1 Asset Performance Modeling For Refinery Steam Systems - Shell

Asset Performance Modeling for Refinery Steam Systems
Ryan Stephens Ricky Bulos Celesta White Nazim Nathoo
Outline

Introduction & overview Reliability modeling and dynamic simulation for utilities Example: refinery steam system
Introduction and Overview
What is a Reliability Modeling Study?
Reliability Modeling Study is a

-
structured process to mathematically simulate the stochastic performance of plant hardware and process systems as well as local/global network of systems. ensure current, new and revamped plants can meet defined operating/project premises such as production levels, availability targets, environmental regulations, etc. For new and revamped plants, ensure design meets premise for the lowest capital investment. make objective data-driven decisions around appropriate equipment capacity, sparing philosophy and system/hardware selection options to meet project premises get the emotion out! assist with defining feed and product contracts as well as security of supply determine storage and logistics requirements. assure project funding entities or lenders that their investment will result in the expected return (production).
Results can be used by project teams to .

-
Dynamic Simulation Technology
Dynamic Simulation Study is a

-
structured process to mathematically simulate the dynamic response of key system parameters (pressure, temperature, flow, etc.) during normally varying and unexpected operating or upset conditions in systems comprising primarily of mechanical elements (pumps, compressors, turbines, valves, etc. along with their associated piping, distribution and control systems). develop insight into which components/sub-systems are primary contributors to errant or undesirable behavior. observe dynamic behavior to known inputs thereby providing verification of logical sequence of events that lead to expected or unexpected behavior. validate, via a systematized approach, the effect of proposed changes to modify system response and to develop a robust solution set. ensure new designs will operate as expected after implementation. develop well-defined scope and sound justification for system modifications during turnarounds.
Results can be used by project teams to .

-
Applications and Scope
This methodology is applied to a wide range of assets, such as:

-
Refineries Petrochemical complexes Gas production and distribution networks Utility Production and Distribution networks System involving product transport and logistic (shipping, rail, trucks, pipelines) Upstream extraction and processing
Depending on the asset and the objectives of the study, the scope of the project might include:
-
Feedstock availability Multiple production plants (down to equipment level) Intermediate tanks Product tanks Product export Utility systems
Performance Analysis: Typical Objectives

Quantifying the future performance of the system and its components (production and utilization). Optimization of the system design (e.g. configuration, redundancy, storage, capacity, equipment sparing, etc). Optimization of the asset operations (e.g. maintenance philosophy, inventory management, product export, load shedding rules, etc). Identification of bottlenecks and key performance drivers (e.g. where to focus reliability improvement efforts). Evaluation and prioritization of investment opportunities (based on life cycle cost analysis).
Reliability Modeling for a Refinery Steam System
Refinery Steam System Example

1500# BLRS (1500 # HDR)
LETDOWN STATIONS
STG
900# 900# BLR BLRS
1500# USERS
(900 # HDR)
LETDOWN STATIONS
600# BLR
STG
600# BLR
STG
600# BLRS (600 # HDR)
LETDOWN STATIONS LETDOWN STATIONS STG STG 600# 600# USERS USERS (150 # HDR)
LETDOWN STATIONS P C
15# USERS
150# USERS (15 # HDR)
10
Approach: Steam System Reliability Model Defined scope and boundaries of steam system (BFW
and fuel systems assumed to be 100% for the preliminary analysis). Acquired detailed system and operating (including failure) data of all equipment and sub-systems. Included operating rules, producer/user priorities, etc. This represented a substantial undertaking with committed and enthusiastic participation of refinery staff. Developed Base Case model and validated against actual operating history key requirement to establish confidence.
11
Steam System LayoutTARO Software

Normal Flow s, U nits/D ay
1500 psi Header Sn.1 Sn.19 P RS 1500-900 (high pr ior ity) 4000 [20] Cap acity: 50 [20] P RS 1500-900 (high pri ority) Capacity: Cap acity: [11] [11] Boil er 34 (normal) Sn.20 900 psi Header 4000 34 STG [32] Capacity: 130 [33] [31] [13] B oi ler 32 (normal) Capacity: [34] [31] 900 psi Header [79] Boil er 34 B oi ler 33 (normal) 34 STG PR S 3 normal 600 psi Header 34 S T G average [50] Capacity: Sn.33 34 STG aver ag e 113.1 36 boiler (no r m al) 93 Sn.15 [39] PR S2 normal Sn.51 [52] Capacity: SRU (600 psi) 304 [55] HT U 3 600 [79] 150 psi Header [81] Capacity: Sn .32 36 Bo iler 155 [15] Capacity: Sn.9 [38] PR S1 normal Sn.31 600 psi Header 4000 [51] [53] C RU 600 Capacity: Sn.50 150 psi Head er 4000 Sn.80 [80] C apacity: Sulfur 85 Sn .79
Actu al Flow s, Un its /D ay

