Energy Solutions - Meeting the Energy Efficiency Challenge Steve Offer

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”

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

“ ” “

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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.