System And Method For Managing Web-Based Refinery Performance Optimization Using Secure Cloud Computing (UOP)

CATEGORY: REFINERY PERFORMANCE OPTIMIZATION
System And Method For Managing Web-Based Refinery Performance Optimization Using Secure Cloud Computing (UOP)
United States Patent Application 20160260041
Horn; Ian G. ;   et al.   September 8, 2016
Applicant: UOP
Abstract
A management system for improving operation of a plant. A server is coupled to the management system for communicating with the plant via a communication network. A computer system has a web-based platform for receiving and sending plant data related to the operation of the plant over the network. A display device interactively displays the plant data. An optimization unit is configured for optimizing at least a portion of a refining or petrochemical process of the plant by acquiring the plant data from the plant on a recurring basis, analyzing the plant data for completeness, correcting the plant data for an error. The optimization unit corrects the plant data for a measurement issue and an overall mass balance closure, and generates a set of reconciled plant data based on the corrected plant data.
FIELD OF THE INVENTION
[0002] The present invention is related to a method and system for managing the operation of a plant, such as a petrochemical plant or a refinery, and more particularly to a method for improving the performance of operations in a plant using a secure cloud computing infrastructure.
BACKGROUND OF THE INVENTION
[0003] Companies operating refineries and petrochemical complexes typically face tough challenges in today's environment. These challenges can include eroding profit margins, increasingly complex technologies, a reduction in workforce experience levels and changing environmental regulations.
[0004] As feed and product prices become more volatile, operators often find it more difficult to make the operating decisions that can optimize financial margin. This volatility may be unlikely to ease in the foreseeable future; however, it can represent economic potential to those companies that can quickly identify and respond to market opportunities as they arise.
[0005] Pressures from capital markets are generally forcing operating companies to continually increase the return on existing assets. In response, catalyst, adsorbent, equipment, and control system suppliers develop more complex systems that can increase asset performance. Maintenance and operation of these advanced systems generally requires advanced skill levels that can be difficult to develop, maintain, and transfer given the time pressures and limited resources of today's technical personnel. This means that these increasingly complex systems are not always operated to their highest potential. In addition, as existing assets are operated close to and beyond their design limits, reliability concerns and operational risks can increase.
[0006] Plant operators typically respond to above challenges with one or more of several strategies, such as, for example, availability risk reduction, working the value chain and continuous economic optimization. Availability risk reduction generally places an emphasis on achieving adequate plant operations as opposed to maximizing economic performance. Working the value chain typically places an emphasis on improving the match of feed and product mix with asset capabilities and market demands. Continuous economic optimization often employs tools, systems and models to continuously monitor and bridge the economic and operational gaps in plant performance.
[0007] There are two levels of gaps (or performance deficits) that refinery operators typically experience:
[0008] 1) Events or "Lost Opportunities" Gap Most refinery operators do a good job of tracking the cost/value of unplanned events in their refineries: unplanned shutdowns, equipment availability problems, etc. The value associated with these gaps is generally large, but the duration is normally short. Well-operated refineries can keep these events to a minimum through effective process and mechanical reliability programs.
[0009] 2) Backcasting Gap
[0010] Some refineries focus on a backcasting (historical) gap. This is typically done on a monthly basis. The operator compares the monthly refinery production plan against the actual achieved operations, and conducts an analysis to understand and resolve the cause(s) for any gap(s). Refinery operators can often uncover substantial economic improvement if they resolve the root causes for deviation from refinery production process plans. However, when root causes are embedded in poor process performance, they are often difficult to identify. This historical analysis also can be costly in that it leaves issues unidentified and un-resolved until the end of the month. As an example only, a 1% debit in octane-barrel production from a 30,000 BPD Naphtha Reforming Process unit can be worth $530,000 over a month (at $0.60/oct-bbl).
[0011] Early identification of this gap and resolution of the problems can avoid significant profit losses. There is a need for a method that can enable continuous, consistent levels of desired performance.
[0012] Therefore, there is a need for an improved management system for operators to respond to these challenges by utilizing a strategy of economic optimization which employs tools, systems and models to monitor and bridge the economic and operational gaps in plant performance.
SUMMARY OF THE INVENTION
[0013] A general object of the invention is to improve operation efficiency of petrochemical plants and refineries. A more specific object of this invention is to overcome one or more of the problems described above. A general object of this invention can be attained, at least in part, through a method for improving operation of a plant. The method includes obtaining plant operation information from the plant.
[0014] The present invention further comprehends a method for improving operation of a plant that includes obtaining plant operation information from the plant and generating a plant process model using the plant operation information. This invention still further comprehends a method for improving operation of a plant. The method includes receiving plant operation information over the internet and automatically generating a plant process model using the plant operation information.
