192 Yer Pe I35 0007

Yanbu Export Refinery Project
PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Advanced Control System (APC) Document No.: 192-YER-PE-I35-0007 Revision No.: FF Issue Date: 28 April 2008
TABLE OF CONTENTS 1.0 2.0 2.1 3.0 3.1 3.2 3.3 3.4 4.0 4.1 4.2 5.0 5.1 5.2 5.3 5.4 6.0 6.1 6.2 6.3 6.4 6.5 7.0 PURPOSE................................................................................................................... 4 SCOPE........................................................................................................................ 4 General........................................................................................................................ 4 REFERENCE DOCUMENTS & STANDARDS ........................................................... 4 Conflicting Requirements ............................................................................................ 4 YERP Reference Documents...................................................................................... 5 SAUDI ARAMCO Specifications and Standards ......................................................... 5 Project Specific Documents: ....................................................................................... 5 DEFINITIONS AND ABBREVIATIONS ....................................................................... 5 Definitions.................................................................................................................... 5 Abbreviations............................................................................................................... 6 FUNCTIONAL REQUIREMENTS ............................................................................... 7 General........................................................................................................................ 7 Multi-variable Predictive Control (MPC) Application Software .................................... 7 Inferred Properties Software ....................................................................................... 8 Hardware Requirements for APC Controller ............................................................. 10 OIL MOVEMENT, STORAGE, AND BLENDING ...................................................... 10 General...................................................................................................................... 10 Product Blending ....................................................................................................... 10 Oil Movements and Storage (OM&S)........................................................................ 11 Properties Analyzer ................................................................................................... 12 Analyzer System ....................................................................................................... 12 DOCUMENTATION REQUIREMENTS..................................................................... 12
General Confidential Page 2 of 14

7.1 7.2 7.3 7.4 8.0 8.1
Functional Design Document .................................................................................... 12 Detailed Engineering Design Document ................................................................... 13 Engineers Manual..................................................................................................... 13 Operators Guide ....................................................................................................... 14 TRAINING ................................................................................................................. 14 General...................................................................................................................... 14

1.0
PURPOSE The purpose of this Functional Specification Document is to describe the minimum requirements for the design, materials, manufacture, supply and testing of the Advanced Process Control System (APC) to be installed as part of the Process Automation System (PAS) for the Yanbu Export Refinery Project (YERP), Saudi Arabia. This specification provides an outline of the overall requirements, control objectives and control strategies of the Advanced Process Control (APC) systems for YERP. The expectation of this system is that Advanced Process Control will be executed at the Distributed Control System (DCS) level, but implemented and managed in the server-grade computers dedicated to APC.
2.0 2.1
SCOPE General The MAC shall provide Advanced Process Control System (APC) solutions based on Yokogawa ExacSMOC & ExaRQE packages and Advance Movement & Blending (AMB) package for the Product Blending System. All APC and AMB specific hardware, software, programming or configuration requirements either for data collection, retention, or implementation of advanced control and optimization are to be described and provided by the Main Automation Contractor (MAC). The MAC is responsible for all APC project activities including a plant performance test. The MAC with the guidance of the EPC CONTRACTOR / YERP PMT will be responsible for strategy development, model building, off-line controller tuning, and all on-line calculations in the DCS and related servers. The MAC shall provide training for YERP PMTs personnel prior to the testing of the systems.
3.0 3.1
REFERENCE DOCUMENTS & STANDARDS Conflicting Requirements Any conflict between this document and any other project specification, or Saudi Aramco standards/specifications, shall be brought to the attention of the YERP PMT for resolution.

3.2
YERP Reference Documents The design, materials and construction of the equipment described herein shall comply with references listed below which are considered part of this specification.
3.3
SAUDI ARAMCO Specifications and Standards YERP-SAES-Z-001 YERP-SAES-Z-010 YERP-23-SAMSS-010 Process Control Systems Process Automation Networks Connectivity Distributed Control System Applications Integration Middleware
YERP-23-SAMSS-060
3.4
Project Specific Documents: 192-YER-PE-I35-0001 192-YER-PE-I35-0002 192-YER-PE-I35-0003 192-YER-PE-I35-0023 Main Automation Contractor (MAC) Scope Definition Project Specification For Process Automation System Main Automation Contractor Supplier Services Process Automation System Architecture Drawing
4.0 4.1
DEFINITIONS AND ABBREVIATIONS Definitions Company Project Management Team (PMT): The Company Project Management Team (PMT) is the group responsible for the management of the entire project and is dedicated to the overall success, development and execution of the work and to ensure alignment across the numerous project interfaces. The PMT consists of Aramco Services Company and ConocoPhillips team members, partner(s), agency personnel, and contractors. These project management resources will form a cohesive, seamless team responsible for the project execution. Saudi Aramco (SA): Saudi Aramco as used in this procedure shall mean Saudi Arabian Oil Company and its affiliated companies, including, but not limited to Aramco Services Company. ConocoPhillips (COP): ConocoPhillips as used in this procedure shall mean ConocoPhillips Company and its affiliated companies, including but not limited to ConocoPhillips Yanbu Ltd.

