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ARC's Larry O'Brien Process Automation Presentation @ ARC Industry Forum 2010
 

ARC's Larry O'Brien Process Automation Presentation @ ARC Industry Forum 2010

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ARC's Larry O'Brien Process Automation Presentation @ ARC Industry Forum 2010 in Orlando, FL. ...

ARC's Larry O'Brien Process Automation Presentation @ ARC Industry Forum 2010 in Orlando, FL.
Using Process Automation to Optimize Energy Consumption
􀂍 The Cost of Energy
􀂍 How Well is Energy Managed in Today’s Plants?
􀂍 Using Your Process Automation Infrastructure
with an Eye Toward Optimizing Energy
Consumption
􀂍 The Business Value of Integrated Power &
Automation
􀂍 Enabling Technologies
􀂍 Training Your People and Managing Knowledge
􀂍 Moving Forward

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    ARC's Larry O'Brien Process Automation Presentation @ ARC Industry Forum 2010 ARC's Larry O'Brien Process Automation Presentation @ ARC Industry Forum 2010 Presentation Transcript

    • Using Process Automation toOptimize Energy ConsumptionUsing Process Automation toOptimize Energy Consumptionp gy pp gy pLarry O’BrienResearch DirectorARC Advisory Grouplobrien@ARCweb.com
    • OutlineOutlineThe Cost of EnergyHow Well is Energy Managed in Today’s Plants?How Well is Energy Managed in Today s Plants?Using Your Process Automation Infrastructurewith an Eye Toward Optimizing EnergyConsumptionThe Business Value of Integrated Power &AutomationAutomationEnabling TechnologiesTraining Your People and Managing KnowledgeMoving Forward2© ARC Advisory Group
    • The Cost of EnergyThe Cost of EnergyOil prices are on the way up, and are going to stay that wayPower consumption in the US has decreased, but rates continueto increase or be increasingly variable during a 24 hour periodto increase or be increasingly variable during a 24 hour periodEnergy makes stuff go. So we’re not just talking about power,and oil but also gas, steam, instrument air, water (WAGES)3© ARC Advisory Group
    • Industry and Its Role in Energy ConsumptionIndustry and Its Role in Energy ConsumptionIndustry is Number One Consumer of Total EnergyIndustry is Number Two Consumer of PowerBehind B ildingsBehind BuildingsEnergy is the second largest expense for industryexceeded only by raw materials.4© ARC Advisory Group
    • Process Industries are the Most Energy Intensive(Amount of Energy Used Per Unit of Activity)Process Industries are the Most Energy Intensive(Amount of Energy Used Per Unit of Activity)1000Industrial Energy Intensity vs. Energy ConsumptionPetroleum1000tyGDP)Energy-IntensiveIndustriesChemicalsPaperPrimaryMetalsNonmetallicMi lWoodTextiles/Apparel100IntensitdBtu/$MiningFood ProcessingMineralsTobacco/BeveragesFurnitureLeather Machinery and ComputersWoodTransportationFabricated MetalsTextiles/ApparelPlastics/RubberPrinting10EnergyhousandEnergy Consumption (Trillion Btu)Leather Machinery and ComputersElectricalPrintingMiscellaneous110 100 1000 10000(Th5© ARC Advisory GroupEnergy Consumption (Trillion Btu)Source: US Department of Energy
    • Growth in electricity Consumption Expected toSlow Due to Increased EfficiencyGrowth in electricity Consumption Expected toSlow Due to Increased Efficiency143-year rolling average percentgrowth HistoryPeriod Annual Growth1950s 9.81960s 7.3101214 1970s 4.71980s 2.91990s 2.42000-2008 0.92008-2035 1.06810Projections246-2026© ARC Advisory Group-21950 1960 1970 1980 1990 2000 2010 2020 2030
    • Where Does the Power Go?Where Does the Power Go?Process Heating (Fired Heaters) is Number OneEnergy ConsumerEnergy ConsumerMachine Drive is Number Two7© ARC Advisory GroupSource: EIA
    • The Role of Process Automation as it Relatesto Energy EfficiencyThe Role of Process Automation as it Relatesto Energy EfficiencyIn general it is not well understood.Most operators are not given the power to makeMost operators are not given the power to makeintelligent decisions about how much energy isused and where.Energy savings potential is not realized because ofembedded work practices.Nothing to measure against. Nobody has beenNothing to measure against. Nobody has beenkeeping baseline measurements.Energy efficiency alone is not enough. Energycosts are increasingly variable at different timescosts are increasingly variable at different timesof day.8© ARC Advisory Group
    • Integration of Power and Automation: BasicPremiseIntegration of Power and Automation: BasicPremiseAutomation and Electrification are Still SeparateIslands of FunctionalityIslands of FunctionalityMotor Control Centers are Also Largely SeparateOperators Have No View Into Power Side, CannotIdentify or Take Advantage of SavingsOpportunitiesFew Suppliers Offer True Capability to IntegrateFew Suppliers Offer True Capability to Integratethe Worlds of Power, Motor Controls/Drives, andAutomation Systems in a Single Environment ThatAllows End User to Make Intelligent DecisionsAllows End User to Make Intelligent DecisionsAbout Energy Management9© ARC Advisory Group