Capacity:
Boiler 34 405
Max imum Stream F low , Units/Day

[19] [21] 1500 psi Header
[19]
[12]
Boil er 35 (normal)
Sq.1
[1]
[22] 20 Sq.4
[14]
[36]
[32]
[79] 9 Sq.1 [9] 36 Boil er [50]
[40]
[50]
[53]
[33]
[82] 80 Sq.13
[2]
Boli er 35
[23]
[3]
B oi ler 32
32 [38]
Sq.7 [41]
PR S4 normal
[54] 51 Sq.10
[35]
31 S T G average
[83]
33 [24] Bo iler 32 Sn.11 Boiler 34 (n or m al) Capacity: 100 [25] Cap acity: LOU F linthill - 1500 (h igh prio r ity) 120 [31] Boil er34 B oi ler 37 (normal) 900 psi Header [79] 3 Sq.1 Sn.13 Boiler 32 (norm al) [30] Cap acity: 215 [28] P rax Air (normal) [42] [34] 31 STG C apacity: Sn.21 [26] P RS 1500-900 (low priority) Capacity: [40] [35] Capacity: 330 [13] Sn .34 31 STG 410 Sn.3 [4] B oi ler 33 [39]
Sq.7 Sn.10 29 Bo iler Capacity: 368 [16] 29 boil er (normal) 33STG to 150psi [15] 36 boil er (normal) [55] [37] 32 S T G Average [84]
15
Sq.2
[16] Sn.35 31 S T G aver age 218 Capacity: 10 Sq.1
[56]
[77]
[85] FCC U 150 C apacity:
Sn.81 44
[50] Sn.16 29 boiler (no r m al) 276 [49] 33 STG (normal )to 600 [57] FCCU (600 psi) Capacity: CR U W HB (normal) [50] 600 psi Header 273 26 S T G 600 psi Sn.52 [78] 27STG (normal) [79] 150 psi Header [86]
[1]
[19]
[26] [19] 1500 psi Header [23]
[27]
[41]
[31]
[79] [10]
29 Boil er
[17] [50]
[58]
[69]
[87] 81 Sq.13
11
Sq.2 21 Sq.4 [3] Boil er 32 [31] [5] B oi ler 37 [43]
34
Sq.7 [18] Sn.49 33 STG (nor mal) to 600 35 Sq.7 Cap acity: 170 16 Sq.2 [43] PR S1 to 600 psi (excess) [60] 52 Sq.10 P RS 2 MVH CO Boil er(normal) [59] [70] P RS 1 MVH [88]
[6]
P rax Air
[44]
[71]
[89]
Sn.23 Sn .12 Boiler 35 (n or m al) C apacity: 297.1 [21] LOU Flinthi ll - 1500 (hi gh priority) Capacity: LOU Flinth ill 388 Sn.4 Bo iler 33 Capacity: [19] [2] Bolier 35 [19] 900 psi Header [79] 1500 psi Header 330 [14] [46] [37] Cap acity: 13 Sq.2 [45] Sn.36 32 S T G 611 [29]
33STG extracti on (to 600)
[50] [44]
PR S2 to 600 (excess)
[61]
[72]
P RS 3 MVH
[90] Sn.82 CRU 150 C apacity: 42
[45] 49 Sq .8
PR S3 to 600 psi (excess)
[62] Sn .53 CRU 600 Capacity: 158
[73]
P S2 PRS 1
[91] 150 psi Header
[79] P S2 PRS 2
[31] 23 Sq.5 [47]
[31]
[46] Sn.17 Sn.37 32 STG Aver ag e CRU W HB (no r m al) Sn.7 CRU WHB Capacity: 126 [17] Cap acity: 91 [9]
[63]
[74]
[92]
12
Sq.2 4 Sn.22 33 STG min flow Cap acity: 50 Cap acity: Boiler 33 (norm al) 220 Sq.1 Sn.14 [48] 36 Sq .7 Capacity:
335
36 Boi ler
[50]
600 psi Header [64]
[79] [75]
P S2 PRS 3
82 [93]
Sq.13
[7] [36] 1500 psi Header Boil er 33 32 STG [79]
CRU WH B [50]
[50] [10] 29 Boi ler [65] 53 Sq .10 [47] MVHPS to 150 header
[19] Sn.2 Bolier 35 Capacity: 400 [12]
[24]
[4]
[31] 33 STG
Sq.1 17 Sq.2
[25]
[66]
[66]
P S2 PRS 4 Sn.83 VPS4 150 Capacity: 236
37
Sq.7 [7] CR U W HB [67] [32] 34 S T G 150 psi Header
22 [19]
Sq.4 Sn.24 33 STG Aver ag e flow Cap acity: 376
14
Sq.2
Sn .54 Sn.8 CO Boiler [8] 403 [18] 600 psi Header [69] [50] Cap acity: Sn.18 C O Boiler (nor mal) 124 33STG to 150psi [70] 8 Sq.1 CO Boiler 54 Sq .10 C apacity: 210 [25] Sn .77 33 S T G [36] 32 S T G Capacity: LCD U CO Boil er [68] Capacity: 22 [34] 31 S T G
[79]
Sq.1
[22]
33 STG mi n fl ow
[50] [25] [19] 1500 psi Header
83
Sq.13
24
Sq.5 PRS1 n or m al C apacity: Sn.5 Bo iler 37 Capacity: 300 [27]
Sn.38 125
[8]
[50] [71] [25] 33 ST G [68]
27 S T G 600 psi
[79] Sn.84 VPS2
[72] Sn.25 33 STG C apacity: [24] 33 STG Average fl ow 673 [31] [29] Sn.27 Boiler 37 (norm al) [19] 1500 psi Header 5 [50] Sq.1 Cap acity: 175 38 Sq .7 Capacity: PRS 1 to 600 psi (excess) 238 [74] Sn.43 [73] 600 psi Header [31] 900 psi Header [50] 18 Sq.2 Cap acity:
