Process Optimization
2023
Real-Time Optimization System Standardization
Shell (Canada)Standardized online sequences, model implementations, and data exports for three real-time optimization (RTO) systems to enhance monitoring and maintenance efficiency.
2012
Optimal Heat Exchanger Bypass Using Hydraulic Models
Shell (Canada)System to generate optimal heat exchanger bypass flow targets by adding network hydraulics to an existing preheat model. Resulted in significant increases in feed preheat temperatures and reduced energy costs.
2008
A&V Unit Real-Time Optimization System
Shell (Canada)Design and implementation of a real-time optimization (RTO) system for a 155K bbl per day upgrader A&V unit. Generated 36 advanced control (APC) targets with tools to monitor target utilization, constraint relaxation, and heat exchanger cleaning benefits.
2002
Energy Optimization System
Dow (USA)Online optimization of a steam/power system using HYSYS.RTO. System included equipment selection/line-up optimization and what-if cases.
1997
Refinery Steam Real-Time Optimization System
Repsol (Spain)Real-time optimization system for a refinery steam/power plant. Operating targets included changes to boiler status and drive selections.
1996
Hydrocracker Unit Real-Time Optimization System
Petrochemia Plock (Poland)Real-time optimization system for a new hydrocracker unit (HCU) at a 200K bbl per day refinery. Delivered as part of an advanced control and automation project.
1994
Energy Management System
Samsung Chemicals (South Korea)Real-time optimization system for the steam/power plant at a large petrochemical complex.
1994
Multi-Site Energy System Analysis
Dow-Bayer-NOVA (Canada)Study of the economic benefits of coordinating the operation of a multi-site steam/power system.
Data Reconciliation
2020
Crude Feed Composition Estimation
Shell (Canada)Novel data reconciliation technique for crude feed composition estimation (FCE) that utilized a piecewise linear function for pseudo-component adjustment, and component collections for pure component adjustment.
2014
Flow Meter Gross Error Workflow
Shell (Canada)A systematic approach for troubleshooting meters in gross error (operation, installation, design, compensation, and technology) and identifying short- and long-term actions.
2013
Refinery and Chemical Plant Data Reconciliation System
Shell (Canada)Implementation of a data reconciliation system consisting of 430+ flow measurements and 120+ mass balances across 21 refinery and chemical plant operating units. Reconciled flows adopted by business, technical, and environmental groups for reporting and analysis.
2011
Upgrader Data Reconciliation System
Shell (Canada)Implementation of a multi-plant bitumen upgrader data reconciliation and mass balance system consisting of 560+ flow measurements and 150+ mass balances across 16 operating units. Used to monitor flow meter health and daily mass balances.
Process Modeling
2019
Crude Column Relief Load Estimation
Shell (Canada)Implementation of a model-based relief load estimator for a crude column. Online estimation of feed composition changes allowed maximum feed diet flexibility while ensuring continued safe operation. [Executive VP Award for Increasing Capacity]
2019
Corrosion Monitoring Tool
Shell (Canada)Online prediction of NH4Cl salt formation temperature and ionic dewpoint in preflash, atmospheric, and vacuum column overhead systems using process models.
2018
Heat Exchanger Fouling and Cleaning Benefits
Shell (Canada)Online model to estimate heat exchanger fouling, flow distribution, and bypass flows for a heat exchanger network. Resulting fouling rates and economic sensitivities were used to produce cleaning benefits and schedule.
2016
Fired-Heater Safeguarding
Shell (Canada)Development of an adaptive online model for firing limit prediction. The system ensured safe on-going operation while maximizing crude column product yields.
2011
Performance and Flooding Prediction of Crude Unit Columns
Shell (Canada)Calculation of vapor and liquid loading parameters for crude unit distillation columns. Allowed continuous online monitoring of column section performance and the potential for jet flood, downcomer flood, and flash zone entrainment.
Process Control
2015
Model-Based Control of Diluent Production
Shell (Canada)Development of a non-linear control method to produce high quality C5-C6 diluent with existing advanced control (APC) and optimization (RTO) applications.
2004
Kraft Pulp Digestors Batch Control
Domtar (Canada)Enhancement of a large-scale batch digester advanced control program. Resulted in reduced cycle time and improved product quality.
2003
Utility Boiler Advanced Control
Domtar (Canada)Performance analysis, modification, and tuning of the advanced control system for a 230 tonne per hour utility boiler to improve load disturbance rejection.
