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DeltaV Distributed Control SystemProduct Data SheetSeptember 2106SmartProcess FractionatorImprove operation efficiency, while reducing costs with Emerson’s SmartProcess Fractionator Maximize fractionator columns throughputIntroduction Maximize the feed rate against unitconstraints at required product quality whendesiredFractionator columns yield intermediates and finishedproducts that drive bottom line refinery business results.They can also be bottlenecks, if not operated safely and inoptimum balance with refinery and market demands. Stabilize and control product qualities tospecifications Maximize the yield of more valuable sidedraws up to quality limitsThe keys to profitability in fractionator column operationsdemand operational excellence in the areas of safety,optimizing throughput and yields, maximizing heatrecovery, dealing with crude composistion changes,maximizing equipment availability , and consistent, stableand reliable unit operations, day after day. Minimize the energy consumption of the unit Maintain consistent operation across all shiftsto reduce operator workloadIntroduction

SmartProcess FractionatorEmerson Process Management has a long history ofproviding total automation solutions that improveperformance in these key operating areas, through ourSmartProcess Fractionator solution, a pre-engineered,modular solution for model predictive control (MPC) offractionator columns using DeltaVTM’s embedded advancedprocess control (APC) technologies. This solution includessoftware and services to implement MPC and Neuralmodules for control of any four product oil fractionatorcolumn.September 2016 Pumparound exchanger duty Pressure-compensated temperatures Dew point of top tray Hydrocarbon and steam enthalpy correlations Jet flooding Mass balance errorBenefitsProduct DescriptionOil fractionator columns are often highly constrained, withsignificant controller interactions and long time constants.Advanced Process Control (APC) is an ideal method foroptimizing fractionator performance. Emerson’sSmartProcess Fractionator takes the effort ofimplementing APC on these units to a new level of ease andcost effectiveness. Now even small-capacity units cancapture the benefits of APC that larger refiners have beenenjoying for years:Fast implementation APC solution that is easy to setup, use,and maintain. This automation solution also minimizesdisturbances from crude switching, thus minimizingimpact to all downstream units. 3-5% higher throughput 30-80% reduction in product quality variability 2-5% improvement in distillate yields 2-5% reduction in energy costs.While the solution can be implemented on top of legacycontrol systems, it is specifically designed to run in a DeltaVdigital automation system, working with smart field devicesto improve product quality, recovery and energy efficiency.The DeltaV embedded APC tools provide a platform tocontrol and optimize the fractionation process using anembedded linear program. The solution provides closedloop product quality control using a real-time, multivariablecontroller that calculates optimal control moves for safe,stable operation.Advanced control applications supplied with theSmartProcess Fractionator application, include acombination of advanced regulatory control functions,custom calculations and embedded DeltaV APCtechnologies such as Model Predictive Control (MPC) andNeural Net inferential modeling. The solution allowscustomization to meet the process design, controlobjectives and the regulatory control strategy for eachspecific unit.DeltaV PredictPro - Model Predictive ControlAPC benefits include reduced variability, energy costs, andincreased yield and throughput.Using flexible, pre-engineered templates, process controlengineers can configure an advanced control application toaccommodate a variety of process units, including: Crude atmospheric distillation Vacuum distillation FCC main fractionators Hydrocracker fractionators Coker fractionators Hydrotreater multi-sidecut fractionatorsThe Product Description and Specification may containModel Predictive Control (MPC) is a technique to provideimproved control of multivariable process units. MPC usesdynamic models of the process, and a record of its pastbehavior, to predict how the process will behave in thefuture. These predictions are then used to determine anoptimum sequence of control actions that ensure all processcontrol objectives are achieved simultaneously. The processmodels are obtained from unit testing and are adjustedonline using plant measurements to ensure futurepredictions and actions are always consistent with desiredprocess operation.Based on solving the column heat and material balance, thetemplates can be made to match any configuration ofproduct draws, pumparounds, external feeds, heaters andrefluxes. Standard calculation results include:www.emersonprocess.com2

