Maximize your plant energy efficiency by deploying "Quick Win" solutions

Energy Management & BeyondHaytham Amin

15-17 May 2017

1

Solution

Landscape

Objectives

Engagement

Model

Objectives

2

Modernization Program Initiatives

3

© 2016 by Honeywell International Inc. All rights reserved

Streamline current concession processes and

expand concession agreement portfolio

Investment

Attraction

Structuring

Reform

Create single SOE coverage across the value chain,

and rationalize portfolio of both operations and

companies involved in the Egyptian industry

People AgendaIntroduce comprehensive talent management

system and redeploy people to drive efficiency

Downstream

Optimize downstream and petrochemical sourcing,

output and mass balancing. Drive operations

performance transformation

Upstream Drive operations performance transformation

Regional Oil &

Gas Hub

Optimizing and leveraging existing oil and gas

transport and storage infrastructure

The country’s vision is for the oil

and gas sector to continuously

unlock the sector’s full value

chain potential as a growth and a

sustainable development engine

for Egypt to achieve financial

sustainability, become regional

oil and gas hub and a role model

for the future of modernized

Egypt by 2021

Org

aniz

ation H

ealth

Perf

orm

ance

Process Optimization & Energy Efficiency – Downstream

4

© 2016 by Honeywell International Inc. All rights reserved

Process Performance

Maximize yield

Reduce specific raw material consumption

Minimize waste

Minimize Energy Cost

Real-time optimization

Demand forecasting

Utility production planning

Performance Management

Continuous monitoring of Key Performance Indicators (KPIs)

Economic indicators of improvements and deviations

Collaboration platform across entities to streamline data flow

Energy Efficiency

Minimize specific energy consumption

Reduce emissions

Equipment Performance

Maximize equipment efficiency

Early detection of faults

Honeywell proposition

5

© 2016 by Honeywell International Inc. All rights reserved

• Our value proposition

- focus on Process Performance & Energy Efficiency

• Objective

- implementing low cost solution in short time period with significant ROI

• Approach

- based on technology deployment of predictive controls and not mechanical modifications

• Result in

- quick wins that build the trust to the leadership and provides funding for further improvements

Solution

Landscape

6

Business Processes

Utilities

Scheduling

Production

Planning

Real-Time

Optimization

& Control Production

Scheduling

weekly

Business targets

Scheduling targets

Utility Plant

Process Plant(s)

Energy

& Process

Monitoring

Current objectives

Set pointsobjectives

Set pointsobjectives

Current objectives

• OFF LINE optimizer for industrial power

plant (MINLP Solver)

- Resource allocation planning

fuel, equipment

- Optimal plant configuration planning

Boilers, Turbines, Feed pumps

- Optimal production planning

Electricity, Export steam

• Find and plan the best plant configuration

for forecasted steam demand and power

production.

Utilities Scheduling

Utilities Scheduling

Cooling demand

Power demand

Steam demand

Refining & Petrochemicals Management System (LP Models)Power price

Gas price

0

200

400

600

800

1000

1200

1400

1600

1800

2000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

CHP2_1

CHP1_1

elin_1

CASE I

0

200

400

600

800

1000

1200

1400

1600

1800

2000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

CHP2_1

CHP1_1

elin_1

CASE II

Gas Turbine 2 generation

Purchased power

Gas Turbine 1 generation

0

100

200

300

400

500

600

1 25 49 73

B4_1

B3_1

B2_1

B1_1

Static optimizer resultsdetermines a production schedule in the neighborhood of maximal system efficiency, disregarding costs of unit starts.

0

100

200

300

400

500

600

1 25 49 73

B4_1

B3_1

B2_1

B1_1

VERA Optimizer resultsVERA recommends realistic solutions that include start-up costs and optimize fuel selection.Inappropriate unit switching does not happen.

