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Exploiting Information Systems to AchieveEnergy Operational Excellence
Mohaiyuddin Abdul Hamid29 Feb 2008
Seminar on Energy Efficiency for Process IndustryChallenges & Opportunities in Process Optimisation
Table of Contents
Background of Energy Management at PETRONASWhat is Energy Plant Information Enhancement? PIE Case StudyPIE ApproachLessons Learnt
Energy Plant Information Enhancement (PIE)
Installing an Energy Management
System - dedicated energy panel in the
control room
Enabling operators to monitor energy
performance online
Ensuring that energy operations are set at optimum
levels
The PI Enhancement project was rolled out to increase energy efficiency and reduce energy costs at selected plants.
This was achieved by:
Case Study – PIE project at PETRONAS Terengganu RefineryEnergy Situation:
Given rapidly rising energy costs, growing concern about the cost and environmental impact, PPT was seeking to maximising energy efficiency to reduce use, cost and its impact on the environment.
Approach:Implemented the PIE solution that utilised an online Energy Management System.
Value Delivered:Given the right processes, tools and information, combined with an integrated approach, overall energy savings was 4% of the total energy bill and energy performance was benchmarked in the 1st quartile for refineries/ plants worldwide.
Capital Investment
Realised Saving
Payback period
4% of total energy bill
~ RM 900k
Less than 1 year
Energy Plant Information Enhancement - moving from reactive to proactive Energy Management
Reactive Monitoring PIE - Proactive Monitoring
• Reactive
• Blind
• Post event
• Real-time
• Precise
• Continuous
• Potential savings of 4% of annual energy bills
• Increase energy usage awareness through online energy performance
• Lower energy consumption by operating close to target – enables engineers to focus on critical energy areas thus operate at best practice standards
• Assists with troubleshooting -identify operating inefficiencies quickly and rectify problems earlier
PIE Benefits
PIE Project Scope
• Obtain unit operations for parameters
• Check flow meter accuracy
Process & Utility Optimisation
Performance Review/ Analysis
Energy IndexKPI CalculationMass Balance Determine Energy
Control Parameters
• Reconcile mass balance• Process• Steam Utility• Fuel gas
• Identify bad meters
• Calculate Energy Index and Unit Cost
• Steam Turbines • Compressors;
Distillation Column
• Reactors; • Pumps (Electric
and steam turbine driven);
• Fired heaters; • Cooling towers
• Review equipment performance
• Compare EI to targets
• Operational adjustments
• Process and utility optimisation
Phase 1
1 2 3 4 5
Phase 2
Determine Energy Control Parameters Pages
Locate all the ECPs for process and utilities in separate pages
The variables are segregated by their unit operations
Each variables has its own operating envelopesIdentify optimum target. In time the target should be as close as possible to the optimum value.
Identify ECPs and their optimum targets through simulation and best practices.
Obtain unit energy cost per unit of product
1
2
3
4
5
Determine Energy Control Parameters
1
Mass Balance Module
Mass Balance ModuleMass Balance Module
Unit OperationsUnit Operations UtilitiesUtilities
• Crude Distillation unit (CDU)
• Naphtha Hydrotreating Unit (NHT)
• Catalytic Reforming Unit (CRU)
• Condensate Fractionation Unit (CFU)
•Fuel Gas at refinery plant
•Fuel Gas at aromatic plant
•HHPS, HPS, MPS, LPS, LLPS
•Boiler feed water
•Condensate
Mass Balance Module
2
KPI Calculation & Monitoring
Energy Index
Energy Index(EI)
Crude Distillation Unit (CDU)EI 1
EIV 1aEIV 1b
EIV 2aEIV 2b
Naphtha Hydrotreating Unit (NHT)
EI 2
EIV 3aEIV 3b
Catalytic Reforming Unit (CRU)
EI 3
EIV 4aEIV 4b
Condensate FractionationUnit (CFU)
EI 4
3
Online Utilities Optimiser
WorkstationKey in fuel prices and
equipment status based on demand
PI Process ResultsCurrent vs Optimised case is displayed on PI Process
screens for operator guidance toMinimise fuel consumption and operating cost
Output
PI Data Base
Optimiser calculation
triggered every 15 min
Visual basic program
started in EMS server -
request value from input tag from PI Data
Base
Run Lingo to calculate
current and optimal cost & store current
and optimised values
Optimiser Program (Lingo)
Process & Utility Optimisation
4
Optimisation Modelling
Modelling Considerations
Equipment Capacity
Equipment Status
• Min capacity < Boiler capacity < Max capacity• Min capacity < pump capacity < Max capacity• Min capacity < instrument air compressor capacity < Max capacity
• Must Run – due to operational requirement• Out of service - when under maintenance• On/Off OK – free for optimiser to choose
Mass Balance
Mass Balance for the entire utilities system• HHPS, HPS, MPS, LPS, LLPS• Boiler feed water• Condensate
Process & Utility Optimisation
4
Multiple considerations will be taken into account in the modeling to achieve the objective function which is to minimise the fuel consumption and power import.
