Executive Summary
PetroChina Dushanzi Refinery and
Petrochemical Complex, Dushanzi,
China
PetroChina, a subsidiary of China National Petroleum Corporation (CNPC), is China's largest oil producer. The company has recently completed construction of a huge integrated refinery and petrochemicals complex at Dushanzi in the Xinjiang Autonomous Region, in China's far west. The complex includes a 10 million ton per year (t/y) refinery and a 1 million t/y ethylene production facility, and is an important part of the China-Kazakhstan energy cooperation strategy.
The facility mainly processes Kazakhstan high sulfur crude from the Kazakhstan-China pipeline.A total of 30 billion Chinese yuan ($4.4 billion) was invested in this integrated refinery and petrochemical complex, making this one of the country's largest construction projects. The refinery has 10 processes, including a 3 million t/y diesel production process, a 2 million t/y paraffin process, and a 1.2 million t/y delayed coking process. The petrochemical plant also has 10 different facilities, and these include 600,000 t/y HDPE, 550,000 t/y PP, and 600,000 t/y aromatics facilities.
While following PetroChina's basic philosophy of "Safety, Quality and Cleanliness," an Integrated Project Management Team (IPMT) completed this project in just 25 months, and the start-up of the various facilities proceeded quickly and efficiently. Of the approximately 100 major construction projects that were underway around the country at the time, this was number one in efficiency, an achievement that was recognized on the occasion of the country's 60th anniversary.
For this new integrated refinery and petrochemical complex, Yokogawa China successfully installed the CENTUM CS 3000 process control system and the Plant Resource Manager (PRM) package.
Petrochemical plant
The Challenges and the Solutions
1. Integration of plantwide process control system for production excellence
CNPC is always striving to improve production efficiency and product quality. One of the key issues at this integrated refinery and petrochemicals complex is the collective management of all process data. Yokogawa's CENTUM CS 3000 production control system and PRM package are integrated with an analyzer system and other PLC systems via a Modbus interface, so all process data and status information can be monitored at the human machine interface (HMI) stations in the central control room (CCR). Based on the collected process data, which is accessed using the CENTUM CS 3000 system, many kinds of plant key performance indexes are calculated and analyzed to produce further improvements in efficiency throughout this integrated complex.
Central control room
2. Safe operation for safety excellence
At such a huge refinery and petrochemical complex, plant safety is a primary concern. The core CENTUM CS 3000 production control system is integrated with a safety instrumented system (SIS), emergency shutdown (ESD) system, and compressor control system, allowing plant operators to have a comprehensive and detailed view of what is happening everywhere in the complex. They are thus able to take quick and decisive action whenever required, ensuring safety excellence.
3. Proactive maintenance for asset excellence
At this major complex, another important issue is how to minimize the total maintenance costs for more than 40 processes and over 100,000 instruments, including HART devices. Through the DCS architecture, CNPC Dushanzi wished to centrally manage many different devices from multiple vendors. Yokogawa's PRM package integrates all field device information and device diagnostic information into a single database, allowing real-time remote maintenance via the DCS network. During plant start-up, PRM helps the customer's engineers perform all the loop checks. When a problem occurs, the related instruments can be remotely checked and verified in just a few minutes.
Customer Satisfaction
Sun Zhaoshan, Chief Instrument Manager, said, "The basic starting point for reducing the total cost is to select the right instruments. The measurement method, accuracy, and type of material used in the wetted parts and the instrument body should be carefully checked right at the beginning of the project. Selecting the right instrument for each application ensures that it will work properly, and this can eliminate some problems that often occur later. This is based on my experience. For this big refinery and petrochemical complex, the biggest issue is how to minimize the labor time and cost of maintaining its nearly 100,000 field instruments. Yokogawa's PRM is a really good package for monitoring all of these field devices from my office." He went on to say, "We are going to use APC packages under the CENTUM CS 3000 system to access all of the field data, analyze the efficiency and other performance characteristics of the process units, and improve product quality. Yokogawa's CENTUM provides us a very reliable platform to achieve this."
Sun Zhaoshan, Chief Instrument Manager
Industries
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Chimie
Les usines chimiques s'appuient sur des processus de production continus et discontinus, chacun posant des exigences différentes en matière de système de contrôle. Un processus continu nécessite un système de contrôle robuste et stable qui ne tombera pas en panne et n'entraînera pas l'arrêt d'une ligne de production, alors que dans le cas d'un processus discontinu, l'accent est mis sur un système de contrôle qui permet une grande flexibilité dans les ajustements des formules, des procédures, etc. Les deux types de systèmes doivent être gérés en fonction de l'historique de la qualité du produit et être en mesure d'exécuter des opérations non routinières. Avec son large portefeuille de produits, ses ingénieurs systèmes expérimentés et son réseau mondial de vente et de service, Yokogawa a une solution pour chaque processus d'usine.
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Pétrochimie
Les besoins des entreprises pétrochimiques sont extrêmement variés. Pour se démarquer sur le marché hautement concurrentiel d'aujourd'hui, les producteurs s'efforcent d'améliorer la qualité et la productivité. Yokogawa fournit des solutions sur mesure pour répondre à ces besoins en s'appuyant sur sa longue et vaste expérience dans ce domaine.
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Pétrole et Gaz (raffinage et distribution)
Ces dernières années, l'industrie pétrolière et gazière en aval a été confrontée à un nombre croissant de défis. Ceux-ci comprennent les caractéristiques changeantes des matières premières à traiter, le vieillissement des installations et des équipements de traitement, l'augmentation du coût de l'énergie, le manque d'opérateurs d'usine qualifiés capables de faire fonctionner une raffinerie de manière sûre et efficace, et les exigences en constante évolution du marché et du client.
Au fil des ans, Yokogawa s'est associé à de nombreuses sociétés en aval pour fournir des solutions industrielles axées sur la résolution de ces défis et problèmes. Les solutions de Yokogawa ont aidé les propriétaires d'usines à atteindre une rentabilité maximale et une sécurité durable dans leurs usines.
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Raffinage
Dans un marché en constante évolution, les raffineries sont considérées non seulement comme des unités de traitement du brut, mais aussi comme des centres de profit. Dans le même temps, il existe une conscience aiguë du besoin de sécurité dans ces installations. Une solution de production totale qui englobe la planification, l'ordonnancement, la gestion et le contrôle est nécessaire pour atteindre les objectifs à long terme en matière de rentabilité, d'efficacité et de protection de l'environnement. Avec des années d'expertise dans le domaine de l'automatisation, Yokogawa peut vous apporter des solutions globales abordables pour une meilleure opérabilité et un monde plus propre.
Les produits et solutions liés
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Plant Resource Manager (PRM)
Have the facility managed properly for high-reliable and stable plant operation? PRM contributes to improving the quality of maintenance plans and optimizing maintenance costs throughout the plant life cycle.
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Distributed Control System (DCS)
Our distributed control system (DCS) enables automation and control of industrial processes and enhanced business performance. Over 30,000 systems entrust Yokogawa DCS to deliver their production goals.