energy solutions - meeting the energy efficiency …...slide 2 ” energy facts and challenges “...
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Energy Solutions - Meeting the Energy Efficiency Challenge Steve Offer
slide 2
”
Energy Facts and Challenges
“ For some, energy costs constitute more than 25 percent of their total operating costs, and even small improvements can have a dramatic impact on their bottom line. Control Global Magazine ” The EU imports 66% of all natural gas consumed and
42% of solid fuels. The total EU energy bill for 2013 amounted to €400B. EU Parliament report 2014
“ EU Energy Efficiency Directive is targeting 1.5% energy savings per EU member countries. Applied to the Process Industries this amounts to €1.4B/year energy savings. until 2020 EU Energy Efficiency Directive 2011/172 ”
Typical refinery costs: 16% manpower, 41% maintenance and raw materials, 43% energy costs National Energy Education Development Project
“ ” “
slide 3
European Legislation Driving Energy Efficiency
Source: JRC, Axens, Europia, Envir Agency
Emissions 20%
Efficiency 20%
Renewable 20%
European Climate Change Policy (ECCP)
ETS Phase III (2013-20) Emissions Trading
Scheme
EED Energy Efficiency
Directive
Cap & Trade System, EU set to drive carbon pricing from €6to € 20/tonne 2020 1.74%/yr Cap reduction 40% carbon allowances to be purchased
Legally binding energy efficiency measures. Covers energy transformation, distribution & consumption. Req energy audit every 4 yrs (apply to >€50M/250+ employees) Implementation of y-o-y energy saving projects
EU CO2 Reduction Targets 20% by 2020 40% by 2030 80-95% by 2050
slide 4
NL Medium size company Emission Trading Scheme Analysis
ETS Phase 3 •Effective July 1, 2013 •1.74% Cap reduction each year from 2013-2020 •40% FY15 allowences to be purchased rising to 80% by 2020 •900 Million allowances less
Until 2013, the ETS was an additional revenue stream, going forward this will be a burden, if they do nothing
slide 5
Implement an Energy Management System
Energy Management System Team
headed by Energy Manager
Energy Improvement Opportunities
Programs & Projects
Energy Policy Determine
Plan & Goals
Energy Monitoring and
Reporting Energy Management Information System
Energy Management Processes and
Procedures
Energy Management System
EU Directives Encourage Implementation of Energy Management System (EMS)
http://emersonprocess.com/EEDUserGuide
slide 6
What is Energy Management?
Energy Monitoring, & Reporting
Energy Management Information System
Energy Flow Measurements
Energy Savings Reporting
Energy Accounting and Billing (cost allocation)
Energy Loss Measurement & Detection
Energy Improvement
Opportunities. Energy Saving projects.
Best Available Technologies
Implement Best Practices
Energy Saving opportunities e.g. Process Optimisation
Performance Monitoring e.g. EAM, GPA, APM
Standard Operating Procedure Amendment
Delivering Sustainable Energy Efficiency
Visibility Control
Energy Management
slide 7
What is Energy Management: Reporting
Energy Monitoring, & Reporting
Energy Management Information System
Energy Savings Reporting
Energy Flow Measurements
Energy Accounting and Billing (Cost Allocation)
Energy Loss Measurement and Detection
Energy Improvement
Opportunities. Energy Saving projects.
Best Available Technologies
Implement Best Practices
Energy Saving opportunities Asset Optimisation etc
Performance Monitoring EAM, GPA, APM etc
Standard Operating Procedure Amendment Control
Energy Management
slide 8
Get the Full Energy Picture - Real Time Energy Advisor
Detect abnormal changes in energy performance to trigger corrective action real time
Identify opportunities to understand periods of best performance and make actions repeatable
Move from reactive to proactive energy management
Understand WHY energy consumption is not as expected using Dynamic Energy Targets: 1st Principle Models, Regression Analysis
Choose the level 1
Report type 2
Time-frame 3
Generate 4
Generate Powerful Analytic Reports Identify and monitor Energy Saving Projects
Role based KPI’s to drive decision making & culture
slide 9
Energy Measurement Best Practices Energy Flow Measurements and Losses
Best practice measurement technology for Energy Stream
Minimize Permanent pressure loss and installation cost
WirelessHart enabled Energy flow measurement acquisition
Primary Fuel Energy Content Analysis
Fiscal Accounting Improved Quality Finished Product
Energy consumption monitoring kWh, kVAh
Monitor Unit Health
Full range of CT sensors
Energy Fluids Measurment
Electrical Energy Measurment Energy Content Measurement
Stack Heat Loss Measurement
Final Product Heat Measurement Accreditation DIN EN 17025 Air and Water coolers Losses
Energy Loss Measurement
Emerson Climate Technologies
slide 10
Energy Measurement Surveys Mass & Energy Balances
Energy Measurements in place providing cost effective energy management insight Project Management Documentation Review Operating Data Review Current Instrumentation Review Additional Instrumentation Recommendation Additional Instrumentation Costing Survey Report Methodology to determine effective energy measurement for Real time monitoring is essential
Missing Measurements
Balance Model Offline/Online monitoring tool Identify actual energy consumption vs design Causes for discrepancy Actions (cures) leading to energy savings
Mass & Energy Balances
slide 11
What is Energy Management: Energy Savings
Energy Monitoring & Reporting
Energy Management Information System
Energy Flow Measurements
Energy Savings Reporting
Emissions Monitoring
Energy Loss Detection
Energy Improvement
Opportunities. Energy Saving projects.
