Automated Batch Control for Delayed Coker Valve Sequencing
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Solution Overview
Problem
The operation of a delayed coker unit remains labor-intensive despite partial automation, requiring significant human intervention and risking exposure to hot hydrocarbons due to the complexity of valve sequencing and lack of comprehensive verification systems.
Innovation Solution
An automatic batch sequence control system is implemented to remotely operate process valves in a delayed coker, utilizing primary and secondary verifications through position sensors and pressure transmitters to ensure safe and precise valve operation throughout a complete coke drum cycle, reducing the risk to personnel and enhancing operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual valve operation is used, then operators can directly control the process, but labor intensity increases and safety risks arise from exposure to hot hydrocarbons
Solution Approach 1:
The patent replaces manual mechanical valve operation with an automated control system that uses position sensors, pressure transmitters, and programmable logic to automatically sequence valve operations. This substitution eliminates direct human exposure to hot hydrocarbons while maintaining precise control over the coking process cycle.
Solution Approach 2:
The control system incorporates self-verification mechanisms where position sensors and pressure transmitters automatically monitor and confirm valve positions and process conditions. The system verifies its own state through feedback loops, reducing the need for manual intervention and enhancing safety without requiring continuous human oversight.
2Ease of operation
If remote automated valves are used, then labor requirements are reduced, but comprehensive verification of valve positions becomes more complex
Solution Approach 1:
The patent implements a feedback-based verification system where position sensors on each valve provide real-time status information to the control system. Pressure transmitters provide additional feedback on process conditions. The control system continuously compares actual valve positions with commanded positions and adjusts operations accordingly, creating a closed-loop verification system that is robust but not overly complex.
Solution Approach 2:
The control system performs preliminary verification of valve positions and process conditions before advancing to the next step in the sequence. This preliminary action ensures that all prerequisites are met before executing potentially hazardous operations, simplifying the overall verification approach by breaking it into discrete, manageable checks.
3Reliability
If multiple verification methods are implemented, then safety is improved, but system complexity and cost increase
Solution Approach 1:
The patent applies different verification methods at different locations in the system based on specific needs. Position sensors are installed on critical isolation valves where precise position verification is essential for safety. Pressure transmitters are placed at key process points to verify process conditions. This localized application of verification methods provides comprehensive safety coverage without uniformly complicating the entire system.
Data Source
AI summary
An automatic batch sequence computer control system is configured to automatically operate process valves in a delayed coker for a complete coke drum cycle. Double verification of the movement of the process valves is used to confirm advancing to the next step. Primary verification is achieved by using position sensors on the valves. Secondary verification is achieved by using monitored process conditions and confirming the measured conditions correlate with expected process conditions for an arrangement of valve positions at a given sequence in the coke drum cycle. A safety interlock system may be integrated with the control system.