Complex unstable situation –switching cannot be resolved

by operators optimally

Optimal schedule is realistic and immediately

applicable

Boilers operation

Optimal Schedule for Boilers

Utilities Modelling

Plant scheme

Software model

Business Processes

Utilities

Scheduling

Production

Planning

Real-Time

Optimization

& Control Production

Scheduling

weekly

Business targets

Scheduling targets

Utility Plant

Process Plant(s)

Energy

& Process

Monitoring

Current objectives

Set pointsobjectives

Set pointsobjectives

Current objectives

• ON LINE closed loop optimization for

industrial power plant

- Advanced Process Control (specially built for

IPP)

- Optimization in real time under constraints for

given plant configuration

- Continuous balance between produced vs.

consumed utilities

- Reduce fuel consumption

- Stabilize emissions

• Economic optimization to minimize

production cost and maximize profit

Utilities Real-Time Optimization – drive energy efficiency

Utilities Real-Time Optimization

• Economic load allocation for overall demands

• Optimal schedule to meet demands at lowest cost

• Ensures economically efficient operations

• Real-time power generation vs consumption monitoring

• Total generation prediction and trajectory optimization

• Real-time Optimization of power generation

• Advanced predictive control to stabilize steam pressure

• Guarantees continuous balance between produced and consumed steam

• Advanced control of combustion process

• Tightly control fuel and air ratio

• Multiple fuel co-firing

• Reduces fuel consumption & stabilizes emissions within given limits

ACC MPC

ELATRGO

Advanced Combustion Controller - ACC

• Objectives:

- Closely follow the released heat/fuel

demand trajectory computed by ELA

Needed for maintaining stable steam

pressure

Released heat demand replaces fuel

demand for multi-fuel boilers and for

CFB boilers

- Adjust combustion air to maintain the

optimal air/fuel ratio trajectory

computed by ACC optimizer

Ratio optimized for max combustion

efficiency while keeping risks of

exceeding emission limits small

EL

A-B

ACC

coordinator

ACC

optimizer

MPC

ACC

coordinator

ACC

optimizer

ATC

ATC

To

tal fu

el

de

ma

nd

Steam pressure /

steam flow from Hp header

fuel

demand

fuel

demand

O2, CO, NOx

O2, CO, NOx

A/F

A/F

Air & Fuel SP

Air & Fuel

Air & Fuel

Fu

el

Fu

el

Wate

r

SP

Wate

r

SP

Ste

am

tem

p/f

low

Noticeable Transformation – Utilities Optimization

16

Air/Fuel ratio histogram, representing boiler combustion quality

BEFOREAFTER

Industrial Power AES

• Master Pressure Control - MPC

- Control steam networks balances + estimate

unknown disturbances

• Economic Load Allocation - ELA

- Steam/Power optimization

Produce planned energy with minimum costs

Maximize energy production

Under constraints

• Cases

Produce given process steam and planned

MWe with minimum costs

Maximize MWe while process steam demand

satisfied

90 100 110 120 130 140 150 160 170 180

20

25

30

35

40

45

50

Total steam flow

Ste

am

flo

w

Optimum allocation

A

B

C

D

• ON LINE closed loop optimization for

process plants

- Advanced Process Control techniques

- Maximize Yields

- Minimize specific consumptions of raw

materials

- Energy duty optimization

• Optimal compromise between yield

maximization vs. energy consumption

Real-Time Process Optimization

Layered Optimization

Profit Optimizer

Process

PVO OBJECTIVE FUNCTION

{PRODUCT VALUES, FEED COSTS, ENERGY COSTS, FEED LIMITS}

SS

Model

Profit

Bridge

Planning &

Scheduling

Furnace 6

Profit Controller

DC1

Profit Controller

DC2

Profit Controller

DC3

Profit Controller

C2S

Profit Controller

C3S

Profit Controller

Furnace 1

Profit Controller

Business Processes

Utilities

Scheduling

Production

Planning

Real-Time

Optimization

& Control Production

Scheduling

weekly

Business targets

Scheduling targets

Utility Plant

Process Plant(s)

Energy

& Process

Monitoring

Current objectives

Set pointsobjectives

Set pointsobjectives

Current objectives

• ON LINE real-time energy and process

efficiency monitoring

- Unified environment for Energy & Process

monitoring

- Identifying issues and opportunities as they

happen

- Detailed equipment monitoring to identify

reason for inefficiencies

- Monitoring your performance against

Dynamic targets

• Generating process intelligence & using

that intelligence to make effective decisions

Process & Energy Monitoring

© 2016 by Honeywell International Inc. All rights reserved.