Best Available Technologies
Implement Best Practices
Energy Saving opportunities e.g. Process Optimisation
Performance Monitoring e.g. EAM, GPA, APM
Standard Operating Procedure Amendment Visibility
Energy Management
slide 12
Operate at Economical Best Point
How Do Energy Saving Projects Deliver Results?
MAN AUTO
Automate Operation
Improved Regulatory Control
Control Audits, Loop Tuning
Model Predictive Control
Process Stabilization
Less Energy Consumed
Economical Operation
Increased Throughput
Improved Product
Quality
Value & Benefits
Best Practice
Reduce Variability
Best Practice
Best Available Technology
slide 13
Energy Performance Improvement - Powerhouse Power House Energy
(Producer)
Combustion Control
Multi-fuel, Combustion
Economic Dispatch Steam & Electricity
Optimisation, Boiler, Header, Soot Blowing
Governor Control & Optimisation
BMS
CEMS
Water Treatment
Boiler Efficiency
Steam Leaks
Overall Utility Optimised Power & Energy Management
Reliable Burner Management Eliminate False Trips
Automatic Header Control, Responsive steam delivery, >MW
Increase Use of Cost Effective Alternative Fuels
Boiler Optimal Performance
slide 14
Our Customers Have Improved Powerhouse Response, Stability and Performance
• HRSG boiler part of Cogen (2 x GT’s) supplies steam to manufacturing plant
• Standalone operation NG only, performance variability and poor efficiency.
• Emerson established full automatic
control, improved speed of load response, and increased boiler efficiency by 2.7%
• (2) multi-fuel wood boilers and coal boiler
• Unit interaction made powerhouse unstable and difficult to run
• Coal used to manage demand swings
• Emerson greatly improved boiler turndown and overall stability while reducing coal use by 5 tons/day
EUR Packaging Plant NA Pulp Mill EUR Steel Mill
• (7) multi-fuel boilers, (8) steam turbines, (5) steam headers
• Gas, COG, and BFG • Constant reliability issues and
frequent unplanned shutdowns
• Emerson established full automatic control, trips virtually eliminated, and negated use of Natural Gas (pilots only) to balance the boilers
Improved Boiler Efficiency
Cascade trips eliminated
Boiler stability improved Natural Gas eliminated
slide 15
Energy Performance Improvement - Process
Process Energy (Consumer)
Optimisation Distillation etc
Model Predictive Control
Regulatory Control and Energy Audit
Adaptive tuning
Control Strategy Design
Inferential Measurement
Load management
Load Balancing
Steam Leaks
Improved Product Quality
Increased Product Throughput
Optimised Energy Efficiency
Reduced Process Fluctuations
Steady state control Improved Reliability
slide 16
Our Customers Have Lowered Energy Costs, Increased Throughput and Product Quality
Lower Energy and Process Variability
Reduced Fuel Consumed Aromatics
Crude Unit profitability Improvement
• 2 processing trains, each consisting 3 distillation columns & fired heaters
• Significant manual control • Issues with product quality due to control variability.
