Focus Oil & gas
Intelligent control Problem: Eni Norge and Statoil required condition monitoring equip- ment to provide accurate and timely information regarding valve perfor- mance on the Norwegian Goliat Floating production storage and offloading (FPSO) plant in the Barents Sea. This was to help ensure safety in the extreme sea conditions. Solution: Metso will supply stainless steel valve controllers to the FPSO. The intelligent controllers will equip all pneumatic actuated control, on/off and ESD valves of the plant and will help Eni Norge to monitor and report valve performance for asset management purposes. The availability of valve related information makes predictive maintenance possible, improves safety and minimises the operational and maintenance costs of the valves. Metso Automation
www.metso.com
Enter 219 Accuracy and reliability means increased safety
Problem: Level transmitters, used on BP Exploration’s floating production, storage and off-load- ing (FPSO) vessel off the west coast of Africa, were proving to be unreliable. Changing process conditions and the presence of foam and vapour, as well as dirty sticky fluids, made this a diffi- cult application. The guided wave radar (GWR) transmitters had compatibility issues with the FPSO’s Foundation Fieldbus net- work, and their limited capabili- ties was resulting in unplanned shutdowns. Solution: The problematic trans- mitters have been replaced with GWR transmitters from Emerson Process Management. The more accurate and reliable level read- ings from the Rosemount 5300 Series GWR transmitters have
helped BP Exploration increase safety, reduce shutdowns and increase production.
The transmitters are able to detect low dielectric fluids, so can send and receive a cleaner, stronger signal. This allows the use of single-lead probes that increase tolerance to solids build-up and coating, and elimi- nate trips due to false readings. In addition, the Rosemount 5300’s Foundation fieldbus inter- face made installation and con- figuration both quick and easy. The susceptibility of the exist- ing GWRs to material build-up on the co-axial probes, and the subse- quent unreliability, compromised one of the layers of protection used to ensure safe operations. Now, with improved level detec- tion, the new instruments have helped improve safety. Emerson Process Management
www.EmersonProcess.com Enter 220
Valve control proves flexible in tank farm project
Problem: The expansion project at the Emarat Fujairah terminal in the United Arab Emirates Rotork includes the construction of ten new storage tanks, increas- ing the site’s total capacity from 50,000 to 260,000 cubic metres. The facility is designed for the storage and distribution of gas
oil, petrol and jet fuel and the tanks have to comply with the highest safety criteria. Solution: Rotork valve actuation technologies make an important contribution to the successful achievement of the control and safety standards. More than one hundred Rotork IQ explosion- proof intelligent electric actua- tors with Rotork Pakscan two-wire digital control have been installed for the majority of valve duties.
The IQ actuators feature non- intrusive, intrinsically safe com- missioning, data-logging and predictive maintenance capabili- ties. Reliability is enhanced by the double-sealed IP68 watertight
enclosure, whilst the ability to download and diagnose operat- ing data enables effective asset management to be implemented with the minimum interruption to plant operations.
The Pakscan two-wire digital control system provides built-in redundancy from the valve to the control room, ensuring the secu- rity of vital control command and monitoring data. In addition, data from actuator data-loggers can be downloaded over the Pakscan network for diagnostics and analysis, so this function can be performed in the control room. Rotork Controls T: 01225 733200
www.rotork.com
Enter 221 Standardisation made possible by interchangeable parts
Problem: In industries such as off- shore production that use sub- stantial volumes of centrifugal pumps on a single facility, being able to standardise on one pump type is an economic proposition when it comes to stocking spare parts and maintenance. The goal is finding a company that can supply such products. Solution: The SPX Johnson Pump CombiSystem is designed to meet such needs. The modular programme of single stage cen- trifugal pumps offers inter- changeability of parts between different pump constructions and contains models suited to offshore production facilities. The Johnson Pump CombiPro
20
is a horizontal centreline sup- ported pump designed for han- dling all types of low viscosity, clean and slightly contaminated liquids. It is constructed to satisfy the latest API 610 requirements. The pump will operate at pres- sures up to 35 bar, temperatures between -30˚C and +350˚C and
has a flow capacity of 350³m/h. The pump is available with a choice of closed and half-open impellers. The closed impeller design ensures a good circulation of flushing liquid and minimises the risk of contamination of the shaft sealing environment. The alternative half-open impeller unit is easy to clean if the pumped liquid adheres to the internal surface of the impeller. The CombiPro’s seal chamber will accom- modate all types of seals, in particular API 682 car- tridge seals. SPX Flow Technology T: 01604 889921 Enter 222
www.spx.com
Risk reduction
Problem: Valero Energy Corporation needed a safe way of monitoring and measuring hydrofluoric (HF) acid levels in real time. Commonly used in petrole- um processing, HF is a highly toxic cat- alyst. Accurately analysing how much HF is re-circulating within the process contributes to refinery efficiency, but early approaches to monitoring involved taking manual samples and analysing them. This method potentially exposed lab workers to severe toxins and its accuracy was limited. Solution: Invensys Operations Management has signed a multi-year licensing agreement with Valero Energy Corporation, allowing use of its ACA.HF Advanced Alkylation Measurement Solution. In the first phase, Valero will implement the solu- tion at seven refineries globally. The Invensys solution monitors and measures hydrofluoric acid levels in real time by analysing differential responses from online sensors, helping to improve the safety, reliability and environmental performance of the refinery and creating new opportunities to reduce operating costs. By using real-time online sensors instead of people, the measurement solution reduces the possibility of acci- dental exposure, diminishing the risk to employees and the potential for environ- mental hazards. And because it replaces conventional manual laboratory sam- pling and other types of analysis, it can improve the efficiency of the operation while lowering costs.
Invensys Operations Management T: 01295 526000
iom.invensys.com
Enter 223 JULY 2012 Process & Control
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