Sn.55 HTU 3 600 80 [79] 150 psi Header
C apacity:
468
77
Sq .11
[50]
[79]
84
Sq.13
[77] 25 Sq.5
[5]
Boil er 37
[31]
[31]
900 psi H eader
[50]
[75]
55
Sq.10
[79] Sn .29 33STG extr action (to 600) Capacity: 387 Capacity: Sn.6 P rax A ir 175 [28] [31] 33 S T G 900 psi Header 27 Sq.5 C apacity:
Sn.39 PRS2 n or m al 60 43 Sq.8
[76]
Sn.85 DCU 150 C apacity: Sn .56 110
[50] Capacity:
ALKY 600 43 [79] 150 psi Header
[25]
[49] [31] [50] Sn.44 39 Sq .7 Capacity: PR S2 to 600 (excess) 308 56 Sq .10 600 psi Header
85
Sq.13
19
Sq.3 29 Sq.6
Sq.1
[31] Sn.28 Pr ax Air (norm al) Cap acity: Sn.26 PRS 1500-900 (lo w pr ior ity) Cap acity: 338 [6] Prax A ir 130 Capacity: PRS 3 no r m al 75 Sn.40
900 psi H eader
[50] LOU F linthill 600 Sn .57 LOU Flin thill 600 (high pr ior ity) Capacity: 200 [57] LOU Flinthi ll 600 (high pri ority) Capacity:
Sn.67 365
44 [31] [31] 900 psi H eader [50]
Sq.8 [50] 600 psi Header [67]
[50]
600 psi H eader Sn.86 HCU 150 C apacity: 30
[19]
1500 psi Header
[31] 67 Sq.11 [79] 28 Sq.5 40 Sq.7 57 Sq .10 150 psi Header
26
Sq.5 P RS3 to 600 psi (excess) Cap acity:
Sn.45 267
86
Sq.13
Sn .68 27 STG 600 psi Sn.30 PR S 1500 losses Cap acity: 428 PRS 4 n or m al Cap acity: [19] 1500 psi Header 45 [31] 900 psi Header [50] Sn.78 27STG (norm al) 30 Sq.6 68 Sq .11 C apacity: 125 [79] 150 psi Header Sq .8 45 [50] 600 psi Header 600 psi Header [79] HTU4 150 [50] [68] Capacity: 70 Sn.87 Sn.41 27 STG (h ig hp r io r ity) Cap acity: 50 [31] 900 psi Header C apacity: [50] Sn.58 [58] 27 ST G (hi gh priori ty) 304 [78]
58 41 Sq .7
Sq.10 [68] 27 STG 600 psi [79] 87 Sq.13
Sn.46 PRS4 to 600 psi (excess) Capacity: 325 78 Sn.59 26 STG (h ig hp r io ir ty) [31] 900 psi Header Cap acity: [50] [59] 60 26 STG (high pri oi rty) Capacity: 600 psi Header [50] Sn.42 MVHP S (nor mal) Cap acity: 10 88 Sq.13 46 Sq.8 600 psi Header Cap acity: 26 STG 600 psi 65 Sn.88 MP P 150 468 Sn.69 Sq.11
[50]
[69]
[79] [79]
150 psi Header
59
Sq.10
69
Sq.11
[31]
900 psi Header
[47]
42
Sq .7 Capacity:
Sn.89 Alky 150 33
Sn.47 MVHPS to 150 head er Capacity: [42] MVH PS (normal) 140 [79] 150 psi H eader
[31]
900 psi Header
[79]
89
Sq.13
Sn.70 47 Sq.8 PRS 1 MVH C apacity: 60 [60] PRS 1 MVH Sn.90 HTU5 600 psi Header 600 psi Header [70] [79] Capacity: 39 Sn .60 Cap acity: PRS 1 MVH 305
[50] 31 Sq.6 Sn.48 900 lo sses (constan t) Capacity: 28
[50]
[79]
150 psi H eader
70 60 [31] 900 psi Header Sq .10
Sq.11 90 Sq.13
Sn .61 PRS 2 MVH C apacity: 48 Sq.8 60 [61] PRS 2 MVH Cap acity: PRS 2 MVH
Sn.71 311
[50]
600 psi Header [50]
[71] 600 psi Header
[79]
Sn.91 MVHPS AUx Tur bine Cap acity: 265
61
Sq .10
71
Sq.11 [79]
150 psi Header
Sn .62 PRS 3 MVH C apacity: 60 Cap acity: [62] 600 psi Header PRS 3 MVH PRS 3 MVH 306 Sn.72 91 Sq.13
[50]
[72] [79] [50] 600 psi Header
Sn.92 PS2 Aux tur bine 62 Sq .10 72 Sq.11 Cap acity: 108
[79]
150 psi Header
92
Sq.13
Sn.73 Sn.63 PS2 PRS 1 Capacity: 60 [63] P S2 PRS1 PS2 P RS1 Capacity: 122
[79] [50] 600 psi Header [50] 600 psi H eader [73] Oth er s Capacity: 650 Sn.93
73 63 Sq.10
Sq.11
[79]
150 psi Header
Sn.64 PS2 PRS 2 Capacity: 60 [64] P S2 PRS2 Capacity: PS2 P RS2
Sn.74 170
93
Sq.13
[50]
600 psi Header [50]
[74] 600 psi H eader
[79]
64
Sq.10
74
Sq.11
Sn.75 255
[50] 50 Sq.9
600 psi Header [50]
[79]
65
Sq.10
75
Sq.11 79 Sq .12
Gross Steam Demand Distribution 1500 psi