• Emerson Advanced Loop Services optimized reflux ratios, reduced process variability by 84%, increased product quality & reduced energy consumption by 47%
• Need to improve variable cost performance of Aromatics
• Reduce process variability (improve product quality) through improved control stability
• Through Emerson DeltaV Advanced Process Control variability considerably reduced saving 20% energy on Aromatics plant €2.1M/year
• Crude Unit Fractionator and Fired Heater performance dependant on operator intervention
• Limited throughput and constrained separation
• Emerson optimization using MPC maximized unit, lowered utilities energy consumption and increased profitability by €750K/year
MOL Gas Processing Hungary GALP Refinery Portugal Rompetrol Refinery Romania
Advanced Loop Services Advanced Process Control Advanced Process Control
slide 17
CDU Control Objectives and Scope
Fired Heater Vacuum Tower
Atmospheric Tower Fired Heaters
Crude Feed
Gas
Naphtha
Kerosene
Lt Diesel
Diesel
AGO
To Vacuum System
LVGO
HVGO
Residue
Stripping Tower
Steam Steam
Steam
Steam
Steam
Steam
1. Maximize Throughput
1
2
3
3
4 4
2. Maximize value of product recovery
3. Maximize heat Recovery
4. Maximize heater efficiency
slide 18
CDU Control Design
Vacuum Tower Atmospheric Tower
Crude Feed
Naphtha
Kerosene
Lt Diesel
Diesel
AGO
To Vacuum System
LVGO
HVGO
Residue
Stripping Tower
Steam Steam
Steam
Steam
Steam
Steam
T
T
T
T
T
F
F
F
F
F
F
F
F
F F
T T
Fuel F
HV
F F
T T
F
F F
T T
O2
F F
T T
F
F
F
F
T
T
T
T F
F
F
F
F L
L
L
L
FBP
IBP FBP
IBP
Cong. D360
T
T
P
P
Flood
O Flash
Flood
T P
Interactions Disturbances Long Time to
Steady State Optimization
Why Use MPC? Gas
F F
D360
O2
O2
HV Fuel
F
Air F
CO
CO T
Fired Heaters
Fired Heater F
HV Fuel
T
P
P
slide 19
APC 2 (4x4)
APC 4 (11 x 11)
CDU Control Design
APC 5 (6x6)
APC 3 (5x5)
APC 1 (3x3)
Vacuum Tower Atmospheric Tower
Crude Feed
Naphtha
Kerosene
Lt Diesel
Diesel
AGO
LVGO
HVGO Stripping Tower
Steam Steam
Steam
Steam
Steam
Steam
T
T
T
T
T
F
F
F
F
F
F
F
F
F F
T T
Fuel F
HV
F F
T T
F F
F T
T
O2
F F
T T
F
F
F
F
T
T
T
T F
F
F
F
F L
L
L
L
FBP
IBP FBP
IBP
Cong. D360
T
T
P
P
Flood
O Flash
Flood
T P
Gas
F F
D360
O2
O2
HV Fuel
F
Air F
CO
CO
T
Fired Heaters Fired Heater
F HV Fuel
T
P
P
slide 20
CDU Control Design (Atm Section)
C1: MPC4
H2: MPC2
H1: MPC1
Outlet Temperature
Total C1 Flow
O2 Outlet Temperature
O2
Manipulated Variables 3 Pump Around Flow Rates 4 Product Flow Rates Reflux Drum Pressure Base Steam Ratio
Pass 1 Flow Rate
Pass 2 Flow Rate
Fuel Pressure
Air Flow Rate
Pass 1 Flow Rate
Pass 2 Flow Rate
Fuel Pressure
C2 Base Level
Base Steam Ratio
4 Product Flow Rates
AUTO RCAS
AUTO RCAS
AUTO RCAS
Top Pressure
4 Pressure Corrected Temperatures
dT dT
Control Variables
Control Variables
Manipulated Variables
slide 21
CDU Control Design (Vacuum Section) C5: MPC5
H3: MPC3
Outlet Temperature
Manipulated Variables Recycle Flow 2 Pump Around Flows Quench Flow
4 Pass Flow Rates
Fuel Pressure
C1 Base Level
Average Feed Temperature
4 Pressure Corrected Temperatures
AUTO RCAS
Total C5 Feed Flow
AUTO RCAS
Control Variables
Manipulated Variables
Control Variables
slide 22
Benefits Audit (Summary) Compare before and after operating periods
Crude throughput constrained by downstream units!
Increased production of more valuable products for a given feed rate
Improved heater efficiency by a significant amount
Quantified benefits: – Audited project benefit of US $1.8m (3-month
payback) Non-Quantified Benefits:
– Reduced operator actions – Better response to disturbances such as crude
changes
slide 23
Benefits Audit (Details) Quantified benefits (Column):
– Reduced giveaway of valuable product into AGO stream
– Quantified benefit: • US$ 1.79 million / year
Quantified benefits (Heaters): – Improved efficiency due to
• Pass balancing • Improved excess O2 control
– Quantified benefit: • US$ 103,000 / year
Payback Time: – 3 months
slide 24
Real-time visibility into the health of critical steam traps Fast and easy to install & maintain
– No training required; no calibration – Non-intrusive steel band mounting – No downtime or risk to the process – Set & forget 10+ year battery
Pressure Relief Valve & Steam Trap Monitoring
The first audit showed 25% of steam traps were failing, that were unknown. Payback in one year in energy savings by correcting issue.
