Plant Energy Conservation by Cloud Computing & Data Analysis

Transcription

1 Plant Energy Conservation by Cloud Computing & Data Analysis January 29, 2013 Yokogawa Electric Corporation

2 Table of Contents 1. Introduction of Yokogawa 2. Introduction of the previous best practices Green IT initiative Introduction of the target company Schedule overview 2012 program contents Summary Contact information All Rights Reserved, Copyright GIPC

3 Introduction of Yokogawa Name: Yokogawa Electric Corporation Our goal: Contribute to society through broad-ranging activities in the area of Measurement, Control and Information Operation Efficiency Improvement Software/Solutions ERP Advanced Process Control Software/solutions MES Plant Information Management System Subsidiaries/Affiliates: 89 in 55 countries (19 in Japan, 70 outside Japan) Advanced PLC Distributed Control System Control System & Field devices Asset Diagnostics Software/Solutions Employees: Overseas affiliates 10,036 As of March, 2012 Global Total 19,437 Yokogawa Electric Japan 4,211 Japan affiliates 5,190 Safety system Digital Sensing Technology Process Analyzers A large range of green products lineups Sustainable synergy Network-based control system Installed nearly 24,000 control systems All Rights Reserved, Copyright GIPC 2013 A suite of solution services for continual improvement of plant productivity and energy efficiency 2

4 All Rights Reserved, Copyright GIPC 2013 What is VigilantPlant Services? Help customers to realize VigilantPlant by improving the effectiveness of automation systems/products over the entire plant lifecycle Provided based on a solution approach in consideration of the current stage of each client s continuous improvement programs Plant Decommissioning Operation Plant Lifecycle Plant Expansion System Migration Plant Construction Operation Opportunity Identification Services TM Identify new improvement possibilities & prepare for solution implementation Solution Implementation Services TM Implement identified solution based on a best practice Lifecycle Effectiveness Services TM Sustain the effectiveness of implemented solution through plant lifecycle

5 VPS for Energy Conservation Opportunity Identification Visualization by EnPIs monitoring, Comparison & Further drilling down, taking measures Analysis & Simulation Analyze data, find opportunity, improvement planning, benefit simulation Gas Heavy oil Energy Monitoring System - For Entire Plant Data Drilling Down Energy Monitoring System - For Process Units Utility Section Plant wide utility optimization Data Energysupplying Energyreceiving Electricity Steam W ater Drilling Down Production Section Asset management & maintenance Production /Operation/ Quality Solution Implementation Implement New function, retuning, Control system modification Operation & Maintenance Keep benefit, Verification of the result All Rights Reserved, Copyright GIPC 2013 Wide variety of green products Systems/Packages for Solution Implementation Other Products Lineups Power Plant APC BTG Optimization Energy conservation master planning Asset Performance Improvement Plant Remote Analysis Lifecycle Effectiveness Services Regulatory Control Stabilization Furnace Efficiency Improvement Other Solutions Lineups 4

6 Regulatory Control Stabilization Example 1.1 How stable operation contributes Energy Conservation 1Retuning of PID parameters DCS Process Variables Deviation=SV-PV PV SV(Set Point) Cnt l MV Set Point (Before) SV Deviation 1 PID Cnt l Parameters Control Loop Point (After) Constraints 2Reduced Point Lower Energy2Set Additional Space Process Time Control Variable Manipulated Variable Field Instruments Energy Saving by RCS All Rights Reserved, Copyright GIPC

7 Regulatory Control Stabilization Example 1.2 A study of energy saving in a steel company in China Oscillations suppressed to 1/16 Enabling Energy Conservation by set point changes After Before SV Change Before Optimization After Potential for energy saving Economical impacts Expected Savings Test Plant (1 line) As COG 569,400 Nm 3 /y Potential (30 lines) 17,082,000 Nm 3 /y 14,519.7 t-co 2 /y COG: 0.85t-CO2/1,000Nm 3 (METI Guideline) Even a small step, impacts are large All Rights Reserved, Copyright GIPC

8 Asset Performance Diagnostics Example 2.1 Clear path to CBM(Condition based maintenance) Issues: As no heat performance monitoring tools are available for hundreds of heat exchangers, maintenance targets and timings are listed up only on human experiences(tbm=time based maintenance) Solutions: Energy condition monitoring and analysis using asset performance diagnostics technology Heat exchanger Heat exchanger(hex)diagnostics system All Rights Reserved, Copyright GIPC

9 Asset Performance Diagnostics Example 2.2 Future condition and best maintenance timings of four target HEXs were precisely forecasted using 1.5 year past data with advanced curve fitting technology for accurate predictions (=CBM) Energy efficiency improvement (= Energy saving) HEX pumping power saving HEX heat transfer efficiency improvement Extraction of plant wide bad acting HEXs Fig-1: Heat transfer efficiency deterioration by fouling Heat transfer efficiency Current HEX performance Operation cycle Cleaned Difference of energy consumption Not Cleaned Time Turn around All Rights Reserved, Copyright GIPC 2013 Turn around Advanced curve fitting technology 8

10 Furnace Decoking Optimization Example 3.1 Naphtha flow Exhaust CO2 density Raw materials are supplied to metal tube. Cokes are stacked at inner tube wall as production goes by and it deteriorate heat transfer efficiency, then finally tube metal temperature (TMT) reaches to the mechanical limit. 6 paths Dilution steam flow Air (For decoking) 6 paths 6 paths Ambient temperature Tube metal temperature 6 paths/ 24 tubes Olefins (Ethylene, propylene, etc) Coil inlet temperature Coil inlet pressure Furnace pressure Furnace temperature Hence periodic De-coking is performed every 45 days by stopping the furnace. Decoking furnace is stopped but the plant is kept operating. Combustion air Fuel gas Released at decoking Coil outlet temperature Coil outlet pressure All Rights Reserved, Copyright GIPC 2013

