SS S&T-11 A ExxonMobil Rotterdam Refinery Dynamic Simulations Overview

Sept 26, 2014

SS S&T-11 A
ExxonMobil
Rotterdam Refinery
Dynamic Simulations
Overview
      Mos, Henk Jan

This presentation includes forward-looking statements. Actual future conditions (including economic conditions, energy demand, and energy supply) could differ materially due to changes in technology,
the development of new supply sources, political events, demographic changes, and other factors discussed herein (and in Item 1A of ExxonMobil’s latest report on Form 10-K or information set forth
under "factors affecting future results" on the "investors" page of our website at www.exxonmobil.com). This material is not to be reproduced without the permission of Exxon Mobil Corporation.

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Agenda

 Introduction
 Refinery
 DYNSIM models
 Rotterdam Refinery Simulator Room
 DYNSIM Operator Training Simulator (OTS) training
 DYNSIM OTS exercises
 DYNSIM OTS experiences
 DYNSIM usage by Engineering
 Value provided by Dynamic Simulation
 Question?

Introduction

Introduction
About me :
• 33 years in service for ExxonMobil.
• 20 years experience in Operations as a process-operator,
  console operator and team-leader
• Switched to Technical department as an unit engineer,
  application engineer and last 5 years Simulation Coordinator
  maintaining DCS database and keeping models up-to-date /
  improving current models
Refinery:
• Initial start-up in 1959
• Major expansion in mid 80’s

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Refinery
Configuration

Refinery Configuration
• Refinery Onsites is divided in 5 “consoles”

• A Console team has 7 members : 2 console / board operators,
  4 unit operators and a teamleader.

• The board /console is operated by 1 Console Operator on duty

• All 5 Onsites Console Operators in 1 control room

• 5 Shifts, 5 Consoles : 50 + Console operators

• 85% of the units have a DYNSIM OTS

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Rotterdam Refinery Control Room

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DYNSIM OTS
models

DYNSIM models
• Currently running on DYNSIM 4.5.5, Windows Server 2003
• 6 separate models, some share hardware
• Atmospheric Pipestill, Vacuum Pipestill and HydroTreaters
    2 DYNSIM servers, 7 engines
    1453 analog IO’s
    345 digital IO’s

• Flexicoker
    2 DYNSIM servers, 6 engines
    891 analog IO’s
    1150 digital IO’s ( including complete SafeGuarding system )

• PowerFormer, HydrogenPlant & Refinery Treatgas system
    2 DYNSIM servers, 6 engines
    1136 analog IO’s
    1387 digital IO’s ( including complete SafeGuarding system )

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DYNSIM models ( cont. )
• Utilities ( Refinery wide steam and fuelgas systems )
     1 DYNSIM servers, 2 engines
     580 analog IO’s
     303 digital IO’s

• Hydrocracker
     1 DYNSIM servers, 4 engines
     791 analog IO’s
     535 digital IO’s

• Sulphur block ( Sulphur Plants, Gastreating units )
     2 DYNSIM servers, 6 engines
     902 analog IO’s
     466 digital IO’s

•   Chemicals : 3 simulator models

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DYNSIM OTS
training

Rotterdam Refinery Simulator Room

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DYNSIM OTS training
• Console Operator Training Simulator :

  DCS automation
   • Advanced Model Based Control and optimization.
   • SafePark applications ( Automated SlowDown or Shutdown application )

  Much improved / reliable operation of units

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DYNSIM OTS exercises
• Tailor-made exercises depending on level of experience

 • Field Operators:
   • Show unit operators how unit works and operates

 • New console operators
    Starts with simple exercises like cutpoint change of 5 deg C and see what happens
     incl. the use of TPM and standard scenario’s
    Builds up to Equipment trips / malfunctions, instrument malfunction and emergency
     shutdown.

 • “Experienced” console operators
    More complicated exercises like
      Emergency Shutdowns,
      Shut-Down and Start-up,
      Equipment trips / malfunctions,
      Instrument malfunction based on real plant experiences

 • Training is led by instructor ( PowerUser = Experienced Console Operator )

 • Every console has 2 PowerUsers and are trained DYNSIM trainers

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DYNSIM OTS
experiences

DYNSIM OTS experiences
Examples :
• Refluxpump trip on a Debutanizer:

     Invensys vs. 100+ years Process incl. Technical experience
     Workaround installed
     Until analyzing real event of the same Reflux pump trip
     Workaround removed

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DYNSIM OTS experiences ( cont. )

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DYNSIM OTS experiences ( cont. )
Examples :

• ShutDown & StartUp training prior to Turn around
   First ShutDown / TA for a number of Trainees
   Trained for several days on simulator
   Performed fully confident a successful ShutDown.

• ShutDown procedure on a GastreatingPlant changed after a more
  effective procedure was tested on simulator.
   More effective means a quicker way to get the unit empty and “sweet”.

• SafePark training prior to implementing
   No alternative.

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DYNSIM usage by Engineering
Unit / Contact Engineer:
     Lot of opportunity for engineering use of simulator – still need to mature
      work process
     Developing & Checking Design Specs
     Problem solving / Unit troubleshooting
     Reproduce an upset and improve the requested console operator
      response and train the operator on that improvement
     Energy conservation studies , heat integration studies
     Check if vessels ( drums ) can be re-used after a big unit throughput
      increase by 30%
     Training of new unit / contact engineer
     …………

Application Engineer :
     Development and testing / tuning of new ( complex ) applications like
      SafePark
     Development and testing / tuning of new ( project ) control loops before
      completion / turn over.
     Training of new application engineer
     …….

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Value provided by
DYNSIM OTS

Value Provided by Dynamic Simulation
• Value Provided by Dynamic Simulation
  Accelerated development of training Console Operators
  Flawless execution of startup and shutdown procedures.
  Better handling of non-routine or abnormal operations (e.g., fewer/shorter
   upsets)
  Optimization by increasing operator confidence to operate closer to
   constraints
  Offline studies for unit optimization, safety/reliability/feasibility studies,
   controls strategies, new application testing & training
  Provides excellent initial assignment for newer engineers
   + Broad process, control, and operations experience

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Questions?

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Backup

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