2012 Decoking

Conference

Decoking Drum Monitoring and

Automation
September 2012
Subramanya Prasad
Engineering Manager, Instrumentation and Controls

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 2012 Decoking
Agenda Conference

• Introduction
• System definition
• System architecture
• Capabilities and benefits
• System design and installation
• System operation
• System demonstration

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 2012 Decoking
Introduction Conference

• Safety, Remote Cutting & Process optimization

• Auto-shift tool
• Automatic tool enclosure & guide plates
• Decoking control system with safety interlocks
• Drum monitoring
• Audio system
• Vibration system
• Video system
• Automated decoking
• Data recording tools

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Focus…… 2012 Decoking
Conference

Drum monitoring systems

• Vibration based system
Automated decoking

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The Goal…is … transition from 2012 Decoking
Conference

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To…. modern systems 2012 Decoking
Conference

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 2012 Decoking
System definition –Drum monitoring Conference

• Uses vibration sensors as feedback on the

cutting operation
• System comprises of
• IPS APEX
• Vibration probes
• HMI

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System definition -Automated decoking 2012 Decoking
Conference

• Ultimate safety – complete automation of the

coke removal process
• System comprises of
• Decoking control system
• IPS APEX
• Vibration densors
• HMI

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 Drum monitoring & automation system 2012 Decoking
Conference
architecture
HMI

IPS APEX

Serial Modbus
communication
Decoking
Control
System

Coker Drums Vibration Sensors

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Drum monitoring & automation components 2012 Decoking
Conference

• Vibration sensors
• IPS APEX
• Software
• Decoking control system
• Safety interlocks
• HMI

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Vibration sensors 2012 Decoking
Conference

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IPS APEX 2012 Decoking
Conference

• Flowserve designed hardware to embed

algorithms such
• Decoking Drum monitoring
• Automated decoking
• Type PR/Ebullator monitoring
• High speed data processing capability
• Serial Modbus RTU communication
protocol
• Software customized based customized
to customer site specific information

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 2012 Decoking
Decoking control system & HMI Conference

• Decoking control system

• Flowserve designed
heritage permissive
system
• Safety interlocks
• Actuation
• Register map for
communication
• HMI
• Displays cutting status

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Automated decoking benefits 2012 Decoking
Conference

Features Benefits
Completely automated coke Enables remote cutting and increases safety
removal process

Ability to start, pause, and reset Enables the operator to use his judgment to control the operation
the operation sequence

Vibration values and strip chart graphs would be a visual indication of a step change in vibration values
display when the jet gets closer to the wall –enables consistency in process

Clean drum indication The graphic indicates a particular level is clean there by indicating the status
of the operation – helps prevent aggressive cutting

accommodate decoking control Works closely with the safety system, does not send commands to actuate
system generated safety alarms when there is an alarm/trip generated by the decoking control system

auto-calibrate drum sensors Recalibrate drum signatures to keep them updated without the need for
service personnel

Exception handling Intelligently manages exceptions in the process – slack cable, drum collapse
etc.

Software backup & data recording Decoking control system has a stored preprogrammed cut sequence that can
be engaged in case of any failure in communication to the IPS APEX

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 Drum monitoring capabilities 2012 Decoking
Conference

Drum monitoring
• Instantaneous drum vibration
values/ Strip charts on the HMI
• Ability to start and reset the drum
monitoring sequence
• Onscreen Guidance to assist
starting the system
• Drum clean/empty indication
• Tool position indication

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 2012 Decoking
Drum monitoring and automation summary Conference

• Improved cutting personnel safety

• Remote cutting

• Process efficiency and consistency

• Improved equipment reliability
• Aggressive cutting practices reduced

• Data recording for process optimization or

troubleshooting

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 2012 Decoking
System Design & Installation Process Conference

• System configuration
• Drum parameters
• Typical cut style/procedure
• Coke type
• System test
• System FAT/SAT
• System commissioning
• Clean drum signature
• Cut signature

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 2012 Decoking
Drum Overview Conference

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 2012 Decoking
Cutting Overview Conference

Cutting Pressure

Rotary Speed

Tool Position

Cable Tension

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Process overview 2012 Decoking
Conference

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Demonstration 2012 Decoking
Conference

• Automated decoking
• Questions ?

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