    • Using Process Automation as a Path to EnergyOptimizationUsing Process Automation as a Path to EnergyOptimizationppIntegration of various power related systems,devices, equipment, and power related data withdevices, equipment, and power related data withthe process automation systemDriven not just by functionality, but an overallstrategy to implement a collaborativestrategy to implement a collaborativemanufacturing environment with a holisticapproach to power and energy managementWork processes are essentialInformation is provided in context, to the rightpeople at the right timepeople at the right time10© ARC Advisory Group
    • Business Value of Integrated PowerManagement and Automation SystemsBusiness Value of Integrated PowerManagement and Automation SystemsIn many cases the potential savings can equal 10 percent oftotal energy consumptionAgain, value goes beyond cost of energy – integrated powerand automation gives improved visibility into entire scope ofplant operations that leads to improved early event detection,increased reliabilityincreased reliabilityIn many cases this is unexplored territory and there are a lot ofopportunities that do not immediately present themselvesLarge investments are not required to realize benefitsLarge investments are not required to realize benefits11© ARC Advisory Group
    • What technologies and methods are you using toreduce energy consumption?What technologies and methods are you using toreduce energy consumption?34% 16% 12% 9% 10% 5% 14%Control systems (58 respondents)41%62%23%16%16%7%7%9%2%4%2%2%7%4%Real-time performance management (56)Simulationor optimizationsoftware (45)40%49%26%16%10%16%10%8%2%2%2%6%2%6%6%Intelligent fielddevices (50)Decisionsupport (49)33%37%49%22%26%15%11%19%17%11%9%7%9%5%7%5%5%6%5%Variable speeddrives (54)Advanced boiler or burner controls (43)Combustion analyzers (41)63%33%18%%11%%5%% 9% 7%3%6%0% 20% 40% 60% 80% 100%Intelligent pumps (38)p ( )12© ARC Advisory Group
    • Which best describes your plant’s ability tomonitor energy usage?Which best describes your plant’s ability tomonitor energy usage?20.5%6.4% 5.1%Full automaticSemi-automatic42.3%25.6%Manual readingNoneDont know13© ARC Advisory Group
    • What percent of energy measurements are onlineand available?What percent of energy measurements are onlineand available?25 7%25 7%5%to 10%11%to 15%25.7%10.0%17.1%8.6%7.1%5.7%25.7%16%to 20%21%to 30%31%to 40%41%to 49%50%or more14© ARC Advisory Group
    • Everything in Process Automation Feeds intothe Energy Optimization EquationEverything in Process Automation Feeds intothe Energy Optimization EquationDrives and Motor ControlsProcess AutomationSystemElectricalEquipmentEnergy OptimizationEnergy OptimizationSensors andActuatorsProductionManagement15© ARC Advisory GroupOptimization, APC, Simulation
    • Integration of Electrical and ProcessAutomation Assets and Work PracticesIntegration of Electrical and ProcessAutomation Assets and Work PracticesElectricalEquipmentEnergy OptimizationEnergy Optimization16© ARC Advisory Group
    • Automation & Electrical SystemsAutomation & Electrical SystemsLong tradition ofseparate roles,separate domains in theplant, separaterequirementsBusinessSystemrequirements.Many commonalities insystem requirements:high reliability andg yavailability, safety, etc.When you look at mostpeople’s depictions of aDCS/PAS th d ’tISA S95ManufacturingWork ProcessesProductionManagementTransactions OperationsManagementDCS/PAS, they don’ttake Electrification intoaccount.Sensors, Actuators and Logical DevicesISA S88Real-TimeControl &Events17© ARC Advisory Group
    • Integrated Power and Automation is Enabledby IEC 61850Integrated Power and Automation is Enabledby IEC 61850IEC 61850 is an Ethernet based solution that hasthe capability to provide tight integration betweenthe capability to provide tight integration betweenAutomation and Power systems.IEC 61850 does for protection and processmeasurement in a substation what fieldbus ismeasurement in a substation, what fieldbus isdoing for process control and multivendor devicestandardization.Enhanced diagnostics.It’s Fieldbus for electrical!18© ARC Advisory Group
    • IEC 61850 Brings Power of Digital Networkingto Power ManagementIEC 61850 Brings Power of Digital Networkingto Power Management19© ARC Advisory Group
    • IEC 61850 Benefits, ChallengesIEC 61850 Benefits, ChallengesBenefits: Challenges:Reduced implementation time• Application Development• IntegrationIEC61850 is relatively new• Will continue to evolveProduct AvailabilityGrowing but remains somewhatReduced Wiring CostsEasier equipment upgrade• Growing, but remains somewhatlimitedIEC61850 compliance does notyet guarantee interoperability• Different interpretations of standardsby developersEasier application migrationto new technologyLess vendor lock-inby developers• Standard and product improvementsand updates are ongoingLearning curve – newtechniques and terminology• BUT long term training reduced dueBetter, more uniformengineering and tools• Standardized naming semantics• e.g. Failure analysis, maintenance,system simulations• BUT, long-term training reduced dueto common data models andcommunication techniquesNetwork design is critical• Ensure networking expertise isincluded on project teams20© ARC Advisory Groupsystem simulations included on project teams
