Improving Operational Efficiency with Data Acquisition Systems in Refineries

This blog post will walk you through all the ways having a Data Acquisition System for refineries can improve overall operations and efficiency.
Improving Operational Efficiency with Data Acquisition Systems in Refineries

How Does a Data Acquisition System Improve Efficiency in Refineries?

As you may know, refineries are required by the Environmental Protection Agency’s (EPA) Refinery Sector Rule (RSR) to prioritize flare minimization, as well as monitor and report emergency flaring events and deviations within as low as a 24-hour time frame. Without a Data Acquisition System (DAS), complying with RSR requirements can be highly difficult. This blog post will walk you through how DAS’s such as StackVision can help refineries both meet these requirements and improve overall operational efficiency. For more information on the RSR and how Data Acquisition Systems for refineries are useful, read How StackVision™ Helps Refineries With RSR Regulations.


Real-Time Monitoring

A DAS enables real-time monitoring of critical parameters such as those that the RSR requires refineries to report. This allows you to quickly identify and address emergency flaring events or related issues and reduce downtime for your refinery. There are several required individual components to be tested daily for refineries, and without a DAS that automates this process, this presents you with daily opportunities for compliance failure. Using the traditional and now outdated Digital Control System (DCS), historian, and spreadsheet method simply does not allow for the required data and timeframes to be measured accurately or quickly enough.


Predictive Maintenance

Another benefit of a Data Acquisition System is that it can help predict potential equipment failures, enabling proactive maintenance measures. Utilizing a DAS for refineries can help minimize unplanned shutdowns and extend the overall lifespan of refinery assets.


Optimized Operations

Data-driven insights provided by DAS can aid in optimizing operational processes. These include adjusting parameters for maximum efficiency, lowering energy consumption, and improving overall process control. Since the Data Acquisition System continuously monitors and calculates these values, operators can control flows and adjust parameters as needed at all times.


Compliance and Reporting

Refineries can be a highly regulated environment to work in, which can be frustrating at times. With a DAS, complying with these regulations is a much less daunting task. The following are some of the compliance challenges that require real-time reporting to meet:

• 15-minute block averages and documentation

• Increased quality control requirements

• Ready access to compliance parameters for operators

• Requirement to report, retain, and make data available


Learn how Calumet Refinery used the StackVision DAS for flare monitoring and compliance with the Refinery Sector Rule (RSR).


Enhanced Safety

 One last benefit of a DAS that can’t be understated is the ability to detect deviations and errors within a refinery in real-time. The quicker that these anomalies are acted upon, the more likely it is that accidents can be avoided.

How ESC Spectrum Can Help Refineries

StackVision is the leading Continuous Emissions Monitoring (CEM) Data Acquisition System for refineries. It works seamlessly with the 8864 Data Controller to collect, monitor, QA, and report on emissions data from CEMS accurately and reliably. This Data Acquisition System is backed by 24/7 best-in-class customer support from a dedicated team of experts, services, and online and in-person training. Contact us today to see how StackVision can help your facility stay in compliance.
Picture of Dan Napolitan - Marketing Specialist I

Dan Napolitan - Marketing Specialist I

Daniel joined ESC Spectrum in August of 2023 as a Marketing Specialist I. He started this position shortly after graduating from the University of Missouri with a degree in Journalism and Strategic Communications. Prior to working with ESC Spectrum, Daniel gained experience in the digital marketing field doing SEO and keyword research to produce successful organic content. He is now responsible for completing various marketing tasks such as blog writing, social media posts, paid search advertisements, web analytics, and more.

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