Supplier of professional automation control systems for the refining industry

The integrated plant solution provided by HollySys can boost the flexibility and adaptability of the whole supply chain of the refining industry. At the same time, it is able to provide predictive diagnosis and maintenance for its advanced asset equipment, fully realising the equipment’s potential and maximising its utilisation. With the coordinated optimisation of the three major indicators, which are production, equipment, and safety, it is possible to secure the minimisation of the investment and maintenance costs within their client’s refinery’s life cycle to optimise its production operation targets.

This is the total solution provided by HollySys for the integrated plant:

Safe, Reliable, and Easy to Use Products
The usability of the MACS DCS system of HollySys is 99.999%, and the mean time between failures (MTBF) is 200,000 hours, which adequately ensures that the oil refining plant continues to run in a stable manner. The software configuration is fully compatible with the international control configuration language standard IEC61131-3.

Program Design and Program Implementation
HollySys has undertaken over thousands of projects in the oil refining industry, where it has earned a high-level of trust from its clients. During the whole refining process, we are able to provide a full set of solutions encompassing program design and project execution, which mainly includes prophase program design consultancy for the project, FEED design, and the implementation of construction work for systems such as MIV and MAC.

Services and Optimization
24/7 operations and after sales support, online diagnosis and optimisation support.

System Upgrade and Asset Optimisation Management
Online upgrade programs, full lifecycle system solutions, and management of equipment asset optimisation.

System Restructuring and Expansion
Able to provide clients with system restructuring and replacement solutions, and optimised system expansion solutions.

Integrated System Management
We provide a full range of integrated system management solutions for the automation control industry, connecting to every operating information source, collecting and storing data, providing reliable, safe, and integrated system application platforms.

Process Introduction

Through its constant application and in-depth understanding of the oil refining industry, HollySys has accumulated a wealth of application experience in the oil refining industry. The company has developed a large team of industry managers in the refinery industry. To provide solutions for the client, the company has built-up a unique bank of knowledge pertaining to control and improvements of specific processes, and believes that it will provide the client with more value when compared to ordinary automation companies.

Atmospheric and Vacuum Distillation

Atmospheric and vacuum distillation is also referred to as a primary crude oil processing process, which is the first process after the crude oil enters the oil refinery.

Key Control Solutions Including

Atmospheric and Vacuum Distillation

  • Atmospheric furnace outlet temperature control and furnace temperature cascade regulator.
  • Vacuum furnace outlet temperature control and furnace temperature cascade regulator.
  • Initial boiling bottom level and crude oil insertion cascade control.
  • Atmospheric top temperature and top return-flow cascade control.
  • Vacuum top temperature and top return flow cascade control.
  • High-pressure gas pressure control.
  • Fuel oil pressure control.

  1.  Oil feed pump,
  2. Heat exchanger,
  3. De-salter,
  4. Heating furnace.
  5. Atmospheric and vacuum distillation column.
  6. Liquid storage tank.
  7. Stripping column.
  8. Condensate cooler.
  9. Vacuum distillation column.
  10. Steam ejector.
Catalytic Cracking

Catalytic cracking is a type of heavy oil weight reduction process to improve the crude oil processing depth at the refinery. Currently, the catalytic cracking equipment is being developed to become more advanced and economically efficient.

The catalytic cracking equipment mainly comprises: Reaction – regeneration unit, energy recovery unit, fractionation unit, and absorbing stabilisation unit. Additional sections include: Desulfurisation unit for dry gas and liquefied petroleum gas, a sweetening unit for gasoline and liquefied petroleum gas, and other sections.

Key Control Programs
  • Reactor oil catalyst temperature control.
  • Settler reserve control.
  • Fractionator bottom level adjustment control.
  • Temperature adjustment control for diesel fuel entering the stripper.
  • Stable overhead liquid hydrocarbon pressure split control.
  • Crude oil temperature cascade control.
Delayed Coking

Delayed coking equipment is for a type of heavy oil thermal processing process, which is a key method for oil refineries to reduce the weight of heavy oil, and improve light oil yield.

Introduction of Control Programs
  • Cascade control of the level control of the fractionation tower.
  • Cascade control of the outlet temperature control of the coke tower.
  • Split control of the fractionation tower crude oil feed temperature.
  • D-1102/B water injection flow single-loop control.
  • Outlet temperature and furnace temperature cascade control for furnace outlet temperature chosen for the cascade control of the heater outlet temperature
  • Furnace thermal efficiency
  • Pressure machine anti-surge control, which can use fixed value flow control and also use the follow-up flow control system.
  • Pressure machine, hydraulic decoking interlock circuit

For hydrotreating, the raw materials are straight run diesel provided by the atmospheric distillation unit and catalysed diesel provided by the catalytic cracking unit. The new hydrogen is provided by the catalytic reform unit. After hydrotreating to generate diesel, it is sent to the blending tank as a high-quality diesel fuel blending component. The refined naphtha sub-product becomes the raw material for the reforming pretreatment unit.