100% 90% 80% Cumulative Probability (%) 70% 60% 50% 40% 30% 20% 10% 0% 0 100 200 300 400 500 600 700 800 900 1000 1500 psi steam demand (mpph)
Average demand
Max 1500 psi boiler capacity
13
Scenarios ConsideredBoiler Outages

1500 psi Header Sn.1 Sn.19 P RS 1500-900 (high pr ior ity) 4000 [20] Cap acity: 50 [20] P RS 1500-900 (high pri ority) Capacity: Cap acity: [11] [11] Boil er 34 (normal) Sn.20 900 psi Header 4000 34 STG [32] Capacity: 130 [33] [31] [13] B oi ler 32 (normal) Capacity: [34] [31] 900 psi Header [79] Boil er 34 B oi ler 33 (normal) 34 STG PR S 3 normal 600 psi Header 34 S T G average [50] Capacity: Sn.33 34 STG aver ag e 113.1 36 boiler (no r m al) 93 Sn.15 [39] PR S2 normal Sn.51 [52] Capacity: SRU (600 psi) 304 [55] HT U 3 600 [79] 150 psi Header [81] Capacity: Sn .32 36 Bo iler 155 [15] Capacity: Sn.9 [38] PR S1 normal Sn.31 600 psi Header 4000 [51] [53] C RU 600 Capacity: Sn.50 150 psi Head er 4000 Sn.80 [80] C apacity: Sulfur 85 Sn .79

