AI for Prediction of Steam Eruptions in Cokers: Enhancing Safety in Delayed Coker Units

Executive Summary

Process Point deployed AI for Prediction of Steam Eruptions in Cokers Units, enhancing safety and reducing operational risks. The solution achieved 93% accuracy, improving efficiency and delivering long-term cost savings.

Client

A major refinery operator with 3 million BPD capacity across 36 plants, including a Delayed Coker unit.

Challenge

Geysers/steam eruptions during the "Coke Cutting" step in Delayed Coker Unit operations, spreading steam, hot water, and coke particles across a 2-3 mile radius.

Objective

Predict and minimize dangerous steam eruptions to enhance safety during coke cutting.

Our Solution Approach

Process Point implemented a data-driven intelligence solution to enhance operational efficiency and safety. Our approach involves meticulous data collection, advanced model development, seamless implementation, and continuous improvement to ensure optimal performance.

  • Data Collection and Analysis: Gathered historical data on eruption factors and applied Principal Component Analysis to identify key variables.
  • Model Development: Built a predictive model using machine learning, achieving 93% prediction accuracy.
  • Implementation: Integrated real-time monitoring and developed operational guidelines.
  • Continuous Improvement: Established ongoing monitoring and model refinement.

Results

An industrial setting with reduced steam eruptions, showcasing clean and organized machinery.

Reduced Steam Eruptions

Lower frequency and severity of steam eruptions, enhancing operational safety.
A safety officer monitoring operations with a tablet in an industrial setting.

Enhanced Personnel Safety

Improved safety measures for personnel, reducing risk and ensuring a safer work environment.
A modern control room with professionals monitoring real-time data analytics on high-tech screens.

Improved Efficiency

Optimized processes leading to better operational efficiency and productivity.
A line-art illustration of a financial graph showing a steady upward trend for long-term cost savings.

Long-term Cost Savings

Achieving significant cost savings over the long term through innovative solutions.

Conclusion

  • Challenge Addressed : Mitigating a critical safety risk while enhancing efficiency.
  • Approach Taken :
    • Data-driven strategy for risk reduction and process optimization.
    • Advanced analytics applied to solve complex industrial challenges.
  • Key Outcomes :
    • Improved workplace safety through proactive risk management.
    • Boosted operational efficiency , leading to more profitable operations.
    • Long-term adaptability ensured via continuous improvement strategies .
  • Industry Impact :
    • Demonstrates Process Point’s expertise in safety and performance optimization.
    • Highlights the value of AI and analytics in industrial risk management.