Haytham Amin May Energy Management & Beyond Maximize your plant energy efficiency by deploying "Quick Win" solutions

Transcription

1 Haytham Amin May 2017 Energy Management & Beyond Maximize your plant energy efficiency by deploying "Quick Win" solutions

2 1 Objectives Solution Landscape Engagement Model

3 Objectives 2

4 Performance Organization Health Modernization Program Initiatives 3 Investment Attraction Structuring Reform People Agenda Streamline current concession processes and expand concession agreement portfolio Create single SOE coverage across the value chain, and rationalize portfolio of both operations and companies involved in the Egyptian industry Introduce comprehensive talent management system and redeploy people to drive efficiency 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 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 2016 by Honeywell International Inc. All rights reserved

5 Process Optimization & Energy Efficiency Downstream 4 Process Performance Maximize yield Reduce specific raw material consumption Minimize waste Minimize Energy Cost Real-time optimization Demand forecasting Utility production planning Equipment Performance Maximize equipment efficiency Early detection of faults Energy Efficiency Minimize specific energy consumption Reduce emissions Performance Management Continuous monitoring of Key Performance Indicators (KPIs) Economic indicators of improvements and deviations Collaboration platform across entities to streamline data flow 2016 by Honeywell International Inc. All rights reserved

6 Honeywell proposition 5 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 2016 by Honeywell International Inc. All rights reserved

7 6 Solution Landscape

8 Business Processes Utility Plant Set points objectives Utilities Scheduling Current objectives Real-Time Optimization & Control Set points objectives Scheduling targets Production Scheduling weekly Current objectives Energy & Process Monitoring Business targets Production Planning Process Plant(s)

9 Utilities Scheduling 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.

10 Utilities Scheduling Power demand Refining & Petrochemicals Management System (LP Models) Power price Cooling demand Gas price Steam demand CASE I CASE II CHP2_1 CHP1_1 elin_ CHP2_1 CHP1_1 elin_ Purchased power Gas Turbine 1 generation Gas Turbine 2 generation

11 Optimal Schedule for Boilers Static optimizer results determines a production schedule in the neighborhood of maximal system efficiency, disregarding costs of unit starts. Complex unstable situation switching cannot be resolved by operators optimally Boilers operation B4_1 B3_1 B2_1 B1_ VERA Optimizer results VERA recommends realistic solutions that include start-up costs and optimize fuel selection. Inappropriate unit switching does not happen. B4_1 B3_1 B2_1 B1_ Optimal schedule is realistic and immediately applicable

12 Utilities Modelling Plant scheme Software model

13 Business Processes Utility Plant Set points objectives Utilities Scheduling Current objectives Real-Time Optimization & Control Set points objectives Scheduling targets Production Scheduling weekly Current objectives Energy & Process Monitoring Business targets Production Planning Process Plant(s)

14 Utilities Real-Time Optimization drive energy efficiency 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

15 Utilities Real-Time Optimization 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 Advanced predictive control to stabilize steam pressure Guarantees continuous balance between produced and consumed steam TRGO ELA Real-time power generation vs consumption monitoring Total generation prediction and trajectory optimization Real-time Optimization of power generation Economic load allocation for overall demands Optimal schedule to meet demands at lowest cost Ensures economically efficient operations

16 Water SP Fuel ELA-B Total fuel demand Fuel Water SP Steam temp/flow 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 MPC fuel demand Steam pressure / steam flow from Hp header ACC optimizer ACC A/F coordinator O 2, CO, NO x Air & Fuel Air & Fuel SP ATC - Adjust combustion air to maintain the optimal air/fuel ratio trajectory computed by ACC optimizer ATC Ratio optimized for max combustion efficiency while keeping risks of exceeding emission limits small fuel demand ACC optimizer A/F ACC O 2, CO, NO x Air & Fuel coordinator

17 Noticeable Transformation Utilities Optimization 16 Air/Fuel ratio histogram, representing boiler combustion quality BEFORE AFTER

18 Steam flow Industrial Power AES Master Pressure Control - MPC - Control steam networks balances + estimate unknown disturbances Economic Load Allocation - ELA - Steam/Power optimization Cases Produce planned energy with minimum costs Maximize energy production Under constraints Produce given process steam and planned MWe with minimum costs Maximize MWe while process steam demand satisfied Optimum allocation A B C D Total steam flow