Yanbu Export Refinery Project (YERP): The Yanbu Export Refinery Project (YERP) as used in this procedure, shall also mean the Yanbu Export Refinery Company and its affiliated companies. It is also named as the COMPANY. Contractor or Contractors: Any Design, Construction or Service Contractor(s); Manufacturer(s); Vendor(s); Government Agencies; and other similar organization(s) having a contractual relationship or a prospective contractual relationship with the Company. When used in this or referenced documents the following words are used in the manner described below: Shall and must are used in the imperative sense. Will is used in the preferred sense. May is used in a permissive sense to state authority or permission to do the act prescribed or provide the function being defined in the prescribed manner, and the words no person may. or a person may not. mean that no person is required, authorized, or permitted to do the act prescribed. May not means that the item being described is not required, authorized, or permitted in the prescribed manner. Includes means includes but is not limited to. 4.2 Abbreviations The following abbreviations apply to this document: AMB APC BPC DCS ESD EPC HMI MAC MPC NIR OM&S OMSB PAS Advance Movement and Blending Advanced Process Control Blend Property Control Distributed Control System Emergency Shutdown System Engineering Procurement Construction Human-Machine Interface Main Automation Contractor Multi-variable Predictive Control
Near Infrared
Oil Movements and Storage Oil Movement, Storage and Blending Process Automation System

RVP TIM
Reid Vapor Pressure Tank Inventory Monitoring
5.0 5.1
FUNCTIONAL REQUIREMENTS General The Advanced Process Control System shall consist of all the necessary application software and interfacing software for YOKOGAWA DCS and any hardware required for implementing advanced process control (APC) applications for the Yanbu Export Refinery. The EPC Contractor shall be responsible for DCS configuration (base layer) required before APC implementation. The MPC application software, inferential package, and DCS integration package etc. shall be of latest revision, field proven with demonstrable record. Software shall have compatibility with YOKOGAWA CS 30000 without deteriorating the performance of DCS preferably using a YOKOGAWA certified gateway.
5.2
Multi-variable Predictive Control (MPC) Application Software MPC is an advanced process control application used to implement optimal, multivariable, model predictive, constrained control. The MPC shall be used to control interactive, multivariable systems that exhibit complex process dynamics (inverse response, large process dead time, etc.), have multiple constraints and must maintain the system at one or more constraints. Dynamic models are used to project system response, calculate optimum control moves, (present and future), and prevent constraint violation. MPC software shall be an on-line, field-proven multivariable model predictive controller and shall have ability to use sub-controllers for logical organization of the control variables within the main controller and the ability to combine subcontrollers with different dominant response times into a larger steady-state solver. In addition, sub-controllers can have different execution periods corresponding to different process dynamic requests. MPC software must provide superior control performance, execution efficiency and exceptional constraint handling to maximize asset utilization. MPC applications shall improve plant operations and profitability through improved control by achieving one or more of the following benefits as a minimum. Reduce the variability of product quality and key variables Improve the approach to product specification

Increase the production of high value products Increase unit throughput by operating the unit at one or more process constraints Minimize overall energy usage Maintain the units within operating and safety constraints
The MPC may accept optimization target from a global plant optimizer. These targets can differ from user-specified values as well those computed by local optimizer if available. The MPC controller shall handle constraints across the entire time horizon to steady state for controlled variables and related variables that depend on manipulated variables and/or controlled variables. MPC software should include package for Process model identification. The model identification software shall be able to find the best fit between multi-inputs and multi-outputs, including integration model and inverse response. MPC software shall have built-in Economic optimization objective function. Automatic Economic Optimization shall be provided through a flexible user function for specifying and optimizing unit economics. The Economic optimization objective function should be able to be in bi-linear form. It shall provide an optimization of product values (e.g. cost for feeds, products, utilities etc.). It shall be possible to change the economic factors on-line. The operation window for advanced control and optimization is via the DCS. User input changes for key variables shall be allowed using the DCS schematics. Parameter adjustments necessary for advanced control and optimization shall be able to access from MPC server. Advanced control shall be implemented by the MAC standard APC packages. A bumpless degradation of the MPC control scheme to the pre-defined fallback mode in the event of any control failure is compulsory. The MPC application(s) must include internal tuning parameters to filter the measurement noise of the controlled variable. 5.3 Inferred Properties Software Inferred properties are property values of product streams that are calculated rather than being measured by means of an analyzer. These inferred properties would be used as controlled variables for MPC controller. A separate tag will calculate each inferred property and corresponding code and will appear in the DCS as a normal analog input tag. The inferred properties reduce the long time delays caused by the analyzers, improve the dynamic response of the controllers, and save the cost of purchasing and maintaining on line analyzers. The development of Inferred properties shall be based on a representative period of operational data. Special care should be taken in selecting the process data

