In process industries, automation involves using computer technology and software engineering to help companies operate more efficiently and safely. In the absence of process automation, plant operators have to physically monitor performance values and the quality of outputs to determine the best settings on which to run the production equipment.
This generally results in operational inefficiency and unsafe operating conditions, and that’s why process automation and control is so crtitical to the refining and petrochemicals industries.
“Process automation simplifies this with the help of sensors at thousands of spots around the plant that collect data on temperatures, pressures, flows and so on,” says Juan-Carlos Mani, vice president of Process System Enterprise.
“The information is stored and analysed on a computer and the entire plant and each piece of production equipment can be monitored on a large screen in a control room.
Plant operating settings are then automatically adjusted to achieve the optimum production. Plant operators can manually override the process automation systems when necessary,” he says.
The main drivers behind automation of process downstream facilities are to improve efficiency and increase profitability, in addition to safety.
“A good automation system uses digital technology to improve profitability of a plant, and to reduce risk of a major incident,” says Jon Stroup, project manager for Solomon Associates’ APC and automation studies.
Improved profitability comes from using base regulatory controls (DCS, PLC) to reduce variability in process parameters such as temperature, pressure, and concentration.
Reduced variability allows the plant to operate closer to the product specification, which in turn reduces quality “giveaway” and may allow the plant to operate at higher throughput and lower energy usage.
Improved profitability also comes from the ability to capture, store, and present plant operating data in a way that is meaningful to engineering and business staff.
“These staff use the data to ensure the plant is operating at the highest possible performance (for example, the FCC yields are at the expected level for a given feed and catalyst).
The information is also used for yield accounting, and for planning and scheduling,” says Stroup.
Reduced risk comes from using control systems like safety instrumented systems to safely shutdown a plant when an unsafe condition arises, to properly use alarms to alert operators of abnormal situations, and to use cyber security techniques to minimize chance of accidental or malicious misuse of computer control systems.
Automation solutions consist of many different components. “There is the control system level, typically the distributed control system (DCS), which manages the process information and controls and is the hub for information to the business.
Other components are advanced regulatory control, advanced process control, real-time optimization, safety instrumentation systems, operator training simulators, and plant historians,” notes Stroup.
“These systems are managed and maintained through engineering standards, reliability
programmes, policies, and procedures covering instrumentation, control systems, cyber security, alarm management, and business practices.
A good automation system incorporates all of these attributes and, if managed well, is a competitive advantage to a facility,” Stroup explains.
For a plant owner, it is important to have a clear automation strategy for all aspects including specification documents that support their strategy to be followed during project execution.
“It is equally important to involve “users” like operators and maintenance engineers already in the early design phase and continue to involve them in reviews during execution,” says Bjarne Andre Asheim, region business unit manager, oil, gas and petrochemicals at ABB in the Middle East.
“At the end, it is relevant to provide a good operating environment and a common platform for information sharing of data from automation systems to business systems.
ABB has competency and solutions for each of these stages starting from consultation to actual commissioning and start up.”
When buying an automation solution, plant operators should consider many different aspects such as safety management, reliability, process control capabilities, and adaptation to advanced technologies such as advanced process control (APC).
“Since major automation vendors are primarily focused on their core competency, the platform, processing companies should consider the culture of these companies when they make new purchases. Successful automation companies have come to recognise that manufacturers want “best-in-breed” automation solutions,” says Eddie Habibi, founder and CEO, PAS.
“No single automation company has all the best answers that satisfy the needs of an operating company. The successful automation companies recognise that not only must they deliver an open platform that allows third party applications to run, they should also embrace a culture of collaboration with third parties to deliver a complete best-in-breed solution to their customers,” Habibi adds.
“So, in a nutshell, operating companies should consider the openness of both the automation system platform and the culture of the automation company as it pertains to teaming with and collaborating with third parties,” Habibi notes.
As downstream projects in the region become increasingly complex, so too do the process automations that help them work.
“An integrated project has a more complex structure that needs to be managed carefully. We have a broad product offering that these customers as they need to be optimised for market and price condition,” explains Norm Gilsdorf, president of Honeywell Process Solution.
A common issue that faces process and automation solutions companies is the rapid software turnover of software providers, which create challenges for both individual consumers as well as larger corporate users.
“We use Microsoft and various other software as a base layer in the control systems, and any change or turn-over requires an upgrade of new patches. Rendering software adaptations is no easy feat for an industrial customer,” says Gilsdorf.
But despite this challenge, process automation companies, like Honeywell Process Solution, and Emerson Process Management, manage to tackle it and find the right solution.
“First of all, we make customers aware of the changes, and help them manage these new adjustments. We have a service engineer that comes in and assists with re-installation and upgrades in any patches. This can be done remotely; as we have several centres around the world, or we can do it live, with assistance through transition,” concludes Gilsdorf.