[0015] The present invention utilizes configured process models to monitor, predict, and optimize performance of individual process units, operating blocks and/or complete processing systems. Routine and frequent analysis of predicted versus actual performance allows early identification of operational discrepancies which can be acted upon to optimize financial impact.
[0016] This method of this invention is preferably implemented using a web-based computer system. The benefits of executing work processes within this platform include improved plant economic performance due to an increased ability by operations to identify and capture economic opportunities, a sustained ability to bridge performance gaps, an increased ability to leverage personnel expertise, and improved enterprise management. The present invention is a new and innovative way of using advanced computing technology in combination with other parameters to change the way plants, such as refineries and petrochemical facilities, are operated.
[0017] The present invention uses a data collection system at a plant to capture data which is automatically sent to a remote location, where it is reviewed to, for example, eliminate errors and biases, and used to calculate and report performance results. The performance of the plant and/or individual process units of the plant is/are compared to the performance predicted by one or more process models to identify any operating differences, or gaps.
[0018] A report, such as a daily report, showing actual performance compared to predicted performance can be generated and delivered to a plant operator and/or a plant or third party process engineer such as, for example, via the internet. The identified performance gaps allow the operators and/or engineers to identify and resolve the cause of the gaps. The method of this invention further uses the process models and plant operation information to run optimization routines that converge on an optimal plant operation for the given values of, for example, feed, products and prices.
[0019] The method of this invention provides plant operators and/or engineers with regular advice that enable recommendations to adjust setpoints allowing the plant to run continuously at or closer to optimal conditions. The method of this invention provides the operator alternatives for improving or modifying the operations of the plant. The method of this invention regularly maintains and tunes the process models to correctly represent the true potential performance of the plant. The method of one embodiment of this invention includes economic optimization routines configured per the operator's specific economic criteria which are used to identify optimum operating points, evaluate alternative operations and do feed evaluations.
[0020] The present invention provides a repeatable method that will help refiners bridge the gap between actual and achievable economic performance. The method of this invention utilizes process development history, modeling and stream characterization, and plant automation experience to address the critical issues of ensuring data security and well as efficient aggregation, management and movement of large amounts of data. Web-based optimization is a preferred enabler to achieving and sustaining maximum process performance by connecting, on a virtual basis, technical expertise and the plant process operations staff.
[0021] The enhanced workflow utilizes configured process models to monitor, predict, and optimize performance of individual process units, operating blocks, or complete processing systems. Routine and frequent analysis of predicted versus actual performance allows early identification of operational discrepancies which can be acted upon to optimize financial impact.
[0022] As used herein, references to a "routine" are to be understood to refer to a sequence of computer programs or instructions for performing a particular task. References herein to a "plant" are to be understood to refer to any of various types of chemical and petrochemical manufacturing or refining facilities. References herein to a plant "operators" are to be understood to refer to and/or include, without limitation, plant planners, managers, engineers, technicians, and others interested in, overseeing, and/or running the daily operations at a plant.
[0023] In one embodiment, a management system is provided for improving operation of a plant. A server is coupled to the management system for communicating with the plant via a communication network. A computer system has a web-based platform for receiving and sending plant data related to the operation of the plant over the network. A display device interactively displays the plant data. An optimization unit is configured for optimizing at least a portion of a refining or petrochemical process of the plant by acquiring the plant data from the plant on a recurring basis, analyzing the plant data for completeness, correcting the plant data for an error. The optimization unit corrects the plant data for a measurement issue and an overall mass balance closure, and generates a set of reconciled plant data based on the corrected plant data.
[0024] In another embodiment, a management system is provided for improving operation of a plant. A server is coupled to the management system for communicating with the plant via a communication network. A computer system has a web-based platform for receiving and sending plant data related to the operation of the plant over the network. A display device interactively displays the plant data. The display device is configured for graphically or textually receiving an input signal from the management system using a human machine interface via a dedicated communication infrastructure. A visualization unit is configured for creating an interactive display for a user, and displaying the plant data using a visual indicator on the display device based on a hue and color technique, which discriminates a quality of the displayed plant data.
[0025] In yet another embodiment, a management method is provided for improving operation of a plant. Included in the method are providing a server coupled to a management system for communicating with the plant via a communication network; providing a computer system having a web-based platform for receiving and sending plant data related to the operation of the plant over the network; providing a display device for interactively displaying the plant data, the display device being configured for graphically or textually receiving an input signal from the management system using a human machine interface via a dedicated communication infrastructure; creating an interactive display for a user, and displaying the plant data using a visual indicator on the display device based on a hue and color technique, which discriminates a quality of the displayed plant data; and generating a plant process model using the plant data for predicting plant performance expected based on the plant data, the plant process model being generated by an iterative process that models based on at least one plant constraint being monitored for the operation of the plant.
[0026] The foregoing and other aspects and features of the present invention will become apparent to those of reasonable skill in the art from the following detailed description, as considered in conjunction with the accompanying drawings.
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