'Mission impossible' succeeds at giant Esso refinery
January 2002
System Integration & Control Systems Design
The Esso Petroleum Company refinery at Fawley on Southampton Water is the largest in Europe. The refinery's 330 kb capacity supplies over 15% of all the oil products used in Britain, with 85% of its products delivered by pipeline to Avonmouth, Birmingham, Manchester, West London, Purfleet and Heathrow airports. The Fawley site also incorporates an integrated chemical plant operated by Exxon Mobil Chemical.
Each type of crude oil has its own composition and flexible operations mean that the Fawley refinery can process between 20 and 30 different types of crude oil from all over the world. As part of a crude tank farm optimisation project, Esso has developed a more efficient method of managing its industry. New flowmeters were required as part of this project in an on-line blending process to bring efficiency to their resources and make provision for cutting costs.
Krohne has supplied six 12" and six 20" diameter UFM500 ultrasonic flowmeters. They are arranged in pairs, with the first flowmeter configured to protect the pump against low discharge flow (which could lead to pump cavitation), and the second for regulating the flow via a control valve to enable the correct crude ratios to be blended.
Ultrasonic flowmeters were chosen to meet the 5% accuracy stipulated by the project for the entire range of flows and viscosity's required for the blending process. The offsite piping-network extends over an area of nearly 8 km2, thus line size flowmeters helped to minimise the inherent pressure drop within the overall system.
Foster Wheeler, the main engineering, procurement and construction contractor for the project, purchased the units on behalf of Esso after Esso's engineering team at Fawley provided the exact flowmeter specification.
It was a demanding specification which, according to expert sources within ultrasonic flow technology, could be difficult to meet because of low velocities and high viscosity's, coupled with the overall range of velocities and viscosities taking the flow through the laminar, transitional and turbulent regions. This process requirement together with physical restrictions resulting in multiple out of phase pipe bends upstream of flowmeters has taken the flowmeters outside their normal performance ranges. Velocities in the range of 1,03 to 3,81 m/s were required for the 12" flowmeters, and 0,41 to 1,37 m/s for the 20" flowmeters, with viscosities ranging from 3 to 1800 centistokes.
Field trials have demonstrated that the Krohne flowmeters were able to meet the performance criteria. With pairs of the flowmeters arranged in series, consistent flow outputs have been achieved despite the potential for a distorted flow profile from the upstream pipe bends and cross talk between the flowmeters. The blending systems control software conducts a self-check of the flowmeters against tank movement via the radar ATG's installed in the crude tanks.
Krohne says that its UFM500 features a unique patented double-beam sensor arrangement with sensor mounts welded perpendicular to the tube centreline. The system reduces overall flowmeter length and increases measuring accuracy and repeatability, with an unimpeded tube cross-section, which means no water and no pressure drop. The parameters for flowrate are 1-450 000 m3/h, while the flow velocity is 0,5-18 m/s, however Fawley is now successfully operating down to 0,41 m/s.
Each Atosonic UFM500 also incorporates a microprocessor controlled signal converter for digital signal processing. At Fawley this is linked to the control system enabling remote process operation from the off-site control room over a conventional 4 to 20 mA loop.
Krohne
(011) 315 2685
Further reading:
The time is now for systems integrators
Editor's Choice System Integration & Control Systems Design
Integrators combine sophistication regarding technology innovation with practical, hands-on experience. Collaborating with systems integrators is the means to significant productivity improvement, powered by the convergence of automation and information and operations technology.
Read more...
System integrators are a diverse market
Editor's Choice System Integration & Control Systems Design
System integrators (SIs) combine expertise on emergent technologies with real world experience. Working with SIs, it’s inevitable that at some point someone will say, “We’re not a typical SI.” And in many ways, it’s true. SIs come in all shapes and sizes.
Read more...
Avoiding the pitfalls of PLC and scada control system integration
Iritron
System Integration & Control Systems Design
Upgrading your control system by integrating PLCs with scada systems should be a simple seamless process. Regrettably, the industry is plagued with control system integration and upgrade myths and misconceptions that can lead to liability issues, project delays, cost overruns and decreased plant performance.
Read more...
EtherCAT measurement terminals for vehicle development at Mercedes-Benz
Beckhoff Automation
System Integration & Control Systems Design
At the Mercedes Technology Centre plant in Sindelfingen, Germany, car axles are examined with the highest precision on four test benches, in parallel with road tests and simulations. All data is acquired using PC-based control from Beckhoff.
Read more...
Loop signature 23: Tuning Part 2.
Editor's Choice System Integration & Control Systems Design
It is my opinion that most tuning methods are very crude. They do of course also offer a starting point for tuning if one is not fortunate enough to have a sophisticated tuning package like a Protuner around.
Read more...
PIC microcontrollers with integrated FPGA features in TME
System Integration & Control Systems Design
The new PIC16F131xx microcontrollers in TME’s offering from Microchip are ideal for the evolving and miniaturising electronic equipment market, offering efficient power management and predictable response times for controllers.
Read more...
Five smart machine trends you need to know
Adroit Technologies
System Integration & Control Systems Design
The last ten years have brought about dramatic advances in technologies that OEMs had never realised would affect their designs or the saleability of their machines, much less impact business models and profits so dramatically. The following discussion will cover key advancements and recommendations all OEMs should be adopting in their design processes to stay current and competitive.
Read more...
36 years of innovation and success
SAM Systems Automation & Management
Editor's Choice System Integration & Control Systems Design
Systems Automation & Management was established in 1988 at a time when there were no other systems integrators (SIs) in the process business.
SA Instrumentation & Control’s editor caught up with managing director, Claudio Agostinetto to find out more about how this thriving company has prospered over the last 36 years.
Read more...
Understanding the role of AI in generative engineering design
System Integration & Control Systems Design
When a design engineer sets out to design a new part, component, or assembly, the intent is to meet the design requirements for fit, form and function, and also incorporate a certain degree of innovation and elegance to the overall design. There is no reason to re-invent the wheel by introducing a new design.
Read more...
PCS stays up so you don’t have to
PCS Global
System Integration & Control Systems Design
Maybe it’s time to look at a solution that stays online 99,99999% of the time so you don’t have to. This the world of Stratus computer platforms, tailor-made for your critical applications.
Read more...
printer friendly version