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Case Study: Refinery Using StackVision Saves $300K in Less Than a Year

After installing our DAS on the four refinery flare gas chromatographs (GC's) with the most downtime, the refinery was able to better track and manage their data and saw a 48% reduction in CEM downtime and 83% reduction in unscheduled downtime.

Before

“The refinery experienced difficulties caused by hard-to-read pass/fail emails, missed alarms and lack of visibility. ”

After

“The achievement was that we ended up saving over 500 PM man hours and reduced CGA hours by 50% since the installation. The CEMS downtime was down 48% with an 83% reduction in CEM downtime. It's been impressive what we've been able to do.”

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Company

A leading, integrated, downstream energy company.
 

Industry

Petrochemical
 

Facility

Refinery

 

Challenges

  • Pass/fail emails were time consuming and difficult to read.

  • DCS alarms in the central control room were difficult to notice and frequently missed.

  • No remote visibility or control of Analyzer shack operations.

 

Solution

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Summary

The refinery installed StackVision on the four refinery flare gas chromatographs (GC's) that had the most downtime and were not providing operators with much data. The GC's were connected to an analyzer network for remote access that utilized MODBUS for communication and allowed for remote calibrations and CGA's.
 

Benefits

The refinery received data directly from analyzers automatically. The information included detailed reports on daily calibration, weekly calibration trends, and immediate pass/fail notifications via text alerts (eliminating false call-outs from PI issues. 
 

Return on Investment

The proactive calibrations reduced GC Emergency Work Orders (EWO's) by 50%, and allowed the refinery to save over 500 PM hours per year. CGA hours were reduced by 50% due to StackVision's automated reporting and immediate pass/fail notifications.

 
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Overall, the 50% reduction in an analyzer EWO's resulted in an overall cost savings of $71,000. The reduction in overall analyzer work orders resulted in cost savings of $207,500. Compared to 2019, the refinery saw a 48% reduction in Continuous Emissions Monitoring downtime of 48% and 83% reduction in unscheduled downtime.

 
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    Published: 12/15/2020 2:28:23 PM

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