19 Real-Time Process Optimization 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

20 Layered Optimization SS Model Profit Bridge PVO OBJECTIVE FUNCTION {PRODUCT VALUES, FEED COSTS, ENERGY COSTS, FEED LIMITS} Profit Optimizer Planning & Scheduling Furnace 1 Profit Controller Furnace 6 Profit Controller DC1 Profit Controller DC2 Profit Controller DC3 Profit Controller C2S Profit Controller C3S Profit Controller Process

21 Business Processes Utility Plant Set points objectives Utilities Scheduling Current objectives Real-Time Optimization & Control Set points objectives Scheduling targets Production Scheduling weekly Current objectives Energy & Process Monitoring Business targets Production Planning Process Plant(s)

22 Process & Energy Monitoring 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

23 Static Targets vs. Dynamic Targets You could do better! Really? Good job! Not really 2016 by Honeywell International Inc. All rights reserved. False targets won t take you to right objectives Green.. actuals Red... static target (Statistical) Blue... dynamic target (Dynamic)

24 What Calculations are needed? 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 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

25 Units and Equipment Models

26 Real-time Monitoring 25 Embedded Performance Trend Trends Equipment Status Displays 2016 by Honeywell International Inc. All rights reserved

27 Real-time vs. Ad-hoc 26 Manually Search & Collect Tag, Lab & Other Data Cumbersome Isolated Tools Excel & Other Tools Manual Periodic Calculations Informal Work Processes Reports Tag Name XUTT901.PV XUTT902.PV Tag Desc. HE91 Shell In Temp HE91 Shell Out Temp Blind Spots Time Consuming 2016 by Honeywell International Inc. All rights reserved T1 T2 T3 Missed Opportunities Difficult to Sustain 91.4 Varied Approaches & Results Silos of Information Labor Intensive / Periodic / Informal

28 27 AND BEYOND? 2016 by Honeywell International Inc. All rights reserved

29 Business Processes Utility Plant Set points objectives Utilities Scheduling Current objectives Enterprise Performance Monitoring Real-Time Optimization & Control Set points objectives Scheduling targets Production Scheduling weekly Current objectives Energy & Process Monitoring Engineering Management Collaboration Across Functions Operations Business targets Production Planning Maintenance & Reliability Process Plant(s)

30 Enterprise KPI Management Vision KPI Categories Safety Operations Reliability Financial KPI Number lost time accidents Number environmental issues Unit effectiveness Unit material balance APC constraints at limit Critical process parameters Alarm rate Category HSE HSE Operations Operations Operations Operations Operations Goals Strategies Objectives KPIs Metrics Actions Energy Emissions Personnel Unplanned downtime Operating envelope exceptions Variable cost Energy/ton of product Reliability Reliability Financial Energy Heater efficiency Energy Quality giveaway Quality Comprehensive metrics management solution drives actions!

31 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

32 31 Engagement Model

33 SMART Approach Replicate Common Standard Across Enterprise Optimization across all Sites Site Functional Excellence Corporate Roll-out 2015 by Honeywell International Inc. All rights reserved. Additional Disclaimers As Needed (Consult Legal) Moving the needle via enterprise optimization

34 How we Deliver Phase 1 Vision & Concept Phase 2 Discovery Process & Opportunity Assessment Phase 3 Quick Wins (Low/No Cost Opportunities) Phase 4 Program Execution Phase 5 Life Cycle Management Validate Program objectives Developing top KPIs that would be the main success criteria Defining competency management framework required to support the vision Identify, quantify (ROI) specific opportunities Develop an ROI Based Deployment Road-map Develop solution, KPI driven execution plan, organization teams for deployment. Review/update business processes (BPM) Deployment of technology with transformed work processes Facilitate Change management Program management to monitor progress, track benefits Develop a Support model (remote, site visits) to assist in ensuring continued business results Scheduled audits/reviews of KPI Performance based support models

35 34 Objectives Solution Landscape Engagement Model

36 Digital Transformation to help improve performance, availability, reliability and safety by Honeywell International Inc. All rights reserved