Catalytic Reforming

Catalytic reforming is one of the important secondary processing processes in oil refining. The raw materials are naphtha oil and atmospheric and vacuum oil and gas, and the process produces organic chemical raw materials such as high octane gasoline components and benzene, toluene, and xylene, and also a cheap byproduct which is hydrogen.

Typical Applications (High-acid Crude Oil)

Summary of revamp of 5million tonne / year processing high-acid crude oil facility for Sinopec Qingdao

The revamp of the high-acid crude oil facility for China Sinopec Qingdao Petrochemical LLC was one of Sinopec’s 20 core projects in 2009 (14 were refinery-related). It was a massive project comprising many combined facilities, with very strong demand and high standards for automation control system products and engineering construction implementation capabilities.

The whole project used a central control room (CCR) to facilitate centralised monitoring of all equipment, and a field apparatus room (FAR), field control station, and different types of terminal cabinets were established near the facilities that were in close proximity, taking charge of the acquisition of field signals. Redundant fiber connections were used between the FAR and CCR.

Equipment Scope
  • 5million tonne / year atmospheric and vacuum pressure facility
  • 1million tonne / year gasoline and diesel hydrotreatment facility
  • 600,000 tonne / year catalytic gasoline and diesel hydrotreatment and desulfurisation facility
  • 1.6million tonne / year delayed coking facility
  • 20,000 tonne / year sulfur recovery and solvent regeneration facility
  • 1.5×104Nm3/h hydrogen production units
Control System Scale
  • 1 CCR (central control room) and 5 FAR (field apparatusrooms)
  • Physical IO points: 4000 points (all HART)
  • Controller stations: 23
  • Engineer stations: 6
  • AMS stations: 6
  • Redundancy control stations: 12
System Network Structure

Project Results

The project was a resounding success with high client satisfaction. Out of over 200 suppliers, HollySys was rated as one of their “Top 10 Suppliers” for their project.

Key factors leading to the project’s success:

  • Extensive experience of team members and excellent team coordination and spirit
  • Perfect system program design
  • Orderly project planning and implementation
  • All-encompassing system services

Typical Applications (Refining)

5 Million Tonne / Year Oil Refining Project by Petrochina Hohhot Petroleum Company

Project Summary
The expansion and revamp of Petrochina Hohhot’s 5million tonne / year oil refining project was a project for the 3-year rolling development plan of Petrochina during the 11th Five-Year Plan period. It was included into the Chinese NDRC’s list of special petrochemical technology projects, whereby the total amount invested for the project was RMB 7,848million, where RMB 7,384million went into construction and the annual production output was nearly RMB 30billion after the construction was completed.

This project is Petrochina’s major integrated oil refining project, where its DCS system construction is defined as a turn-key project. The overall design fully adopts international advanced design concepts and the automation control system is designed to be integarted with DCS, SIS, AMS, and MES systems, with an all-encompassing and smart plant design concept covering automation control to information. The system integration level is high, and the automation level has reached internationally advanced standards, fully achieving the integrated control of the plant.

System Included
  • 1 CCR (central control room), 10 FARs (field apparatus rooms)
  • The whole system is divided into 5 independent facility system domains and 1 public administration domain.
  • The equipment of the facilities are designed to have individual AMS management systems, and the whole factory also has an AMS management system that administers all factory processes.
  • Physical I/O point: 14,000 points (all HART)
  • Control station: 35; Engineer stations: 14; Mobile engineer stations: 3.
  • DCS controllers: 28
  • Total number of different types of cabinets: 100
  • OPC connection stations: Used for 2 MES systems, 1 oil product harmony system, and 1 whole-plant measurement system.
  • Sub-system communication ports: 60 (including: GDS system, SIS system, and CCS system)
  • Provided an abundant and complete set of many different types of system connections, including CCTV, large screen, GPS clock synchronisation, anti-virus system, and tank storage mobile automation management system.
System Network Structure

Client Satisfaction Levels

Beginning with the project’s feed design, HollySys leveraged on its professional system solutions and the standardised size of projects implemented have won ample recognition from users and EPCs. HollySys’ overall automation solutions have provided highest total ownership value for its clients.

General Achievements

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