SmartProcess FractionatorMPC is ideal for controlling fractionator columns, wherethere is more than one interacting controlled variable, longtime constants and multiple equipment limits and operatingconstraints that must be observed. With MPC, futureconstraint violations are predicted such that adjustmentscan be made in advance to prevent critical limits from beingviolated. Priorities are used to achieve the desired controllerbehavior when one or more constraints must be violated,allowing the most critical controlled variables or constraintsto always be maintained.September 2016DeltaV Neural - Inferential ModelingFractionation processes usually exhibit long response timesfor product compositions to react to changes in variables likefeed rate, heater outlet temperature, product draw rates,and reflux rate. Laboratory samples are only performed afew times a day. On-line analyzers provide results manytimes per hour, but may not be installed or justified as part ofan automation project. In the absence of frequent productanalysis, various inferential techniques can be used topredict the real-time product quality values used for controlpurposes. One such technique uses the embedded DeltaVNeural application to predict real-time quality values.DeltaV PredictPro Operator display trends history as well asfuture predictions.Easily Create Product Quality Predictions with DeltaV NeuralDeltaV Neural can be easily applied to automatically createnon-linear process models using historical data. Onceplaced on-line the predictions from DeltaV Neural modulescan be used for operator guidance or, in some cases, as partof a closed-loop advanced control application. Thesepredictions are updated periodically from either laboratorysamples or on-line analyzers.The SmartProcess Fractionator license includes thenecessary DeltaV Neural modules needed for quality modelsof two products.Embedded DeltaV PredictPro tools use dynamic process modelsto predict future behavior.Emerson’s DeltaV Predict/PredictPro represents a newgeneration of Model Predictive Control solutions,completely embedded in the control system. Its ease-of-useis unmatched in the industry. Most clients are able tomaintain the application on their own with limited trainingand experience. The SmartProcess Fractionator includesPredictPro licenses for 15 MV’s, sufficient to control a typical4-sidecut fractionators column.www.emersonprocess.comSmartProcess Fractionator LibraryThe SmartProcess Fractionator Library includes the followingcomponents: DeltaV Module libraries, templates and composites Standard fractionation calculation blocks: Hydrocarbon and steam enthalpycalculationsVapor/liquid traffic in each section of thecolumnJet floodingDew PointReboiler and condenser dutiesOverflash%3

SmartProcess Fractionator Pressure compensated temperatureMaterial balance errorEngineering unit conversionsEnergy savings Example SmartProcess Fractionator configurationwith simulation and graphic Documentation: Installation and ConfigurationGuides, Sample Functional Design SpecStandard DeltaV Libraries Make Configuration EasyCertified Consultant Engineering ServicesEmerson’s Certified Solutions Consultants provide standardengineering services to design, configure, install andcommission a complete SmartProcess solution. The scopecan cover individual fractionators or complete fractionationtrains including heaters, light ends columns and auxiliaryequipment. At the start of a project, our consultants willreview the process, operating objectives, constraints andeconomics to design the APC strategy, benchmark currentperformance and develop a project execution plan.A standard methodology is used for implementingSmartProcess applications as follows:September 2016Most of these activities are done on-site using the actualplant DeltaV system and tools. For a single Fractionatorcolumn, with good performing regulatory controls, theSmartProcess application can be implemented in about 4to 6 weeks from kickoff meeting to on-line operation.Optional Engineering ServicesEmerson, through our field services offices and LocalBusiness Partners offer a full range of services to assist ourclients with their automation systems. Clients have theoption of performing some of the work internally orrequesting support from Emerson. Some examples ofoptional services which are often included as part of aSmartProcess implementation project include: Graphics Development: Custom APC operator screensor displays, modifications to existing displays. P&ID Review and Control Strategy Recommendations:In some situations, Emerson’s consultants can reviewP&ID’s prior to construction and recommendmodifications to the regulatory control strategies forimproved performance. New Instrumentation or Analyzers: At times, aSmartProcess application will justify installingadditional instrumentation or on-line analyzers. Regulatory Control Improvement: As part of theSmartProcess implementation process, Emerson’sconsultant will identify any malfunctioning or poorlyperforming instrumentation, valves and controlloops. However, engineering services to analyze theissue, troubleshoot and correct the problems areadditional.DeltaV Hardware and SoftwareSmartProcess Fractionator applications are standard DeltaVmodules that can be implemented in either a controller oran application station. The additional load these APCmodules place on a DeltaV system is expected to benominal, since the execution frequency for the APCfunctions is typically much slower than the regulatorycontrols and can therefore be implemented on the existingplatform without any additional hardware investment. Formore heavily loaded systems, Emerson can advise ofrecommended changes. Kickoff meeting and site survey Regulatory control performance audit Preliminary step tests and column step test designLicenses for the DeltaV APC tools (PredictPro and Neural) arebundled with the SmartProcess Application Library modulesas described below Functional Design SpecificationSmartProcess Fractionator License Fractionator column step tests and modelidentification Controller simulation and testing Operator TrainingThe SmartProcess Fractionator is licensed on a per-unitbasis. On installation of the software, a standard “clickwrap” license agreement stipulates the terms of the licenseand restricts use to the specific columns for which it waslicensed. Commissioning and tuning.www.emersonprocess.com4