Automated Refractory Dry-Out Operation

Abstract This paper is based on successful implementation of automated heater refractory dry out operation in Habshan-5 SRU using Yokogawa's Exapilot software, in continuation of past success of digitalisation of critical batch operation like SRU start-up & shut down, Ethane recovery /rejection change over in NGL unit. Objective was to automate SRU heater refractory dry out operation (with or without refractory repair) as per standard operating procedures to ensure process safety & asset integrity by minimizing human error. Besides it aims to reduce dry out time & thus energy required for dry out operation. Scope is to integrate Habshan-5 SRU heaters like reaction furnace, Incinerator heater dry out automation with existing SRU start up automated modules. Procedure Heater refractory dry-out is critical operation in SRU startup & carried out manually prior to automation. Drawback Maintaining temperature profile as per OEM dry out curve poses challenges in manual operation. Custom solution based on Exapilot & past dry out data used for automating SRU heaters refractory dry-out. Two modules for each heater were built. Viz. Each module consists of Prediction block Which predict air, fuel demand for every target temperature based on past & current data Monitoring block This block scans all critical parameter related to dry-out & alert operator if deviation Adaptive control This sub module adjusts dynamically the controlling parameter like Air/Fuel based on feedback to maintain target temperature within its range. Conceptually it learns from past action & improve to follow the temperature profile. Validated modules were deployed in Expilot Server and seamlessly integrated with rest of SRU start up modules which enabled operator easy access to perform dry-out operations during start up in an efficient manner exactly as specified in the OEM given dry out procedures. Post testing on U552 heaters dry out & subsequent data analysis & operation feedback revealed the following benefit. Business Benefits This data driven & prediction enabled, heater refractory dry-out automation, first of its kind in ADNOC highlights the success stories of Habshan-5 & Sulphur digital transformation journey of critical batch operations.