used in developing the inferential models. Process data should be properly aligned with the lab analysis results and/or analyzer reading. Inferred properties shall be developed to augment on-line analyzers to provide instantaneous feed back to the APC controllers. The inferred properties shall allow either lab or analyzer feedback, typically updating the bias. The Inferential Model Identification package will have following functionalities and capabilities, as a minimum: 5.3.1 It shall be possible to implement linear or non-linear inferential sensors on-line It shall have capabilities of developing and deploying linear, steady state or dynamic empirical models It shall have an interactive menu that allows the engineer to start, monitor and stop individual or groups of inferential applications The online application shall be able to update by laboratory or analyzer data The package shall be able to validate the inputs from process measurement or laboratory and reject the bad data The package shall be able to linearize the gain between inputs and outputs within different operation zones The engineer should be able to tune the inferential model and its key parameters from APC server
Operator Interface The operator shall be notified (via message or alarm) if the inferential ceases to update due to critical input variables failing validation or ceases to update on feedback due to feedback signal failing validation. The inferential monitoring screen shall show the active status of feedback. A mechanism must be provided on the inferential interface to deactivate and activate the feedback. For lab feedback, the operator shall have a mechanism to enter the lab data and timestamp.
5.3.2
Engineer Interface The engineer's interface shall allow access to all aspects of the inferential model. This includes tuning parameters, feedback filtering, any feedback statistical calculations used within the inferential, validation parameters, and the unbiased prediction.

5.4
Hardware Requirements for APC Controller The proposed advanced controls shall be implemented in a dedicated server. All advanced control applications will be operated through the DCS operator consoles. The Supplier shall also propose the necessary hardware required for these applications in the proposal.
6.0 6.1
OIL MOVEMENT, STORAGE, AND BLENDING General Oil Movement, Storage and Blending (OMSB) shall include the business functionality associated with oil movement and storage including in-line product blending, but does not include any of the functionality associated with the manufacture of refined hydrocarbons. The OMSB system shall be implemented as an advanced process control (APC) application and shall accomplish the following tasks: Monitor, control and optimize the in-line blending of components and additives into finished petroleum products Receive and verify the quantity of raw materials, finished products, intermediates and blend component stocks Transfer and store stocks, feeds and rundown from process units Move and record the quantity and quality of certified finished products
The overall objective of the OMBS shall be to maintain products on specification whilst minimizing quality giveaway, blend corrections, inventory requirements, contamination, laboratory analysis; and assist operator effort in planning, controlling and monitoring the oil and product movements. Online analysis, inferential quality measurements and safe, efficient facility usage shall be maximized. All OMSB activities shall be monitored and controlled via the DCS Operator workstation. In this project, Yokogawa AMB Suite (Advance Movement and Blending) is selected to manage facility and equipment in an offsite environment. 6.2 Product Blending The AMB Ratio Control and BPC (Blend Property Control) shall utilize a nonlinear model to predict the component and additive flow rates required to meet product specifications. The system shall incorporate on-line analyzer and inferential quality measurement feedback for both components and products to refine the model predictions. A number of selectable objective functions shall be provided to minimize component cost, component inventory and/or quality giveaway with varying priorities. The Product Blending system shall include