Capacity:
Boiler 34 405

[19] [21] 1500 psi Header
[19]
[12]
Boil er 35 (normal)
Sq.1
[1]
[22] 20 Sq.4
[14]
[36]
[32]
[79] 9 Sq.1 [9] 36 Boil er [50]
[40]
[50]
[53]
[33]
[82] 80 Sq.13
[2]
Boli er 35
[23]
[3]
B oi ler 32
32 [38]
Sq.7 [41]
PR S4 normal
[54] 51 Sq.10
[35]
31 S T G average
[83]
33 [24] Bo iler 32 Sn.11 Boiler 34 (n or m al) Capacity: 100 [25] Cap acity: LOU F linthill - 1500 (h igh prio r ity) 120 [31] Boil er34 B oi ler 37 (normal) 900 psi Header [79] 3 Sq.1 Sn.13 Boiler 32 (norm al) [30] Cap acity: 215 [28] P rax Air (normal) [42] [34] 31 STG C apacity: Sn.21 [26] P RS 1500-900 (low priority) Capacity: [40] [35] Capacity: 330 [13] Sn .34 31 STG 410 Sn.3 [4] B oi ler 33 [39]
Sq.7 Sn.10 29 Bo iler Capacity: 368 [16] 29 boil er (normal) 33STG to 150psi [15] 36 boil er (normal) [55] [37] 32 S T G Average [84]
15
Sq.2
[16] Sn.35 31 S T G aver age 218 Capacity: 10 Sq.1
[56]
[77]
Sn.81 44
[50] Sn.16 29 boiler (no r m al) 276 [49] 33 STG (normal )to 600 [57] FCCU (600 psi) Capacity: CR U W HB (normal) [50] 600 psi Header 273 26 S T G 600 psi Sn.52 [78] 27STG (normal) [79] 150 psi Header [86]
[1]
[19]
[26] [19] 1500 psi Header [23]
[27]
[41]
[31]
[79] [10]
29 Boil er
[17] [50]
[58]
[69]
[87] 81 Sq.13
11
Sq.2 21 Sq.4 [3] Boil er 32 [31] [5] B oi ler 37 [43]
34
Sq.7 [18] Sn.49 33 STG (nor mal) to 600 35 Sq.7 Cap acity: 170 16 Sq.2 [43] PR S1 to 600 psi (excess) [60] 52 Sq.10 P RS 2 MVH CO Boil er(normal) [59] [70] P RS 1 MVH [88]
[6]
P rax Air
[44]
[71]
[89]
Sn.23 Sn .12 Boiler 35 (n or m al) C apacity: 297.1 [21] LOU Flinthi ll - 1500 (hi gh priority) Capacity: LOU Flinth ill 388 Sn.4 Bo iler 33 Capacity: [19] [2] Bolier 35 [19] 900 psi Header [79] 1500 psi Header 330 [14] [46] [37] Cap acity: 13 Sq.2 [45] Sn.36 32 S T G 611 [29]
33STG extracti on (to 600)
[50] [44]
PR S2 to 600 (excess)
[61]
[72]
P RS 3 MVH
[45] 49 Sq .8
[62] Sn .53 CRU 600 Capacity: 158
[73]
P S2 PRS 1
[91] 150 psi Header
[79] P S2 PRS 2
[31] 23 Sq.5 [47]
[31]
[46] Sn.17 Sn.37 32 STG Aver ag e CRU W HB (no r m al) Sn.7 CRU WHB Capacity: 126 [17] Cap acity: 91 [9]
[63]
[74]
[92]
12
Sq.2 4 Sn.22 33 STG min flow Cap acity: 50 Cap acity: Boiler 33 (norm al) 220 Sq.1 Sn.14 [48] 36 Sq .7 Capacity:
335
36 Boi ler
[50]
600 psi Header [64]
[79] [75]
P S2 PRS 3
82 [93]
Sq.13
[7]
CRU WH B [50]
[50] [10] 29 Boi ler [65] 53 Sq .10 [47] MVHPS to 150 header
X
Sn.2 400 Bolier 35 Capacity: 2 Sq.1
[36] 1500 psi Header Boil er 33
32 STG
[79]
[19]
[24]
[4]
[31] 33 STG
7 [12] 37 Sq.7
Sq.1 17 Sq.2
[25]
[66]
[66]
P S2 PRS 4 Sn.83 VPS4 150 Capacity: 236
22 [19]
Sq.4 Sn.24 33 STG Aver ag e flow Cap acity: [22] 33 STG mi n fl ow 376
14
Sq.2
[25] [19] 1500 psi Header
24
Sq.5
Sn.25 33 STG C apacity: [24] 33 STG Average fl ow 673 [29]
[19]
1500 psi Header
[50]
[77] 25 Sq.5
[79] Sn .29 33STG extr action (to 600) Capacity: 387
X
Sn.5 Bo iler 37 Capacity: 300 5 Sq.1 [5] Boil er 37 Sn.6 P rax A ir Capacity: 175 [49] 6 Sq.1 [6] Prax A ir [31]
Sn.38 PRS1 n or m al C apacity: 125
[27] 900 psi Header
[31]
[50]
[31]
X
Sn.8 CO Boiler Capacity: 403 8 Sq.1 Sn.43 PRS 1 to 600 psi (excess) Capacity: 238 43 Sq.8 Sn.44 PR S2 to 600 (excess) Capacity: 308 44 Sq.8 [50] Sn.45 P RS3 to 600 psi (excess) Cap acity: 267 45 Sq .8 [50]
[7]
CR U W HB
[67]
[32]
34 S T G 150 psi Header
Sn .54 LCD U [8] [18] 600 psi Header [69] [50] Cap acity: Sn.18 C O Boiler (nor mal) 124 33STG to 150psi [70] 54 Sq .10 C apacity: 210 [25] Sn .77 33 S T G [36] 32 S T G CO Boil er [68] Capacity: 22 [34] 31 S T G
[79]
[50]
83
Sq.13
[8]
CO Boiler
[50] [71] [25] 33 ST G [68]
27 S T G 600 psi
[79] Sn.84 VPS2
[72] 18 Sq.2 Cap acity:
Sn.55 HTU 3 600 80 [79] 150 psi Header
C apacity:
468
77 [73]
Sq .11
Sn.27 Boiler 37 (norm al) Cap acity: 175 38 Sq .7
[50]
600 psi Header
[79]
[74]
84
Sq.13
[31]
[31]
900 psi H eader
[50]
[75]
55
Sq.10
Sn.39 PRS2 n or m al C apacity: 27 Sq.5 60
[76]
Sn.85 DCU 150 C apacity: 110
[28] [31]
900 psi Header
Sn .56 [50] Capacity: ALKY 600 43 [79] 150 psi Header
[25]
33 S T G
[31] [50] 600 psi Header
39 19 Sq.3 29 Sq.6
Sq .7
85
Sq.13
56
Sq .10
[31] Sn.28 Pr ax Air (norm al) Cap acity: Sn.26 PRS 1500-900 (lo w pr ior ity) Cap acity: 338 130 Capacity: PRS 3 no r m al 75 Sn.40
900 psi H eader
Sn.67 365
[50] 600 psi Header
600 psi H eader Sn.86
[31] [31] 900 psi H eader [50] [67] C apacity: HCU 150
30
[19]
1500 psi Header
67
Sq.11 [79]
150 psi Header
28
Sq.5 40 Sq.7 57 Sq .10
26
Sq.5
86
Sq.13
Sn .68 27 STG 600 psi Sn.30 PR S 1500 losses Cap acity: 428 PRS 4 n or m al Cap acity: [19] 1500 psi Header 45 [50] 600 psi Header 600 psi Header [79] HTU4 150 [50] [68] Sn.78 27STG (norm al) 30 Sq.6 68 Sq .11 C apacity: 125 [79] 150 psi Header Capacity: 70 900 psi Header Sn.87 Sn.41 27 STG (h ig hp r io r ity) Cap acity: 50 [31] 900 psi Header C apacity: [50] Sn.58 [58] 27 ST G (hi gh priori ty) 304 [78]
[31]
58 41 Sq .7
Sq.10 [68] 27 STG 600 psi [79] 87 Sq.13
[50]
[69]
[79] [79]
150 psi Header
59
Sq.10
69
Sq.11
[31]
900 psi Header
[47]
42
Sq .7 Capacity:
Sn.89 Alky 150 33
[31]
900 psi Header
[79]
89
Sq.13
[50]
[79]
150 psi H eader
70 60 [31] 900 psi Header Sq .10
Sq.11 90 Sq.13
Sn.71 311
[50]
600 psi Header [50]
[71] 600 psi Header
[79]
61
Sq .10
71
Sq.11 [79]
150 psi Header
Sn .62 PRS 3 MVH C apacity: 60 Cap acity: PRS 3 MVH 306 Sn.72 91 Sq.13
X = boiler outage
[50]
[62] 600 psi Header
PRS 3 MVH
[50]
[72] [79] [50] 600 psi Header
[79]
150 psi Header
92
Sq.13
[79] 600 psi Header [50] 600 psi H eader [73] Oth er s Capacity: 650 Sn.93
73
Sq.11
[79]
150 psi Header
= steam shortage
50 Sq.9
63
Sq.10
Sn.74 170
93
Sq.13
[50]
600 psi Header [50]
[79]
64
Sq.10
74
Sq.11
Sn.75 255
[50]
600 psi Header [50]
[79]
65
Sq.10
75
Sq.11 79 Sq .12

