Finding Benefits.pdf

7/30/2019 Finding Benefits.pdf

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Finding Benefits by Modeling and

Optimizing Steam and Power SystemsBennie Jones, INEOS

David Nelson, Visual MESA, LLC

Steam System

Improvements


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Overview

Visual MESA

INEOS Chocolate Bayou

Chocolate Bayou Visual MESA Users

Examples

Operational Changes

User Interface

Conclusions


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Visual MESA

What is Visual MESA?

Components

FeaturesHistory


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What is Visual MESA?

Computer Modeling Program

Models steam, BFW, condensate, fuel,and electrical systems

Online Program Utilizes live plant data

MESA Utility System Models andOptimizer

Integrates MESA with Microsoft Visio andMicrosoft Excel to Form a CompleteEnergy Management Package


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Visual MESA

ComponentsThe Calculation Core: MESA

Models the steam system As Is

Non-linear equipment and

thermodynamics

Includes all common unit operations

Boilers, gas turbines, steam turbines,

etc

90 companies, including several

engineering companies

200 sites


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Visual MESA

ComponentsThe Interface: Microsoft Visio

Easy to learn

Simple and standard graphic interface

Real-time data access

The Reports: Microsoft Excel

Easy to use

Numerous capabilities Easy to share


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Visual MESA Features

Monitoring

Optimization

What-If?

Case StudiesAuditing and Accounting


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Visual MESA History

1983 1992 MESA developed by Steve Delk

Steve models hundreds of plants and develops modelingtools dedicated and optimized for utility systems

1993 1996 Chevron adopted MESA and deployed it at refineries Built Version 1 of the graphically-based Visual MESA

Steve Delk added optimization

1997 2006 Nelson & Roseme, Inc. founded

Nelson & Roseme, Inc. and MESA Co. operate as one

company 2003 2005

Visual MESA rewritten

2006 Visual MESA, LLC formed


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Visual MESA

Installations

53 Gas Turbines ModeledTotal Sites38

1 ChemicalEastman Chemical1

1 RefineryCytec1

5 Refinery/ChemicalRepsol5

1 RefinerySunoco1

1 ChemicalDow Chemical1

1 RefineryIrving Oil1

1 Gas PlantAramco1

1 ChemicalRohm & Haas1

9 Closed LoopRefining Co./Chem Co.10

2 Refineries/ChemicalConocoPhillips2

1 ASU/CogenAir Liquide1

1 RefineryValero1

3 Refineries, 1 ChemicalShell/Equilon/Motiva4

1 RefineryMarathon/Ashland1

1 ChemicalINEOS1

1 Refinery, 1 ChemicalBP1

4 Refineries, 1 ChemicalChevron/Texaco5

CommentsCompany# of Sites


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INEOS Chocolate Bayou

Formerly BP

Chemicals

2 Olefins Units

3 Polypropylene

Units


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Steam System

Overview Four Steam Levels

High-high pressure

High pressure

Medium pressure Low pressure

Generation from Waste Heat, Boilers andCogen

Due to Nature of Processes, Uses SteamTurbines as Pump or Compressor Drives

Numerous Turbine/Motor Pumps toConsider


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Chocolate Bayou

VM Users Primary Users

Shift Supervisors

Site Energy Manager

Secondary Users

Site Engineers

Site Management

WTL/Foreman in Utilities - Boiler area


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Shift Supervisors

Responsible for Site-Wide Operations

Main Day-to-Day User

Coordinates implementation of plan with

unit Team Leaders

Boiler/HRSG loading

Turbine loading to avoid over condensing

Switchable (turbine or motor) pump

selection


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Shift Supervisors

Provide a Single Point of Focus and Site-Wide Understanding

Help avoid sub-optimizing the site as a

whole by moves that benefit individualprocess plants

Utilize Web-Based Report Generated byVisual MESA and Accessible Throughoutthe Site

Distribute recommendations and help allplant personnel understand the currentrecommended operation


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Site Energy Manager

Responsible for Overall Site Energy

Consumption, Balancing and

Development/Implementation of Energy

Improvement Projects

Uses VM to Identify Changes in

Operational Philosophy and Capital

Projects

Saves energy at the site


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Examples of

Operational Changes Identify Key Steam Turbines to be

Replaced with Motor Drives

Due to site venting issues

Where turbines were driven by medium-

pressure steam that was effectively

letdown from the super high-pressure

systems


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Examples of

Operational ChangesUnderstand How to Operate an Older

Cogeneration Unit

Despite a perceived high efficiency,

identified as actually the least efficientincremental steam producer on the site


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User Interface

Graphics of Entire System

Excel Reports


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OSBL 900

0

OF2-FLARE

OF1-FLARE

50LB-VENT

POLYMERS

UTILITIESMISC-LOAD

REPORT-COLLECTORS

1%

TANK-FARM

OLEFINS-1

BFW-WATER-TREAT

SSHTOLEFINS-2

S

F

FF


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Model Status 2: GOOD SOLUTION: SQP STOP DUE TO FRACTIONAL CHANGE IN OBJECTIVE FN

Model Last Ran 12:23:25 11/13/2006

Current Cost Optimized Cost Savings7,000 6,800 200 /hr

2,400 /shift4,800 /day

Current

PP2 10PP3 0PP4 0Olefins #1 0Olefins #2 15Total 25

Current Steam Make Optimized Steam Make DeltaCogen 220 171 -49DB-901A 220 120 -100

DB-901B 134 120 -14DB-901C 0 0 0

DDB-901A 78 180 102DDB-901B 87 128 41

Total 739 718 -21

Steam System Optimization Summary

eam ow o are r

os ummary r

Fired Steam Make (klb/hr)


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Conclusions

Visual MESA Success at INEOS

Chocolate Bayou

Optimization and Management of the Site

Steam System

Shift Supervisors and Site Energy

Manager are Main Users of System on a

Short and Long-Term Basis

Documents

Finding Benefits.pdf