overrides to the optimization system to address temporary operational constraints (inventory management). The overall objectives of the in-line blending supervisory control system shall be: Minimization of product quality give-away Maximize the use of low cost blend components Eliminating off-specification blending to reduce the component and finished product inventories required to meet shipment schedules Accurate product quality control through inference techniques and on-line analysis Providing operators with an overview tank status and progress of current tasks
6.3
Oil Movements and Storage (OM&S) Automation of refinery oil movement and storage operations from crude receptions to product shipments shall including the capture, archiving and reporting of OM&S inventory, blend, task and laboratory data in a relational database environment. Oil movements and storage supervisory control strategies shall integrate a suite of modules that encompasses all aspects of the blending and movement operations. AMB TIM (Tank Inventory Monitoring) provides inventory management functions for the refinery tank farm. This module shall collect tank information (e.g. level, net volume, mass etc) from any of the commercial tank gauging systems. Extensive alarming, stop gauge and time-to-event estimates are to be included in the features of TIM. AMB Control shall provide order management facility for all oil movement and blending operations. Orders may be downloaded from a third party planning and scheduling system via text file transfer or created within the AMB Control. AMB Control then downloads this information to the BPC/Ratio Control modules or the TRANS modules as jobs for operation. It also collects operational data from these modules upon jobs completion for storage and reporting purposes. AMB TRANS shall provide supervisory automated sequencing capability for movements and controls task execution by the DCS operated field elements. When a movement is activated, AMB TRANS controls the actions required to complete the movement. Isolation, lineup, start flow, stop flow, and modification to sources and destination are typical movement phases. It shall allow the operator to monitor tasks and the related start, stop, swing conditions; determines expected states for tanks; calculates task flow and volume; estimates time to completion; and swings and collects each tasks history. Extensive movement alarming functionality shall alert the operator to unusual happenings in

the tank farm. Task summary information shall be directly uploaded to the AMB Control. AMB Path generation shall be implemented as an off-line function in AMB server; it has been designed mainly for engineers, and automatically generates path lists for path selection function of AMB Control. It is necessary to enter all lines and equipment (valves, pumps, etc) included in the paths per combination of a source (the start point of oil movement) and a destination (the end of point of oil movement) beforehand. This module is provided to simplify the above engineering work, and automatically generates paths based on facilities, lines and piping information. 6.4 Properties Analyzer An advanced on-line analyzer shall be provided with real time feedback for product quality control by EPC Contractor. The analyzer shall utilize Near Infrared (NIR) spectroscopy allowing better availability and faster response time for a wide range of qualities. This analyzer system shall measure blended product properties (RVP, RON) and report the results based on acceptable precision. The system shall be able to predict blending indices of blend components. The system shall be designed for ease of calibration and maintenance. The system shall include standard sample auto-collection to facilitate calibration and retention of outliner samples. The system shall be able to communicate with the Blending System. 6.5 Analyzer System The Analyzer System shall be supplied by the EPC Contractor(s). The MAC shall integrate the analyzers to the Blending System. 7.0 DOCUMENTATION REQUIREMENTS The following documents shall be produced during the design, programming, and implementation of advanced process control, and shall be included as part of the completed design of the APC system. All documentation shall be in accordance to the project execution procedures and documentation specifications. The detail engineering work shall be ordered separately by YERP. 7.1 Functional Design Document The Functional Design Document details the APC functionality to include, but not limited to: Control Objectives and Strategy Description Online Instrumentation and Analyzers Requirements

7.2
Online Calculations Requirements Identification of Key Controlled Variables Identification of Key Manipulated and Disturbance Variables Human-Machine Interface Specifications Additional Hardware and Software Requirements (beyond Distributed Control System (DCS) capability) Risks and Benefits Analysis Cost Estimates and Implementation Schedule
Detailed Engineering Design Document The Detailed Engineering Design Document describes the specific information of the APC system in sufficient details such that APC Supplier engineers can carry out the implementation. This document includes, but not limited to: Detailed online calculations Specific controlled variables, operating ranges, and APC tuning parameters Specific manipulated variables, operating ranges, and APC tuning parameters LP Economic Coefficients if Multi-variable Predictive Control (MPC) is used MPC controllers and their inter-connectivity (if MPC is used) HumanMachine Interface (HMI) deliverables Post-audit APC performance (if available)
7.3
Engineers Manual The Engineers Manual shall provide information to the plants technical staff necessary for understanding, modifying or expanding the functionality of the APC system. Specific project deliverable items for each process unit include: dynamic model files controller configuration files with tuning parameters inferential property predictor correlations relevant controller documentation

7.4
Operators Guide The Operators Guide shall provide information to process operators necessary for startup, shutdown, normal operation and upset control of the process related to functions of the APC system.
8.0 8.1
TRAINING General The MAC shall provide training for a minimum of four (4) of the YERP PMTs personnel prior to the testing of the systems. The MAC shall propose the training location. The training shall include, but not limited to: Overview of the employed APC technology Overview of the APC system and its functionality Hands-on practice/exercise using a simulator, if available Operation of the human-machine interface Overview of APC tuning parameters and troubleshooting APC maintenance issues

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Yanbu Export Refinery Project

Yanbu Export Refinery Project

7.1 7.2 7.3 7.4 8.0 8.1

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Yanbu Export Refinery Project

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Yanbu Export Refinery Project

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Yanbu Export Refinery Project

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