Sn.1

Capacity:
Boiler 34 405 [11]
Scenarios ConsideredMaximum Demand

Sn.19 Sn.20 50 Sn.31 Sn.50 4000 1500 psi Header P RS 1500-900 (high pr ior ity) 900 psi Header 600 psi Header Cap acity: 4000 Cap acity: Capacity: 4000 Sn .32 130 Capacity: [11] Boil er 34 (normal) [20] [20] P RS 1500-900 (high pri ority) 34 STG Sn.9 [32] Capacity: 36 Bo iler [38] PR S1 normal [51] Capacity: 155 [15] [12] Boil er 35 (normal) [19] [21] 1500 psi Header [33] Sn.33 34 STG aver ag e [31] [13] B oi ler 32 (normal) Capacity: [34] [31] 900 psi Header [79] Boil er 34 B oi ler 33 (normal) 34 STG PR S 3 normal 600 psi Header [50] Capacity: 113.1 36 boiler (no r m al) 93 Sn.15 [39] PR S2 normal Sn.51 [52] Capacity: SRU (600 psi) 304 [1] [22] 20 Sq.4 [14] [36] [32] [79] 9 Sq.1 [9] Boli er 35 B oi ler 32 32 [38] Sq.7 [41] 36 Boil er [50] PR S4 normal [40] [50] [53] [2] [23] [3] [54] 51 33 [24] Bo iler 32 Sn.11 Capacity: Sn.21 100 [25] Cap acity: LOU F linthill - 1500 (h igh prio r ity) 120 [31] [26] P RS 1500-900 (low priority) Capacity: [40] [35] Sn.35 31 S T G aver age [27] [19] 1500 psi Header [23] 3 Sq.1 Sn.13 Boiler 32 (norm al) [30] Cap acity: 215 [28] P rax Air (normal) [42] [34] 31 STG [79] [10] 29 Boil er [17] [50] CR U W HB (normal) [50] 600 psi Header [58] B oi ler 37 (normal) [41] [31] 900 psi Header [79] 10 Sq.1 Capacity: C apacity: 218 Capacity: [50] Sn.16 29 boiler (no r m al) 276 [49] 33 STG (normal )to 600 [57] FCCU (600 psi) 273 Sn.52 330 Sn.3 [13] [4] B oi ler 33 [39] 29 Bo iler Sn .34 31 STG 410 [16] Capacity: 368 [16] 29 boil er (normal) Sq.7 Sn.10 [15] 36 boil er (normal) [55] Sq.10 15 Sq.2 [56] [19] [26] Sq.2 21 Sq.4 [3] Boil er 32 [31] 35 [6] P rax Air [44] Sq.7 Cap acity: [5] B oi ler 37 [43] Sn.49 33 STG (nor mal) to 600 170 16 Sq.2 [43] PR S1 to 600 psi (excess) [60] 52 Sq.10 34 Sq.7 [18] CO Boil er(normal) [59] Sn.23 Sn .12 LOU Flinth ill [21] LOU Flinthi ll - 1500 (hi gh priority) Capacity: 388 Sn.4 Bo iler 33 Capacity: [19] 1500 psi Header 330 [14] [46] [37] 49 [31] 23 Sq.5 [47] [31] 900 psi Header [79] Sn.17 Sn.37 32 STG Aver ag e 4 Sn.22 33 STG min flow Cap acity: 50 Cap acity: Boiler 33 (norm al) 220 Sq.1 Sn.14 [48] 36 Sq .7 [7] [36] 1500 psi Header Boil er 33 32 STG [79] CRU WH B [50] [50] [10] 29 Boi ler [65] 53 Sq .10 Capacity: 335 Capacity: CRU WHB 126 [17] CRU W HB (no r m al) Sn.7 Cap acity: 91 [9] 36 Boi ler [50] 600 psi Header [64] [79] [46] PR S4 to 600 psi (excess) [63] Sq .8 Capacity: [45] PR S3 to 600 psi (excess) [62] Sn .53 CRU 600 158 Cap acity: 13 Sq.2 [45] Sn.36 32 S T G 611 [29] 33STG extracti on (to 600) [50] [44] PR S2 to 600 (excess) 297.1 [61] [19] Sq.2 [19] [24] [4] [31] 33 STG 7 Sq.1 17 37 Sq.7 [7] CR U W HB [67] Sq.2 [25] [66] 22 Sq.4 Sn.24 33 STG Aver ag e flow Cap acity: 376 CO Boiler Capacity: Sn.8 [8] 403 [18] 600 psi Header [69] [50] Cap acity: Sn.18 C O Boiler (nor mal) 124 33STG to 150psi [70] 8 24 Sq.5 PRS1 n or m al C apacity: Sn.5 Bo iler 37 Capacity: 300 [27] [72] Sn.25 33 STG C apacity: [24] 33 STG Average fl ow 673 [31] [29] Sn.27 Boiler 37 (norm al) [19] 1500 psi Header 5 [50] Sq.1 Cap acity: 175 38 Sq .7 Capacity: PRS 1 to 600 psi (excess) 238 [74] Sn.43 [73] 600 psi Header 77 Sq .11 [31] 900 psi Header [50] 18 Sq.2 Cap acity: Sn.55 HTU 3 600 80 125 Sn.38 Sq.1 CO Boiler 54 Sq .10 C apacity: 210 Sn .77 CO Boil er [68] Capacity: LCD U 22 14 Sq.2 Sn .54 [22] 33 STG mi n fl ow
Sn .79 150 psi Head er Capacity: [53] C RU 600 4000 Sn.80 [80] C apacity: Sulfur 85
[19]
[55]
HT U 3 600
[79]
150 psi Header
[81]
Sq.1
[33]
34 S T G average
[82] 80 Sq.13