Continually reduce environmental impact by reducing energy usage, but unable to determine how much energy they were wasting.
Fluor Global Services
CHALLENGE Monitoring of 187 steam traps and 63 pressure relief valves to ensure proper operation, avoiding equipment damage and wasted energy via lost steam.
SOLUTION RESULTS
Energy Loss Pressure (Bar)
Connection Size
Orifice Diameter
(mm) 3 7 10 20 35 50
DN15 (1/2”) 3 €1,767 €3,134 €4,500 €8,598 €14,062 €20,893 DN20 (3/4”) 5 €4,910 €8,705 €12,499 €23,883 €39,062 €58,034 DN25 (1”) 7.5 €11,048 €19,585 €28,123 €53,737 €87,888 €130,577
DN32 (1¼”) 9 €15,037 €26,657 €38,279 €73,142 €119,625 €177,730 DN40 (1½”) 10 €19,639 €34,818 €49,997 €95,531 €156,245 €232,138 DN50 (2”) 12.5 €30,687 €54,403 €78,120 €149,268 €244,133 €362,715
slide 25
Energy Management System Overview
Emerson Energy Management System
DCS1 DCS2 DCS3 DCSn …
OSI PI
Energy Management Information System
Energy Advisor KPI Monitoring & Reporting Over consumption alarming
Target Calculation and Comparison
Utilities Plant Optimizer
Dynamic Models
Calculation of optimal operating status and setpoints for utilities
equipment
Energy Management System
• Comprises two modules
• Energy Advisor (EMIS)
• Open Loop or Closed Loop Optimisor
APC within DeltaV or Pwr Optimisor
• Based on existing OSI PI historian
• Each system inter dependant
• Utilises collective measurement
data and respective energy
calculations
• Energy Advisor level 3 MES layer
• Optimiser between level 2&3
• Closed loop optimiser Level 2 Chemical and Refining Industries
slide 26
Building the Business Case
Process: • Identify areas of high energy usage
• Perform an evaluation (data gathering)
• Develop a detailed business case • Recommendations
• Cost savings
• Investment required
• ROI and IRR
• Additional benefits (availability, product quality
improvements)
• Implementation
• Measure effectiveness
Collaborative Approach
slide 27
What is Energy Management?
Energy Monitoring, & Reporting
Energy Management Information System
Energy Flow Measurements
Energy Savings Reporting
Energy Accounting and Billing (cost allocation)
Energy Loss Measurement & Detection
Energy Improvement
Opportunities. Energy Saving projects.
Best Available Technologies
Implement Best Practices
Energy Saving opportunities e.g. Process Optimisation
Performance Monitoring e.g. EAM, GPA, APM
Standard Operating Procedure Amendment
Delivering Sustainable Energy Efficiency
Energy Management
slide 28
Emerson Energy Management Solutions
ENERGY CONSULTACY SERVICE
• Energy saving Evaluations and Studies, investment
justifications and ROI
• Mass and Energy Balances
• Utilization of Best practices and Best available technologies
Delivering Energy Efficiency
Emerson Energy Consultancy, Services and Solutions Deliver Significant Sustainable Energy Efficiency savings,
compliance to energy legislation and an increased bottom line
LEGISLATION COMPLIANCE FULL ENERGY PICTURE
ENERGY SAVING SOLUTIONS
• Making the Emissions Trading Scheme work for you, Additional Revenue Stream
• Compliance with the Energy Efficiency Directive • ISO 50001 implementation consultancy • Energy Efficiency Roadmaps to Achieve Corporate Energy Objectives
• Energy Management Monitoring and Reporting accessible by all = energy culture • Pervasive sensing, cost effective implementation of additional
missing energy measurements and Leak Detection
• Instrument Surveys • Instrument Application Best practice
• Boiler Combustion, Powerhouse Optimization and Coordinated Dispatch • Process Energy Improvements, improved Reliability, increased Production Throughput, utilizing Advanced Loop Tuning services and Model Predictive Control
ENERGY MANAGEMENT
Energy specialists. Perceptive technology. Proven advantage.