2500
CDU/VDU
DCU
Ms Block
DHDT/HGU
PFCCU
2222.2
2000
1500
1000
500
0
Minor leak (in Kg/hr)
Major leak (in Kg/hr)
Total leak (in Kg/hr)
Total leak (in tonnes/annum)
Figure 4 Leakage estimation for various units of refinery complex
•Control room hardware. •Software licence (perpetual). Generic prices have been considered for estimation purpose. If wireless infrastructure already exists or is planned in a unit, the cost of control room hardware and gateways will be excluded from the overall cost. Analysis of both cases – plants with existing wireless infrastructure and plants without such wireless infrastructure – has been carried out. For the purpose of optimisation, the Edge devices have been considered only for active relief devices, not for standby devices (which are lock closed). Redundancy in network devices and field hardware has been regarded as standard engineering practice. Also, these devices are not considered for relief valves with rupture discs.
across the five units in Figure 5 is approximately INR. 21,500,000. Case 2: Plant has no existing wireless infrastructure Figure 6 shows the estimated Capex required to implement this system across different units of a typical refinery complex with no existing wireless infrastructure. The total cost of implementation across the five units in Figure 6 is approximately. INR. 35,500,000. Considering hydrocarbon losses of 2,500 tonnes per year, industry data suggest a very quick return on investment (assuming a conservative hydrocarbon price as crude price, with approximately four months for Option 1 and five months for Option 2). Implementation The installation of IIoT-based flare monitoring systems offers notable advantages in terms of deployment efficiency and operational reliability. The clamp-on, strap-in design of Edge devices eliminates the necessity for additional nozzles or stubs, streamlining the installation process. Furthermore, positioning sensors at elevated locations, where pressure safety valves (PSVs) discharge into flare lines, ensures optimal wireless communication with control room gateways, thereby enhancing data transmission reliability.
Case 1: Plant has existing wireless infrastructure
Figure 5 shows the estimated Capex required to implement this system across different units of a typical refinery complex with wireless infrastructure. The total cost of implementation
8 , 000 , 000
6 , 000 , 000 7 , 000 , 000
5 , 000 , 000
4 , 000 , 000
15 , 000 , 000
3 , 000 , 000
10 , 000 , 000
2 , 000 , 000
1 , 000 , 000
5 , 000 , 000
0
0
MS b lock
PFCCU DHDT/ HGU
DCU with unsat. LPGTU
CDU/VDU with s at. LPGTU and FHTU
MS b lock
PFCCU DHDT/ HGU
DCU with unsat. LPGTU
CDU/VDU with s at. LPGTU and FHTU
Figure 5 Capex for plants with wireless infrastructure
Figure 6 Capex for plants with no existing wireless infrastructure
Refining India
30
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