[35]
31 S T G average
[83]
[37]
32 S T G Average
[84]
Boiler 34 (n or m al) Capacity:
[77]
33STG to 150psi
Sn.81 44
[1]
Boil er34
[78]
27STG (normal) [79] 150 psi Header
[86]
[69]
26 S T G 600 psi
[87] 81 Sq.13
11
[70]
P RS 1 MVH
[88]
[71]
P RS 2 MVH
[89]
Boiler 35 (n or m al) C apacity:
[72]
P RS 3 MVH
[73]
P S2 PRS 1
[91] 150 psi Header
[2]
Bolier 35
[79] P S2 PRS 2
[74]
[92]
12
[75]
P S2 PRS 3
82 [93]
Sq.13
[47]
MVHPS to 150 header
Sn.2 Bolier 35 Capacity: 400 [12]
[66]
P S2 PRS 4 Sn.83 VPS4 150 Capacity: 236 34 S T G 150 psi Header
[32]
[19] [79] [34] 31 S T G
Sq.1
[50] [25] [19] 1500 psi Header
83 [36] 32 S T G
Sq.13
[25]
33 S T G
[8]
[50] [71] [25] 33 ST G [68]
27 S T G 600 psi
[79] Sn.84 VPS2 C apacity: 468
[79]
150 psi Header
[50]
[79]
84
Sq.13
[77] 25 Sq.5
[5]
Boil er 37
[31]
[31]
900 psi H eader
[50]
[75]
55
Sq.10
[79] Sn .29 33STG extr action (to 600) Capacity: 387 Capacity: Sn.6 P rax A ir 175 [28] [31] 33 S T G 900 psi Header 27 Sq.5 C apacity:
Sn.39 PRS2 n or m al 60 43 Sq.8
[76]
Sn.85 DCU 150 C apacity: Sn .56 110
[50] Capacity:
ALKY 600 43 [79] 150 psi Header
[25]
[49] [31] [50] Sn.44 39 Sq .7 Capacity: PR S2 to 600 (excess) 308 56 Sq .10 600 psi Header
85
Sq.13
19
Sq.3 29 Sq.6
Sq.1
[31] Sn.28 Pr ax Air (norm al) Cap acity: Sn.26 PRS 1500-900 (lo w pr ior ity) Cap acity: 338 [6] Prax A ir 130 Capacity: PRS 3 no r m al 75 Sn.40
900 psi H eader
Sn.67 365
44 [31] [31] 900 psi H eader [50]
Sq.8 [50] 600 psi Header [67]
[50]
600 psi H eader Sn.86 HCU 150 C apacity: 30
[19]
1500 psi Header
[31] 67 Sq.11 [79] 28 Sq.5 40 Sq.7 57 Sq .10 150 psi Header
26
Sq.5 P RS3 to 600 psi (excess) Cap acity:
Sn.45 267
86
Sq.13
Sn .68 27 STG 600 psi Sn.30 PR S 1500 losses Cap acity: 428 PRS 4 n or m al Cap acity: [19] 1500 psi Header 45 [31] 900 psi Header [50] Sn.78 27STG (norm al) 30 Sq.6 68 Sq .11 C apacity: 125 [79] 150 psi Header Sq .8 45 [50] 600 psi Header 600 psi Header [79] HTU4 150 [50] [68] Capacity: 70 Sn.87 Sn.41 27 STG (h ig hp r io r ity) Cap acity: 50 [31] 900 psi Header C apacity: [50] Sn.58 [58] 27 ST G (hi gh priori ty) 304 [78]
58 41 Sq .7
Sq.10 [68] 27 STG 600 psi [79] 87 Sq.13
[50]
[69]
[79] [79]
150 psi Header
59
Sq.10
69
Sq.11
[31]
900 psi Header
[47]
42
Sq .7 Capacity:
Sn.89 Alky 150 33
[31]
900 psi Header
[79]
89
Sq.13
[50]
[79]
150 psi H eader
70 60 [31] 900 psi Header Sq .10
Sq.11 90 Sq.13
Sn.71 311
[50]
600 psi Header [50]
[71] 600 psi Header
[79]
61
Sq .10
71
Sq.11 [79]
150 psi Header
Sn .62 PRS 3 MVH C apacity: 60 Cap acity: [62] 600 psi Header PRS 3 MVH PRS 3 MVH 306 Sn.72 91 Sq.13
= max demand
[50]
[50]
[72] [79] [50] 600 psi Header
[79]
150 psi Header
92
Sq.13
[79] 600 psi Header [50] 600 psi H eader [73] Oth er s Capacity: 650 Sn.93
73
Sq.11
[79]
150 psi Header
= steam shortage
50 Sq.9
63
Sq.10
Sn.74 170
93
Sq.13
[50]
600 psi Header [50]
[79]
64
Sq.10
74
Sq.11
Sn.75 255
[50]
600 psi Header [50]
[79]
65
Sq.10
75
Sq.11 79 Sq .12
ConclusionsReliability Modeling
Installed steam maximum capacity (using the higher of max rates or observed max rates) is approx. +54.5% above average net steam demand This level of overcapacity mainly benefits the 900, 600 and 150 psi headers where the loss of one boiler on any one of these headers does not impact significantly on the utilisation of the users (apart from the low priority STGs). The system, however, is significantly exposed to boiler failures when the steam demand is at its maximum (all users running at their maximum recorded rates).
16
Dynamic Modeling for a Refinery Steam System
Approach: Steam System Dynamic Model