E-1 E-2 E-3 E-4
P-1
E-5 E-6 E-7E-8
P-2
E-10 E-11 E-9E-12
P-4
E-13E-14E-15 E-16
P-1 P-1 P-1 P-1
P-9
P-2
P-10
P-11
P-12 P-2
P-13
P-14
P-2
P-15
P-16 P-2P-17
P-18 P-4
P-19
P-20 P-4
P-21
P-22 P-4
P-23
P-24P-25 P-26 P-4 P-27 P-4
P-28
P-4
E-17
P-29
P-2
P-30
P-32 P-32
P-34
P-35
P-34
P-36
P-1
P-37
P-34
P-38
P-34
P-39
P-40
P-1
P-41
P-1
P-42
P-1
P-34
P-43 P-44 P-32P-45 P-32P-46 P-32
Plant is set to operate at optimised levels
Optimisation reduces fuel consumption by improving the efficiency of operations
Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump. Prd. Consump.
F I X E DWaste Heat Boiler 8.42 8.41569Reformer Recycle Gas 5.702 5.702115C1 Stripping Steam 0.45C2 Stripping Steam 0.3Steam used in the flare 0.56Others 5.81 0Rec Gas heater 0.8Sub-Total 8.42 6.50 0 7.12 0 0 5.70 0 0 0 0 8.42 0 0 0 0 0 0 0 0V A R I A B L E SAux Boiler 1.50 1.50Steam Turbine 1.03 1.03Electric Motor 0.0Steam Turbine 0.71 0.71Electric Motor 0.0FDF Turbine 0.16 0.16FDF Motor 0.0HPS Letdown to MPS 0.00 0.00MPS Letdown to LPS 1.03 1.026397HPS Export to HP 1 1.51HPS Import from HP1 0.00MPS Export to HP1 0.00MPS Import from HP1 8.15Deaerator 1.03 7.60396445 9.92 1.285328432Electricity ImportDUMP CONDENSATE 0.00 0.00 0.00Sub-Total 1.50 3.41 8.15 1.03 1.03 1.03 1.90 7.60 9.92 1.50 0.00 0.00 0.00TOTAL 9.92 9.92 8.15 8.15 1.03 1.03 7.60 7.60 9.92 9.92 0.00 0.00 0.00
S T E A MHPS
tonne/hour kW-htonne/hourDescription
LLPCMPS LPSDump Condensate
tonne/hour
CONDENSATE BOILER WATER
tonne/hour
FUEL
tonne/hour LHV/hour
DEMIN WATER
tonne/hour tonne/hour
ELECTRICITYCondensate
tonne/hour
LEGENDVariablesCalculatedFixedExcel Formula
Target set by Optimisation Program to reduce fuel consumption
Process & Utility Optimisation
4
Control Room Panel – Optimisation Screen
HP1
F400
F401
G1
G2
G3
G4
Current flow Vs
Optimised flow
Constraints – Operation
Status
Result of Optimisation
P1
P1
Process & Utility Optimisation
4
Control Room Panel – Summary Page
Item Production (T/hr) Optimised (T/hr)HE 1 72.1 42.2HE 2 76.0 42.2HHPS letdown to HPS 20.4 1.0HPS letdown to MPS 20.2 0.9MPS letdown to LPS 23.1 1.4LPS letdown to LLPS 21.8 3.6LLPS letdown to LL condensate 32.6 11.4
Current Operation Optimised Operations Deviation(RM/hr) (RM/hr) (RM/hr)
7,818.74 7,139.07 489,359.18
Boiler 1
Utilities Cost Summary
Utilities Optimisation System
(RM/month)
Process & Utility Optimisation
4
Performance Review & Analysis - reviewing equipment performance to compare current EI to targets and perform operational adjustments
Performance Review/ Analysis
5
Example of Utilities Performance Review
Periodical Audits &
Benchm
arking Periodical A
udits & B
enchmarking
“Maintain and expand benefits”
Energy Management Strategy/ Project ManagementEnergy Management Strategy/ Project Management
Energy Energy Diagnostics/ Diagnostics/ AssessmentAssessment
Energy Energy Targets/ Targets/
KPIsKPIs Processes
People / Organization
Management
Implementation of Implementation of Energy ProjectsEnergy Projects
“Value sources” “Benefits Realisation”
Select initiatives and complete detailed design
Change management – ensure that the Management, Processes and Technologies are aligned and are in place.
Current situation identification –opportunities Potential initiatives definitionPotential benefits identification -Provide business case for selected initiatives
Complete implementation plan
Energy processes implementationSystem/ Technological implementationOrganisational initiatives implementationValue realisation – energy audit/ final diagnostic to ensure value is realised.
Rollout Energy KPIs targetsPrioritisation of Energy InitiativesWork plan definition
EMS/ Technology
Detailed Detailed work plan work plan for energy for energy initiativesinitiatives
• Energy Savings • Internal best practices identification & implementationOutcomes
Lessons Learnt – The EMS is a critical enabler when it is part of an integrated energy strategy
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