Procedural Automation of Ethane Recovery to Rejection in NGL Trains

Abstract

This paper is based on successful implementation of procedural automation of Ethane (C2) recovery - rejection mode change using Yokogawa's Exapilot software, wherein ADNONC Gas Processing Habshan 5 & Sulphur management approved the implementation based on similar success of the Sulphur Recover Unit start-up/shutdown procedural automation & company's drive for digitalisation. Scope was to develop modules for automating C2 Recovery /Rejection change over procedure in NGL unit using M/s Yokogawa Exapilot software. These automated procedures aimed to standardize said mode change over operations by incorporating the operating know how and the expertise of skilled-experienced operators into the Exapilot system as a set of Standard Operating Procedures (SOPs) that are executed in right operating sequence for enhanced operating efficiency. Two main procedures & associated modules were designed, engineered and built using Exapilot to enable single-click change over automation for NGL units. Those were validated with operation and deployed in the Exapilot Server and were integrated with the Operator Consoles (HIS) for access, and was supplemented with operator training. Ethane Recovery to Rejection Mode Change Ethane Rejection to Recovery Mode Change Besides standardization and reduced change over time, this improved the critical asset integrity and lifespan of NGL section equipment by advocating systematic operations. Following benefits including major take away from this project: ➢ Standardized the mode change-over procedures & minimized human error by the digitalization of paper documentation procedures into electronic workflow process. Procedural Automation like Exapilot is powerful tool for digital transformation of batch/discrete operation like unit/equipment start-up/shutdown or grade/mode change over. ➢ Reduced inherent delay due to manual change over. Hence, minimizing the loss-opportunities & operating cost. Besides this tool can be used as training tool (when used in offline mode) which help operator succession plan & effective knowledge transfer ➢ Automated critical operation such as temperature/flow ramping, improved equipment integrity and prolonged equipment life. Procedural Automation using Exapilot thus can improve operation efficiency, asset integrity, equipment or material life span This paper presents a success story of procedural automation of batch operation in continuation of similar success in SRU start-up & shutdown automation. This tool along with proper integration work with DCS, has opened door for automation/digitalization in batch operation in continuous process not only in other sites of ADNOC Gas Processing and other ADNOC Group Companies but also in other industries that helps companies to enhance efficiency and fulfil their digitalization journey. Though Exapilot software belongs to M/s Yokogawa, however other DCS systems have similar software such as Honeywell DCS EPKS has E-procedure for procedural automation.