Static Targets vs. Dynamic Targets

False targets won’t take you to right objectives

You could do better!Good job!Really…?Not really…

Green….. actuals

Red ........ static target (Statistical)

Blue ....... dynamic target (Dynamic)

Calculate actual energy use per unit/equipment (KEIs)

Calculate Tons or Steam/T production; GJ fuel/T production and MW Power /T production

Breakdown according to major units or items of equipment

Also calculate dynamic efficiency targets to provide guidance

Dynamic efficiency targets that help identify when and where Energy targets is being in deviation

Examples include targets for Excess Air; Stack Temp; Overflash; Reflux Ratio; Col Pressure; Off-gas vent; recycle ratio, etc

What Calculations are needed?

Refinery

Crude Unit FCCU Reformer

Preheat Furnace Tower

Fuel Steam Power KEIs

Furnace Inlet Temp

Furnace Excess Air

Furnace Efficiency

Furnace Stack Temp

Furnace Outlet Temp

Fuel LHV

Units and Equipment Models

Real-time Monitoring

25

© 2016 by Honeywell International Inc. All rights reserved

Embedded TrendPerformance Trends Equipment Status Displays

Labor Intensive / Periodic / Informal

Real-time vs. Ad-hoc

26

Tag, Lab & Other Data Reports

Tag Name Tag Desc.XUTT901.PV HE91 Shell In Temp

XUTT902.PV HE91 Shell Out Temp

Excel & Other Tools

Manually Search & Collect

Cumbersome Isolated Tools

Manual Periodic

Calculations

Informal Work Processes

T1 T2 T3

Blind Spots

Time Consuming Missed Opportunities

Difficult to Sustain

Varied Approaches & Results

Silos of Information

86.19

88

91.4

© 2016 by Honeywell International Inc. All rights reserved

27

© 2016 by Honeywell International Inc. All rights reserved

… AND BEYOND?

Enterprise Performance Monitoring

Business Processes

CollaborationAcross Functions

Management

Maintenance & Reliability

OperationsEngineering

Utilities

Scheduling

Production

Planning

Real-Time

Optimization

& Control Production

Scheduling

weekly

Business targets

Scheduling targets

Utility Plant

Process Plant(s)

Energy

& Process

Monitoring

Current objectives

Set pointsobjectives

Set pointsobjectives

Current objectives

Comprehensive metrics management solution drives actions!

Enterprise KPI Management

KPI Category

Number lost time accidents HSE

Number environmental issues HSE

Unit effectiveness Operations

Unit material balance Operations

APC constraints at limit Operations

Critical process parameters Operations

Alarm rate Operations

Unplanned downtime Reliability

Operating envelope exceptions Reliability

Variable cost Financial

Energy/ton of product Energy

Heater efficiency Energy

Quality giveaway Quality

KPI Categories

Safety

Operations

Reliability

Financial

Energy

Emissions

Personnel

Vision

Goals

Strategies

Objectives

KPIs

Metrics

Actions

Enterprise Dashboards

Rich and Interactive Dashboards

• Quickly perform data exploration, analysis and

visualization through highly performant

dashboards

• Advanced analytics with hierarchies and time

dimensions enabling powerful drill-downs and

multi-dimensional analysis

• Enable situational awareness using mobility

Engagement

Model

31

© 2015 by Honeywell International Inc. All rights reserved.

Additional Disclaimers As Needed (Consult Legal)

Replicate Common Standard Across Enterprise

Moving the needle via enterprise optimization

Optimization

across all Sites

Site Functional

Excellence

Corporate Roll-out

SMART Approach

How we Deliver

Validate Program

objectives

Developing top KPIs that

would be the main

success criteria

Defining competency

management framework

required to support the

vision

Phase 1Vision & Concept

Identify, quantify (ROI)

specific opportunities

Develop an ROI Based

Deployment Road-map

Phase 2Discovery Process &

Opportunity

Assessment

Develop solution, KPI

driven execution plan,

organization teams for

deployment.

Review/update business

processes (BPM)

Phase 3Quick Wins

(Low/No Cost

Opportunities)

Deployment of

technology with

transformed work

processes

Facilitate Change

management

Program management to

monitor progress, track

benefits

Phase 4Program Execution

Develop a Support

model (remote, site

visits) to assist in

ensuring continued

business results

Scheduled

audits/reviews of KPI

Performance based

support models

Phase 5Life Cycle

Management

34

Solution

Landscape

Objectives

Engagement

Model

© 2016 by Honeywell International Inc. All rights reserved

Digital Transformation to help improve

performance, availability, reliability and safety.

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