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PACE Zenith Awards 2012: Finalists for Oil & Gas

BOC South Pacific GMA and TIG Arc Projectors

BOC South Pacific GMA and TIG Arc ProjectorsBOC in conjunction with the Linde group has introduced to Australia the GMA and TIG Arc Projector – a state of the art training and demonstration tool which displays the difference BOC shielding gases can make to various welds, helping manufacturers optimise results and cut costs.

The projectors project the welding arc on to a screen enabling larger scale training and demonstrations to larger audiences. The projector can be used to highlight the effect on the welding arc when different gases are used.

It also provides an interactive display, which allows the customer/trainee to control the shielding gas used and see the impact on the arc type (GMA), travel speed and surface appearance, therefore helping them determine the welding gas to use.

The arc projector has been specially designed to work with an optical projection system, as it was found that even today's video cameras could not cope with the extreme contrast and brightness of a welding arc.

Extensive research and development delivered an optical projection system which offered the best possible image quality. To show the welding parameters, the arc projector uses a rugged and self-contained PC measuring system, combined with a standard beamer.

The software used is custom-made and proprietary, and is therefore adapted to the BOC shielding gas range.

Shell Geelong Refinery
Intelligent Vessel Gauging System

Shell Geelong Refinery Intelligent Vessel Gauging SystemThe Intelligent Vessel Gauging System is a high-tech radar-based system for level gauging in a LPG 'bullet' vessel at Shell's Geelong refinery and is one of the first to be installed in Australia.

The refinery, which occupies 120 hectares of land on the shores of Corio Bay, produces vehicle and aviation fuels, solvents, bitumen and other products. With up to 500 employees and some 150 contractors, the Shell Geelong refinery is one of the largest in Australia, with a replacement cost of around $1.5 billion.

The LPG (liquid petroleum gas) vessel only comes out of service every ten to fifteen years, which presents the only opportunity to do maintenance on the monitoring equipment.

Therefore critical requirements of the new technology include high reliability and low maintenance. High pressure is required to keep the gas liquefied, so opening the vessel for inspection can be complicated and expensive.

With a radar gauge there are no components inside the vessel to measure the liquid level that may require servicing, and measurement verification can be carried out with the tank in operation.

The old system was electro-mechanical whereas the new Rosemount Rex RTG 3960 gauge operates by sending a radar signal, so there are no moving parts. As well as measuring the LPG level, the system can also measure temperature and provide an alarm function.

Plantwide Feed Maximiser using Multivariable Control

Qenos Plantwide Feed Maximiser using Multivariable ControlThe project objective was to provide a plantwide Advanced Process Control (APC) scheme to enable the Altona Olefins (ethylene) site operations department to take advantage of high feed availability scenarios. Maximising utilisation of available feed is critical to the ongoing profitability of the site.

The ethylene production facility uses ethane from Bass Straight as the primary feed to the dual train, ethylene manufacturing plant. The APC includes all major unit operations at the Olefins site (ethane cracking furnaces, compression, fractionation and refrigeration systems).

The site is controlled from four control consoles which consist of three process plants and one utility. The majority of the routine plant control is performed by a single panel operator at each of these changing setpoints and modes.

The three process plant consoles were included in this project. The APC replaces around 90 traditional advanced control schemes and simplifies the overall running of the site.

Cylinder Maintenance Centre

BOC Cylinder Maintenance CentreThe Cylinder Maintenance Centre is a world first technology utilising boroscopic photo imaging of cylinder internals. The ultrasonic testing eliminates any risk of contamination issues with cylinders and electronically stores test records should they be required by customers.

The design enables BOC to optimise and increase the efficiency of its cylinder testing through technology rather than manual labour. The fully automated CMC conducts ultrasonic testing and powder coating of steel and aluminium gas cylinders, greatly reducing manual handling and repetitive strain injuries.

Personnel only have to move the cylinders a maximum of 1.5 metres by hand with the rest of the activities performed automatically through pioneering robotics technology. Improvements for customers have been in advantages of ultrasonic testing and photo-image internal inspection of cylinders as well as the high quality powder coating finish which is achieved.

BOC owns and manages approximately 2.2 million cylinders which need to be safety tested in accordance with Australian Standards. This equates to an annual test quantity of around 240,000 for the company.

BJH Controls
Fuzzy Logic use in a Fuel Gas Supply Control System

BJH Controls Fuzzy Logic use in a Fuel Gas Supply Control SystemThe Pressure Reduction Metering Station (PRMS) at the power station is a gas yard designed to reduce gas pipe line pressures down to power station operating pressures. When gas is lowered in pressure, the temperature of the gas also lowers such that the temperature of the gas can render the power station in-operable.

To overcome this drop in temperature, hot water heating is employed prior to the pressure drop. During startup of the plant there is no hot water as the hot water heaters cannot start with cold gas. This is overcome with an electric heater which is the focus of this article.

The electric gas heater is employed at startup of the plant until the hot water heaters reach operating temperature at which point the electric heater then acts as a standby heating source for redundancy. After initial coding and checking was undertaken the first live test took place and though the desired output was not achieved, the improvement was significant.

Subsequent of tuning of the logic took place, and re-testing showed that the system worked to meet specifications. After subjecting to further tests and trials the BJH Controls Fuzzy Logic control system for this part of the plant was accepted and approved.

AMS Instrumentation & Calibration (AMS) has been in existence for close to 40 years providing calibration equipment and industrial instrumentation to wide range of industries.PACE Zenith Awards 2012: Oil & Gas category is proudly sponsored by AMS Instrumentation & Calibration
AMS Instrumentation & Calibration
t: 1800 804 516

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