11 Furnace Decoking Optimization Example 3.2 A study to reduce energy usage by the improvement of asset performance in a petrochemical company in Thailand Solutions: Energy condition monitoring and analysis using asset performance diagnostics technology Targets Ethylene cracking furnace coking tubes conditions (Fig-2) Actions Optimized utility supply for decoking process as per the coke level of each coil tube Relatively clean tubes Before Moderate dirty tubes Dirty tubes Moderately dirty tubes All Rights Reserved, Copyright GIPC 2013 Steam and air flow If coking tube dirtiness is measured, then Energy conservation by variable steam feed would be available Worst 5 severely coking tubes Coking severity indices were measured using statistical diagnostics system Relatively clean tubes Moderate dirty tubes After Dirty tubes Moderately dirty tubes Steam and air flow Coiltubes Coiltubes 10

12 Green IT Initiative 2012 Application of emerging IT technology (Cloud Computing) Opportunity identification of cloud computing applications Implementation of applications and demonstration Application of advanced analytical technology Opportunity identification of advanced plant analytical tools Implementation of analytical tools to actual plant operation analysis Energy Consumption Production volume Energy Consumption Production volume Reduction All Rights Reserved, Copyright GIPC

13 Introduction of the Target Company Target company: A company in process industry (Oil and Gas) that has centralized engineering organization lots of travels for data monitoring and analysis are required between the center and the sites item Overview Target company Time of survey Company overview A June, 2012 Dec, 2012 A company that operates process plants in Malaysia All Rights Reserved, Copyright GIPC

14 Schedule Overview Calendar Fiscal Year 2012 May to Sep Oct Nov Dec Jan Feb Mar Item Jan 29 Seminar Presentation Selection of Target Co Company Visit 6/26 ~ 30 Cloud Tool Development Data Collection & Analysis Site Visit for Analysis Interim Reporting 12/3 7 Final Report Preparation Final Report Submission Financial $ Project Report All Rights Reserved, Copyright GIPC

15 Project Outline Remote Monitoring and Analysis of Plant Operation by Utilizing Cloud Technology Energy saving on travels for site visit Process Analysis for Identifying Energy Saving Opportunities All Rights Reserved, Copyright GIPC

16 Cloud Computing Architecture Authentication by live ID Hybrid Cloud Model where Applications reside in the cloud and the database is hosted privately Cloud Data Center Cloud Applications 3 rd Party Consultants Customer Engineers Engineering Center File server Process Data All Rights Reserved, Copyright GIPC

17 Process Analytical Tools - Development - Step 1- Preparation Step 2- Verification Step 3- Implementation Planning of analysis tools Develop prototypes Functional tests Connectivity tests Other crucial tests Trial run at sites Customization The following products and tools have been developed and/or customized - Plant Wide Oscillation (Loop oscillation analysis) - (Loop diagnostics) - (Alarm & event analyzer for cloud) - Process analyzer (Statistical data analysis) - ^ (Loop tuning simulator) All Rights Reserved, Copyright GIPC

18 Process Analytical Tools - Features - Yokogawa Analyzer Client Unit: comparing trend charts of multi process variables. Good tool to analyze temporal behavior of variables Statistical Analyzer: PPCL s C Visual Explorer (CVE) provides a graphical representation of multi variables. Good tool to identify correlations between variables All Rights Reserved, Copyright GIPC

19 Identified Opportunities for CO2 Reduction Reduction of business travels of engineers A company has centered engineers for servicing many sites by minimum engineers Engineers at the center travels back and forth with sites distributed in the country for process monitoring and analysis as much as 1000 man-times/year In cloud environment engineers can analyze plant operation in remote without limitations of time and place as if they are sitting at the site Reduction of process steam consumption Process analysis revealed variation in steam consumption at the one process unit 20% of steam consumption could be saved by reducing the flow as low as its minimum requirement All Rights Reserved, Copyright GIPC

20 Potential Energy Saving and CO2 Reduction The identified potential reduction of CO2 emission by the proposed schemes is about 3,000 ton-co2 per year CO2 emission reduced by the proposed scheme Result details Reduction Proposal Fuel Energy (KL/Y) CO2 eq. (ton/y) Monetary Effect (MYR/US$) Cloud K / 130K Process 1,000 2,700 4M / 1.3M Reduction (%) All Rights Reserved, Copyright GIPC

21 Summary Cloud computing can trim unnecessary travels of customer engineers Security of data is still a major concern for a customer Needs more applications as SaaS to attract customers Cloud computing makes it easier for 3 rd party consultants such as Yokogawa to analyze plant data from remote place Powerful process analytical tools are very effective for identifying process improvement opportunities Full lineup of tools for analyzing process dynamics is preferable The government should stimulate private sectors for promoting energy saving by incentives All Rights Reserved, Copyright GIPC

22 Contact Information Yokogawa Electric Corporation: Nakacho, Musashino, Tokyo , Japan TEL: Yokogawa Electric (Malaysia) Sdn. Bhd.: No. 9 Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, Puchong Selangor Darul Ehsan, Malaysia TEL: All Rights Reserved, Copyright GIPC