Discussions of Modular Sample System

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Discussions of Modular Sample System Implementatio
n in S. California Refineries
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• Current integration schemes with GEN 1 systems

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Current GEN 1.5 Integration
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Comments

• There is a current inability to integration the
  sample system using multi-drop, plug and play
  digital-bus technology due to a lack of IS,
  digital-bus components in the modular, low-flow
  footprint
• There have been no documented, IS-certified GEN2
  systems installed to date
• End users and OEM alike can still benefit from
  IMSS integration of analyzer to sample system or
  PLC to sample system thru conventional IS
  certified analog instruments
• Automation, closed-loop control, remote alarm and
  monitoring, and some diagnostic functions can be
  performed today which will still bring
  performance and cost of ownership benefits to the
  end user.

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End User Benefits Today
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CEM COO Comments

• Sample system downtime on CEM applications
  results in Missing Data Incidents
• Have to either trade emission credits or pay
  fines if tonnage of emissions are over budget
• There is a high probability that CEM analyzers
  will go down because of a sample system/
  component issues or leak

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Hard COO Data

• A traditional tube and fitting blending system
  was replaced with a modular type system
• Traditional System required 16 hours to rebuild 8
  valves every 6 months
• 8 valves per system
• Parts to Rebuild 150 / valve (highly
  conservative)
• Technician Rate was 50/hour
• New modular type of valves has been in service
  for over two years with no rebuilds needed
• 2 YEAR SAVINGS (16 4 50) (150 4 8)
  8000
• COST SAVINGS PER VALVE/ YEAR (8000 8 2)
  500
• TIME SAVINGS PER VALVE/YEAR 32 HOURS

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Greenfield Extrapolation

• Take these numbers and assume a 10 year valve
  cycle life (1M cycles, 5min analysis cycle time)
  and a refinery scale implementation (1000 valves)
• TOTAL SAVINGS (1000 500 10) 5M
• TOTAL TIME SAVINGS (32 10) 3200 MAN-HOURS

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The Future Modular in S. Cal. Refineries

• NOT SHOWN
• PLC control and monitoring
• Calibration standard and self-validation sample
  cylinders
• Temp control of system and sample lines
• Sample Pumps

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The Future of IMSS in S. Cal. Refineries

• Currently Implemented systems have the following
  capability
• Both Modular and High Flow Tube and Fitting
  Interconnect Technology
• Online Density and Mass Flow Measurement
• Differential Pressure Monitoring of Filters with
  Redundancy and Auto Switch Over
• Flow Control of Bypass, Analyzer, and Calibration
  Flows
• In Situ Validation and Calibration using
  Certified Standards
• Both Discreet Analog 4-20mA and Digital Outputs
  to the Analyzer Control Room
• Complete Closed Loop or Open Loop Control of all
  Flow Controllers, Control Valves, Stream Select
  Valves, Heater Controls, and Sample Pumps
• One of the major refiners has mentioned that
  modular will become a standard for all new sample
  systems due to field proven performance
  enhancements and lower overall COO

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Conclusion

• Proper design and component selection is
  paramount in obtaining desired performance from
  Modular
• Performance benefits have been proven at the
  refineries engaged in this study for Gen 1 and
  1.5 type Modular implementation
• Hard performance and COO data is scarce because
  this new data is considered proprietary
  primarily due to the unique process and
  performance advantages that Modular Sample
  Systems are bringing
• It will not be feasible to utilize modular in
  100 of all applications hence a hybrid modular
  / fitting approach and hybrid analog / digital
  approach will need to be adopted
• End-users do not need to wait for a true digital
  bus implementation to benefit from IMSS systems
  today.