DEFINE scope and objectives COLLECT equipment/instrument/piping data BUILD rigorous, dynamic model VALIDATE using design / actual operating data SIMULATE various dynamic scenarios ANALYZE results
18
Steam System Dynamic Model
Steam System Control Scheme modification

Loss of one Boiler
vs
Loss of two Boilers
vs
Dynamic Modeling & Simulation - Benefits

Identify Actual/Potential system issues
- Control System Design weaknesses - Inadequate instrumentation/equipment/piping specs - Unsafe/Undesirable Operating modes - Product/Steam quality - Incorrect tie-in locations / piping configurations
Better understanding of system

- Answers to What-if questions
Engineering / Training tool
In Summary
Asset Performance Modeling

Tools and Technology are available but the key to success is finding qualified resources who can do it right Helps ensure successful Expansion / Revamp / De-bottlenecking projects Effective tool/approach for improving Utilization & Reliability
23
Q&A

1 Asset Performance Modeling For Refinery Steam Systems - Shell

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

1 Asset Performance Modeling For Refinery Steam Systems - Shell

Transféré par

Droits d'auteur :

Formats disponibles

Asset Performance Modeling for Refinery Steam Systems

Ryan Stephens Ricky Bulos Celesta White Nazim Nathoo

Introduction and Overview

What is a Reliability Modeling Study?

Reliability Modeling Study is a

Results can be used by project teams to .

Dynamic Simulation Technology

Dynamic Simulation Study is a

Results can be used by project teams to .

Applications and Scope

This methodology is applied to a wide range of assets, such as:

Performance Analysis: Typical Objectives

Reliability Modeling for a Refinery Steam System

Refinery Steam System Example

900# 900# BLR BLRS

600# BLRS (600 # HDR)

150# USERS (15 # HDR)

Steam System LayoutTARO Software

Actu al Flow s, Un its /D ay

Max imum Stream F low , Units/Day

[79] 9 Sq.1 [9] 36 Boil er [50]

[16] Sn.35 31 S T G aver age 218 Capacity: 10 Sq.1

[85] FCC U 150 C apacity:

[26] [19] 1500 psi Header [23]

Sq.2 21 Sq.4 [3] Boil er 32 [31] [5] B oi ler 37 [43]

33STG extracti on (to 600)

[90] Sn.82 CRU 150 C apacity: 42

PR S3 to 600 psi (excess)

[62] Sn .53 CRU 600 Capacity: 158

[91] 150 psi Header

[31] 23 Sq.5 [47]

PR S4 to 600 psi (excess)

600 psi Header [64]

[7] [36] 1500 psi Header Boil er 33 32 STG [79]

[19] Sn.2 Bolier 35 Capacity: 400 [12]

P S2 PRS 4 Sn.83 VPS4 150 Capacity: 236

Sq.7 [7] CR U W HB [67] [32] 34 S T G 150 psi Header

Sq.4 Sn.24 33 STG Aver ag e flow Cap acity: 376

[50] [25] [19] 1500 psi Header

Sq.5 PRS1 n or m al C apacity: Sn.5 Bo iler 37 Capacity: 300 [27]

[50] [71] [25] 33 ST G [68]

[79] Sn.84 VPS2

Sn.55 HTU 3 600 80 [79] 150 psi Header

900 psi H eader

Sn.39 PRS2 n or m al 60 43 Sq.8

Sn.85 DCU 150 C apacity: Sn .56 110

ALKY 600 43 [79] 150 psi Header

900 psi H eader

44 [31] [31] 900 psi H eader [50]

Sq.8 [50] 600 psi Header [67]

600 psi H eader Sn.86 HCU 150 C apacity: 30

1500 psi Header

[31] 67 Sq.11 [79] 28 Sq.5 40 Sq.7 57 Sq .10 150 psi Header

Sq.5 P RS3 to 600 psi (excess) Cap acity:

Sq.10 [68] 27 STG 600 psi [79] 87 Sq.13

150 psi Header

900 psi Header

Sn.89 Alky 150 33

900 psi Header

[50] 31 Sq.6 Sn.48 900 lo sses (constan t) Capacity: 28

150 psi H eader

70 60 [31] 900 psi Header Sq .10