Oil & Gas Industry Case Studies
Our products have been effectively applied to solve Oil & Gas problems for nearly 20 years. A few examples of these solutions are listed below. Complete copies of the case studies are available for free using the links below.
Control Loop Management Lowers Energy Costs
An Instant Improvement to Distillation
Hydrocarbon Magazine, 2011
A small group of engineers at LyondellBasell generate instant energy savings on a distillation column. This article was published in Hydrocarbon Processing magazine. Find out how PlantTriage pointed this team directly to the major problem on this column, driving steam costs down within just a few hours.
Ras Gas Plant Saves $1 Million / YearInteraction Detection Using Oscillation Analysis
Inventory and Quality Control Improvements Achieved
Presentation at ISA Expo
pdf, 6 pages
Read the paper now.
Case Study Presented at ExperTune User Conference
Mayan Shah, Ras Gas
View the Powerpoint Slides
"Fastest Start-Up in Company History"
Plant Manager, BorealisControl Performance Supervision Enhances Revamp
Upgraded ethylene cracker achieves targeted production rates in record time
Article in Chemical Processing
Mikko Ronka, Borealis
Read the Article
Petro-Canada Saves $330K/year,Spending <$100K
Problem: Crude Unit Cycling
A small refinery was suffering from stability problems in the crude unit. Persistent cycling upsets were constraining production capacity. A Model Predictive Control (MPC) System was unable to solve the problem.
Using ExperTune's software, the source of the cycling was quickly traced to a single sticky control valve. Repairing the valve completely eliminated cycling on the unit. The total cost of the solution was less than $100,000.
Elimination of the cycling stabilized the unit, reduced energy demand, and allowed for an incremental production increase. The total effect was more than $330,000 per year in increased profit.
Even More Case Studies
|Reduce start-up time, and be more effective.|
|Hydrocarbon Processing Magazine, June 2005|
|Simple study saves over $300,000|
Off-Shore Platform Commissioning
Offshore Oil Processing. An offshore oil field is being developed using a Floating Production Storage and Offloading vessel (FPSO). This facility is a ship-shaped vessel with integrated oil storage.
A new 900 foot long ship with oil separators on the ship. The ship hooks up to the oil well, processes and offloads fuel to a tanker. This is a 3 billion dollar project that produces 100,000 barrels per day of oil. It is important to get the most out of this capital investment by getting the ship up and running quickly and out to sea. They did not want tuning to be a bottleneck in getting the ship started up. There is $3 million dollars a day in revenue from this ship.
Petro Canada purchased PID Loop Optimizer software and trained 2 crews in its use.
Our software conservatively saved at least 1/2 day of start-up time. It probably saved 3 days of start-up time. 4 hours of start-up time on this vessel is worth at least $500,000.Profit and loss matrix:
|Petro-Canada||Off-shore oil processing||System start up||Software and training||at least $500,000|
APC Project on a FCC
A large refining company installed PlantTriage as a pre-cursor to an Advanced process Control project on a Fluidized-Bed Catalytic Cracking Unit.
Difficult interactions and oscillations around the FCC unit made it difficult to develop APC models. Without process stability, reactor setpoints must be lowered to maintain stability.
PlantTriage was installed to monitor the system and determine the sources of interaction. With the interactions identified and source of variation eliminated, Reactor setpoints were raised.
With reactor setpoints raised, there was a direct savings of over $300,000 annually. In addition, the resulting process stability made it simpler to develop the APC project.
Profit and loss matrix:
|Customer||Industry Type||Problem||Solution||Cost Savings|
|Name Witheld||Oil refining||FCC Stability||PlantTriage Software||$300,000/year|
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