Automate Process Chemical Dosing.
Real-Time In-Line Speciation for DCS & SCADA Control.
The ORCA (OndaVia Raman Controller Automation) platform bridges the gap between laboratory analytical precision and continuous plant automation. By extracting automated slipstream samples, performing microfluidic reagent conditioning, and measuring molecular Raman fingerprints on-line, ORCA feeds real-time concentration telemetry straight into your plant DCS—enabling closed-loop chemical pump modulation and cutting chemical over-injection by 20% to 35%.
The Hidden Cost of Manual Grab Sampling
Why retrospective laboratory testing forces plants into runaway chemical over-treatment and hazardous operator exposures.
⚠ 4 to 24-Hour Feedback Lag
- Blind Operation: Plant operators make dosing adjustments based on yesterday's grab sample lab results.
- Dynamic Swings: Process fluid composition, gas flow rates, and temperatures fluctuate hourly, leaving treatment programs constantly out of sync.
- Off-Spec Penalties: Late detection of breakthrough leads to pipeline rejection or downstream unit contamination.
⚡ 20%–35% Chemical Over-Dosing
- Fear-Based Over-Treatment: Because operators cannot verify real-time residual levels, they run 25%+ safety margins on expensive chemical scavengers and inhibitors.
- Capital Waste: Midstream and refinery operations routinely waste \$150,000 to \$500,000+ annually on excess unreacted chemistry.
- Byproduct Fouling: Over-injecting triazines precipitates intractable dithiazine solids in reboilers and exchangers.
☣ Operator EHS Exposure
- Toxic High-Pressure Fluids: Manual sampling requires technicians to tap pressurized lines containing toxic H2S, volatile hydrocarbons, and sour water.
- Hazardous Reagents: Traditional lab titrations consume hazardous acids, bases, and carcinogenic solvents.
- Compliance Overhead: Generates hazardous liquid waste streams requiring strict RCRA manifesting and disposal costs.
The Solution: Closed-Loop Process Analytical Technology (PAT)
The ORCA platform taps directly into your process slipstream, measures individual chemical species at the molecular level, and transmits concentration data directly to your plant DCS. Your control system adjusts variable-frequency drive (VFD) chemical pumps in real time—maintaining exact ppm setpoints 24/7 without human intervention.
Head-to-Head Comparison
How the on-line ORCA platform outclasses manual grab samples and laboratory contract testing.
| Operational Parameter | Conventional Grab Sampling & Lab Analysis | OndaVia ORCA On-Line Analyzer Platform |
|---|---|---|
| Measurement Frequency | 1 to 2 times daily (or weekly batches) | Continuous / Semi-Continuous: Configurable 1 to 12 tests/hr |
| Data Reporting Latency | 4 to 24 hours internal lab; 5–10 days third-party | < 15 minutes from slipstream extraction to DCS tag update |
| Control Loop Capability | Open-Loop: Manual chemical pump adjustments; frequent over-dosing | Closed-Loop: Modulates VFD dosing pumps directly via 4–20 mA / Modbus |
| Chemical Speciation | Bulk Properties: Titration is blind to spent byproducts vs active species | True Molecular Fingerprinting: Isolates active scavenger from spent dithiazine |
| Hazardous Exposure | High: Direct operator exposure to pressurized sour fluids & acids | Zero: Fully enclosed automated fluid handling and line flushing |
| Technician Maintenance | Daily: Sampling rounds, glassware cleaning, chemical disposal | Unattended: 7- to 30-day walkaway reagent autonomy |
Proven Industrial Performance
Real-world operational results from midstream gas processing and refining facilities.
Closed-Loop H2S Contactor Dosing Optimization
The Problem: A 120 MMSCFD gas processing facility relied on manual grab sample titrations once per day to verify MEA-triazine scavenger efficiency. Because inlet gas $\text{H}_2\text{S}$ fluctuated between 120 ppm and 280 ppm, operations routinely over-injected triazine by 32% to prevent pipeline tariff violations, causing severe dithiazine solids deposition in the downstream amine reboiler.
The ORCA Solution: Installed an ORCA-303 Triazine Analysis Unit on the contactor tower slipstream, transmitting real-time active triazine and spent dithiazine data to the plant DeltaV DCS via Modbus TCP/IP once every 30 minutes. The DCS automatically modulated the chemical injection skid.
The Result: Reduced triazine consumption by 29% immediately, saving \$285,000 in chemical spend in the first year. Reboiler run length increased from 4 months to over 18 months without chemical fouling shutdowns.
Continuous Desalter Wash Water Tramp Amine Tracking
The Problem: Opportunity crudes contaminated with upstream scavengers caused volatile monoethanolamine (MEA) tramp amine spikes in the desalter effluent. These amines slipped past the desalter into the atmospheric tower overhead, forming catastrophic amine chloride corrosion salts.
The ORCA Solution: Implemented an ORCA-101 Electronic Control Unit with an ORCA-201 Amine Fluidic Module on the desalter brine water slipstream, analyzing MEA concentration every 20 minutes with automated 4–20 mA alarming to the board operator.
The Result: Detected a 45 ppm tramp amine spike within 20 minutes of an unannounced crude tank switch—allowing operators to divert wash water and ramp up neutralizing filming inhibitor 6 hours before salt deposition could breach overhead metallurgy.
The ORCA System Hardware Portfolio
Choose an integrated turnkey analyzer or configure a modular multi-stream system for your plant.
ORCA-303
Complete turnkey analyzer engineered for midstream gas processing, crude gathering, and H2S scavenger contactors. Pre-packaged enclosure combines electronics and sample conditioning.
- Target Analytes: Active MEA/MMA Triazine, Dithiazine
- Cycle Time: < 15 minutes per test cycle
- Telemetry: Modbus TCP/IP, 4–20 mA, Ethernet
- Enclosure: NEMA 4X / IP66 Wall-Mount
- Hazardous Area: Class I, Div 2 / ATEX Purge-Ready
ORCA-306
High-precision automated analyzer for power generation boiler water loops, high-pressure steam drums, and mining ore extraction slurries. Handles high-concentration solutions with zero dilution labor.
- Target Analytes: Ortho-phosphate, Poly-phosphate, Sulfate
- Application: Boiler corrosion & ore grade tracking
- Telemetry: Modbus TCP/IP, RS-485, 4–20 mA
- Enclosure: Industrial Stainless Steel Enclosure
- Autonomy: Bulk 4-L automated reagent reservoir
ORCA-101 + 20x
Modular architecture separating the computing/optical core (ORCA-101) from dedicated fluidic units (ORCA-201 Amines, ORCA-202 Ammonia, ORCA-205 Formaldehyde) for multi-channel plant monitoring.
- Controller: ORCA-101 Electronic Control Unit
- Fluidic Units: ORCA-201 (Amines), 202 (Ammonia), 205 (HCHO)
- Multiplexing: Controls up to multiple sampling streams
- Computing: Embedded Industrial Windows Engine
- Power: 120/240 VAC or 24 VDC industrial