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

»Back to correction page

Mass Balance Module

2

»Back to – EMS MC page

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

»Back to – EMS MC page

KPI Calculation & Monitoring

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

CDU Review/ Analysis

Performance Review/ Analysis

5

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

Thank You