processing - August 2021 - GP-37
Hydrocarbon Processing - August 2021 - GP-38
Hydrocarbon Processing - August 2021 - GP-39
Hydrocarbon Processing - August 2021 - GP-40
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https://www.nxtbook.com/nxtbooks/gulfpub/catalyst_handbook_2020_v2
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202008
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020
https://www.nxtbook.com/nxtbooks/gulfpub/refining_processes_handbook_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202007
https://www.nxtbook.com/nxtbooks/gulfpub/hp_202006
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_202001
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201912
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201911
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2020
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201910
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201909
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_2017mediaplanner
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