Refining India March 2026 Issue

CO to stack

Conrm guided pre-checks

Lean MeOH Loaded MeOH (CO) Loaded MeOH (CO+HS) Loaded MeOH (CO+HS+HCN)

TG to stack

Loaded MeOH from V002

START C003 BYPASS

FV

Y003 SS

Divert P008 discharge

Loaded MeOH from V003

Set point for FIC A

MV-V004 (FIC A: X m/min)

To SRU

C002

C003

Increase lean MeOH Column FIC B (Y m/h @ Y1 m/10 min)

LLP N2

Set point for FIC B P005 amps < FLC

C004 A/B

Y004

LP steam

Lean MeOH to C001/C101/ C201/C005

V009

Close FIC C Semi-lean MeOH

Loaded MeOH from C001

24”

C006

S015AH

Increase FIC D set point = semi-lean MeOH cuto

S006AF

P004

Y003 TS

S014

Decrease LLP N ow

C003 (W m/h per 15 min)

V005

S007

P005

Stabilise for 1 hr

Figure 3 Automated guidance elimates human error and develops the skills of the operator

abnormal behaviour, or impending failures. By detecting anomalies before they escalate, these systems enable operators to take timely corrective actions, thereby reducing unplanned downtime, minimising equipment damage, and improving overall plant reliability. Early alerts also help operators prioritise tasks, respond more efficiently to deviations, and maintain safe operating envelopes even under variable process conditions. “ By detecting anomalies before they escalate, these systems enable operators to take timely corrective actions, thereby reducing unplanned downtime, minimising equipment damage, and improving overall plant reliability ”  Automating start-up sequences to enhance safety . Automated start-up sequences reduce operator exposure to complex and high- risk activities typically involved in bringing equipment or units online. With more than 154 EED systems deployed, start-ups are now executed with greater consistency, accuracy, and adherence to operational standards. Automation ensures that every step of the start-up sequence, from verifying interlocks and permissive to gradual ramp-up of process parameters, is performed safely and in the

correct order. This not only decreases the likelihood of human error but also standardises operational performance across shifts and facilities. Example : Wireless monitoring of mechanical seal integrity . Mechanical seals are critical components, which when failure occurs can lead to process safety risk due to leaks, equipment shutdowns, and significant maintenance costs. By integrating wireless vibration, temperature, or pressure sensors, operators gain real- time visibility into seal performance without requiring intrusive inspections. The system automatically analyses sensor data, predicts failure trends, and triggers alerts when seal degradation crosses predefined thresholds. This proactive monitoring approach greatly improves equipment reliability and supports predictive maintenance strategies (see Figure 4 ). Impact of data analytics, dashboards, and closed-loop process control The deployment of data analytics, dashboards, and closed-loop process control has delivered sustainable savings and optimisation insights without requiring additional investment or hardware. These initiatives have significantly enhanced performance across safety, efficiency, and reliability. The following are a few key impacts: • Safety enhancement :  Data from platforms such as safety

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