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PACE Zenith Awards 2006

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THE following three companies are the finalists in the PACE Zenith Awards 2006 Oil, Gas & Hydrocarbons Category, sponsored by Samson Controls :

Kontrols & Industrial Weighing

PROJECT NAME: LPG Filling Machine Design.

PROJECT LOCATION: Melbourne.

PROJECT DESCRIPTION: Kontrols & Industrial Weighing (KIW) has designed an LPG filling machine using a highly accurate W&M approved weight indicator that integrates with high speed Programmable Logic Controllers (PLCs). The machine is able to auto-tune the reaction of the filling valve to compensate for variations in pump pressure, cylinder pressure and temperature effects, achieving repeatable accurate filling.

PROJECT OUTCOME: The Ex.d approved machine is suitable for hazardous area class 1 Zone 2 or 1, and does not require specialised service, suiting the remoteness of many filling stations. The controller and user controls are housed inside a flame- and explosion-proof box. The use of rotary encoders and industrial switches ensures long life of the user interface. Set-up and operation are simple. KIW’s AugmentTare feature enables the tare weight for the succeeding cylinder to be set while filling the current one, saving operational time. Built in safety checks verify the tare entered is correct for the selected cylinder. A daily reminder is displayed to check calibration and the test results can be recorded to a PC for quality assurance. The LED displays all fault diagnosis, messages and operator guidance prompts. Options include provision for bar coding or serial number entry, and for communicating via the Internet. The machine can be linked to LPG bulk tanks for stock monitoring, and integrates with data logging and reporting software.

Origin Energy

PROJECT NAME: Production And Safety Management Systems.

PROJECT LOCATION: bassGas Project, Bass Strait, Victoria.

PROJECT DESCRIPTION: Origin’s BassGas gas production facility is located on Victoria’s south-eastern shores, drawing gas from production wells deep within Bass Strait via subsea pipelines. Commissioning of the project commenced in October 2005, with full production achieved prior to the end of that calendar year.

PROJECT OUTCOME: The facility uses integrated production and safety management systems from Yokogawa. Benefits include: simplified information availability from many disparate sources; reduced CAPEX implementation costs through lower combined configuration and programming costs; reduced OPEX operational costs through improved diagnostic information; and reduced requirements for operational and maintenance resources. The production management systems incorporate the Centum CS3000 process management system, Plant Resource Manager asset management system, Exaquantum management information system, remote control (the offshore platform is remotely-controlled from the onshore plant via a satellite communications link) and Foundation Fieldbus. Safety management systems are based on Yokogawa’s ProSafe-PLC and include emergency shutDown systems and fire and gas systems. These systems operate separately from the production systems as required by the IEC 61511 and 61508 standards, but communicate information and status transparently into the production facilities.

Prosys Engineering

PROJECT NAME: LPG Fractionation Unit Advanced Control Revamp.

PROJECT LOCATION: Burrup Peninsula, Western Australia.

PROJECT DESCRIPTION: Woodside Energy recognised well before the commissioning of the new 4th LNG train in September 2004 that additional LNG production and associated increase in LPGs would test the capacity of the fractionation unit at the Burrup Peninsula site. Early in 2004, Woodside Energy engaged ProSys Engineering to revamp the Multivariable Predictive Control (MPC) applications on the fractionation unit.

PROJECT OUTCOME: The project was conducted by a hybrid team to maximise effectiveness and technology transfer: two consultants from PSE teamed up with a site control engineer for the project duration. The methodology used by the project team was as follows: review MPC design, regulatory control review, process step testing, model development, MPC simulation and initial tuning, MPC software installation, commissioning of new MPC applications, and project site acceptance. As the throughputs experienced during the commissioning period were not as high as expected, a further site visit was warranted in November 2004 to review performance. The new MPC was able to circumvent the de-ethaniser flooding limit to a greater extent than anticipated and loads were able to be further increased, to the extent that depropaniser flooding started to become an issue. This development was quite unexpected as the de-ethaniser capacity increases resulting from the MPC revamp were not expected to be so great. A commissioning trip to maximise production to depropaniser flooding limits was completed in April 2005.

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