Shell’s Rotterdam refinery is one of Europe’s largest, processing 400,000 barrels of crude oil daily and producing gasoline, diesel, and petrochemical feedstocks. The refinery relies on 1,200+ control valves to regulate fluid flow, pressure, and temperature in distillation columns, catalytic crackers, and storage tanks. The legacy valve positioners presented critical operational challenges:
- Imprecise Positioning Causes Leakage: The legacy mechanical positioners had a positioning accuracy of only ±2% of full scale, leading to incomplete valve closure. This resulted in 15-20 crude oil and chemical leakage incidents monthly, each costing €15,000 in cleanup and environmental fines.
- Poor Compatibility with Smart Valves: The old positioners couldn’t integrate with the refinery’s new smart valves and digital control system (DCS), requiring manual adjustment of valve positions. This increased operator workload by 30% and led to human error-related process disruptions 8-10 times monthly.
- Slow Response to Process Changes: The legacy systems had a response time of 500 ms, unable to adapt quickly to dynamic process changes (e.g., sudden pressure spikes in distillation columns). This caused process fluctuations, reducing refining efficiency by 5% and increasing energy consumption by €2.8 million annually.
- High Maintenance Requirements: The mechanical components of the legacy positioners were prone to wear and tear in the refinery’s harsh environment (high temperature, vibration, and corrosive fumes). Annual maintenance costs exceeded €1.2 million, with each positioner requiring replacement every 2-3 years.
“Valve reliability is critical for safe and efficient refining operations—even minor leakage can pose environmental risks and disrupt production,” said Jan van der Meer, Shell Rotterdam Refinery Operations Manager. “Our legacy positioners were too imprecise and inflexible to meet modern refining demands. We needed a smart, precise valve positioner solution that could integrate with our digital systems, reduce leakage, and lower maintenance costs.”
ABB VP01 Valve Positioner Module: Smart Precision for Petrochemical Valves
After evaluating solutions from Emerson and Fisher, Shell selected the ABB VP01 valve positioner module for its ultra-high positioning accuracy, seamless DCS integration, fast response time, and rugged design. Key features addressing Shell’s pain points include:
- Ultra-High Positioning Accuracy: The ABB VP01 valve positioner module offers positioning accuracy of ±0.1% of full scale, ensuring precise valve closure and eliminating leakage. Its advanced feedback sensor technology continuously monitors valve position, adjusting in real time to maintain optimal performance.
- Seamless Digital Integration: Supporting HART, Foundation Fieldbus, and PROFINET protocols, the VP01 module integrates seamlessly with Shell’s existing ABB DCS and smart valves. This enables remote monitoring and control of valve positions, eliminating manual adjustments and reducing operator workload by 30%.
- Fast Response Time: With a response time of 50 ms—10x faster than legacy systems—the VP01 module adapts quickly to dynamic process changes. This stabilizes refining processes, improving efficiency by 5% and reducing energy consumption.
- Rugged Design for Harsh Environments: The module features an IP67-rated enclosure and operating temperature range of -40°C to 85°C, withstanding the refinery’s high temperature, vibration, and corrosive fumes. Its non-contact sensor technology eliminates mechanical wear, increasing mean time between failures (MTBF) to 10 years—5x longer than legacy positioners.
- Predictive Maintenance Capabilities: The VP01 module collects real-time data on valve performance (e.g., friction, wear, and response time), using predictive algorithms to identify potential issues 4-6 weeks in advance. It sends alerts to maintenance teams, reducing unplanned maintenance by 70%.
Results: Enhanced Safety, Lower Costs, Improved Efficiency
Six months after deploying the ABB VP01 valve positioner module, Shell’s Rotterdam refinery achieved significant operational improvements:
| Metric |
Before ABB VP01 Valve Positioner Module |
After ABB VP01 Valve Positioner Module |
Improvement |
| Monthly Valve Leakage Incidents |
15-20 |
0-1 |
96% Reduction |
| Annual Maintenance Costs |
€1.2 Million |
€696,000 |
42% Reduction |
| Refining Efficiency |
92% |
97% |
5% Improvement |
| Annual Energy Consumption Costs |
€2.8 Million |
€2.66 Million |
5% Reduction |
| Mean Time Between Failures (MTBF) |
2-3 Years |
10 Years |
300% Increase |
“The ABB VP01 valve positioner module has transformed our refinery operations,” van der Meer said. “We’ve achieved near-zero valve leakage, which not only keeps us compliant with strict environmental regulations but also reduces cleanup costs significantly. The predictive maintenance features have also allowed us to address potential valve issues before they cause downtime, improving overall operational reliability.”
Marco Rossi, ABB’s European Process Automation Product Manager, commented: “Petrochemical refineries require valve positioners that deliver precision, reliability, and seamless digital integration. The ABB VP01 valve positioner module meets these critical needs, helping refiners enhance safety, reduce costs, and improve process efficiency.”
Shell plans to deploy the ABB VP01 valve positioner module across 22 additional refineries and petrochemical plants in Europe, Asia, and North America by 2036, targeting a 95% group-wide reduction in valve leakage incidents and a 40% decrease in maintenance costs.