Process Economics
2023
Third-Party Steam Cost Tracking System
Shell (Canada)Online calculation of a multi-tiered take-or-pay steam purchase contract with a third-party supplier using PI-AF. Generated daily cost projections and analysis for use by plant operators.
2010
Pricing Method for Intermediate Process Streams
Shell (Canada)System to estimate intermediate stream prices for use in real-time optimization (RTO) systems. Method utilized linear programming (LP) volumetric yields, variable unit production costs, and fence-line product prices to calculate back-blended break-even values.
Dynamic Simulation
1999
Nickel Smelter Dynamic Model
Falconbridge (Canada)Dynamic model of a 45 MW electric furnace to predict matte, slag, and off-gas compositions. Used to investigate alternative operating conditions and evaluate process design changes.
1998
Water Management System
SA Water (Australia)Water reservoir process model and case study to determine the feasibility of developing a real-time inventory management system.
1995
Refinery Steam System Dynamic Model
Exxon (USA)Dynamic fired boiler process model with advanced steam drum controls. Used to evaluate process modifications and control designs to improve disturbance rejection.
Software Development
2002
Mixed Integer Nonlinear Programming (MINLP) Algorithm
Hyprotech (Canada)Development of an object-oriented mixed integer optimization algorithm (MINLP) for HYSYS.RTO. The algorithm was used for selection optimization in a steam/power real-time optimization (RTO) project.
2001
Open-Equation Models in HYSYS
Hyprotech (Canada)Added the ability to embed open-equation models in HYSYS process flowsheets. Greatly improved solution speed for highly interactive simulations.
1999
Dynamic Process Model Simulink Interface
Open Models (Canada)Development of an interface between MASSBAL dynamic process models and Simulink for use in control design and operator training (OTS) projects.
1996
Open-Equation Refinery Kinetic Reactor Models
Honeywell (Canada)Creation of equation-based refinery reactor kinetic models from closed-form versions. hydrotreating/hydrocracking (HTR/HCR), fluid catalytic cracking (FCC), and HF-alkylation reactors were required for real-time optimization (RTO) projects.
1995
Online Process Modeling System
Honeywell (Canada)Development of the OPTIMIZER platform for use in online process monitoring and optimization systems. Components included online executive, real-time data interfaces, steady-state detection, and data screening.
1995
Equation-Based Simulator for Real-Time Optimization
Honeywell (Canada)Modification of the MASSBAL process simulator to support hydrocarbon process models, data reconciliation and gross error detection, and optimization. Developed distillation models, physical property packages, real-time process data interfaces, and solution algorithms.
Process Data
2024
Data Visualization Client Migration
Shell (Canada)Migration of 6000+ displays from PI-ProcessBook to PI Vision for 140+ users. Developed standards, site-wide navigation pages, and access control model.
2023
Performance Equation Migration
Shell (Canada)Migration of 7700+ PI performance equations to PI-AF including ownership, templating, retirement, and validation. The project methodology developed was subsequently used for sites world-wide.
2023
Digital Twin Live Data
Shell (Canada)Method to incorporate PI process data on "live" design, process, and instrumentation diagrams. Developed the use case for process monitoring notifications using process data.
2022
Data Archive Configuration Tool
Shell (Canada)Trained 50+ site staff on the use of a PI tag configuration tool for point creation and maintenance. Developed 100+ templates for control system, laboratory, and advanced control data sources using best practices and site standards.
2022
PI Landscape Re-Architecture
Shell (Canada)Consolidated over a dozen systems of a 390K+ point archive into a highly reliable and simplified architecture, resulting in lower support costs and streamlined workflows. [General Manager's Award for Process Simplification]
2021
Online Production Rate
Shell (Canada)Online calculation of total upgrader production rate using PI-AF. System included measurement error-handling, unit status, feed/product routings, and an update method for end-users.
2018
Data Archive Performance Assessment
Shell (Canada)Evaluation of archive read performance for a proposed regional PI system. Used standard clients and developed custom applications. Poor performance results led to system architecture changes.
Environment
2019
Correction of Orifice Meter Flows for Improved GHG Reporting
Shell (Canada)Tool to correct historic vent gas flow measurements using updated design data. The flow measurements were required for greenhouse gas (GHG) emissions reporting.
2014
Reconciled Flow Measurements for GHG Reporting
Shell (Canada)Incorporation of flow meter health and reconciled measurements into the workflow for refinery greenhouse gas (GHG) reporting.