    • Drives and Motor ControlsDrives and Motor ControlsDrives and Motor ControlsEnergy OptimizationEnergy Optimization21© ARC Advisory Group
    • Intelligent Motor Control Centers and VariableSpeed DrivesIntelligent Motor Control Centers and VariableSpeed DrivesMotors consume 64% of all power consumed inindustry.industry.Most industries can significantly reduce theirenergy costs just by addressing inefficiencies thatreside in their motor loadsreside in their motor loads.Rule of thumb: In a single year, motors canconsume up to 10 times their initial cost.22© ARC Advisory Group
    • Intelligent Motor Control Centers and VariableSpeed DrivesIntelligent Motor Control Centers and VariableSpeed DrivesSource: Schneider Electric23© ARC Advisory GroupSource: Schneider Electric
    • Fieldbus Networks for Drives and MotorControl CentersFieldbus Networks for Drives and MotorControl Centers24© ARC Advisory Group
    • Intelligent Motor Controls Example: AC Drives& Energy Savings in Pipeline ApplicationsIntelligent Motor Controls Example: AC Drives& Energy Savings in Pipeline ApplicationsIn oil and gas pipeline applications it is very common tocontrol the output of variable torque loads such as thosefound in pumps fans and blowers by throttling their input orfound in pumps, fans, and blowers by throttling their input oroutput. This method, however, is inefficientThe application of AC drives to large fans and pumps tocontrol flow by modulating their speed can producey g p psignificant energy savingsThe higher the level of motor operating time and the largerthe variation in load duty cycles, the greater the savingsOne pipeline customer expects to save $5 million annually intransportation expenses and achieve reduced pipelineshutdowns that can cost up to $750,000 per shutdown whenthe pipeline is running at full capacitythe pipeline is running at full capacity25© ARC Advisory Group
    • The Process Automation SystemThe Process Automation SystemProcess AutomationSystemEnergy OptimizationEnergy Optimization26© ARC Advisory Group
    • The DCS is the Brain of the PlantThe DCS is the Brain of the PlantThe DCS integrates with every other aspect of thesystem (instrumentation, APC and optimization,system (instrumentation, APC and optimization,drives, motor control centers, etc.)With digital networks, all automation assets in theplant can be monitored through the DCSplant can be monitored through the DCSProcedures can be scheduled for the most energyefficient times to deal with energy cost variabilityDCS operator behavior effect on energy efficiencyManaging alarms and alerts27© ARC Advisory Group
    • Do you provide console operators with energy-related KPIs?Do you provide console operators with energy-related KPIs?8.1% 1.4%None47.3%43.2%SomeMostAll28© ARC Advisory Group
    • Improving Basic Control Loop Performancecan Increase Energy EfficiencyImproving Basic Control Loop Performancecan Increase Energy EfficiencyIncreased accuracy ofmeasurement can allow forchanges in operating conditionsthat can result in energysavings.“Physically relocating a“Physically relocating ameasurement to reduce deadtime in a loop can result inimproved performance.p pFoundation Fieldbus control inthe field can provide the samebenefits in terms of lowerl t d id b ttlatency, and provide betterdiagnostics.29© ARC Advisory GroupSource: Emerson ProcessManagement
    • Sensors and ActuatorsSensors and ActuatorsEnergy OptimizationEnergy OptimizationSensors andActuators30© ARC Advisory Group
    • Intelligent Field Devices and Plant AssetManagementIntelligent Field Devices and Plant AssetManagementUse of intelligent Coriolis Meters to improvefuel gas measurement (see EmersonExample)Integrating electrical and motor controlcenters into PAM systemscenters into PAM systemsIntegrating machinery health managementAre you making the right measurements? AreAre you making the right measurements? Arethey visible?31© ARC Advisory Group
    • Vortex Flowmeters for Steam MeasurementApplicationsVortex Flowmeters for Steam MeasurementApplicationsExpected benefits of using the vortex flowmeter in steammeasurement processes include:Reduced piping and wiring costs up to 1/3 of orificeReduced sealing points up to 1/10 of orifice from theviewpoint of ISO14000Good accuracy 3 times as orifice for process noise proof andprecise cost calculationLow pressure loss 1/3 of orifice for influence decrease on thed f iprocess and for energy saving32© ARC Advisory Group
    • Optimization, APC, SimulationOptimization, APC, SimulationEnergy OptimizationEnergy Optimization33© ARC Advisory GroupOptimization, APC, Simulation
    • MPC Drivers40%1st 2nd 3rd0%10%20%30%HistoricalDrivers30%40%1st 2nd 3rdCurrent0%10%20%Drivers34© ARC Advisory Group
    • Optimization, Simulation, Process ModelingOptimization, Simulation, Process ModelingCoordinated control between assets (boilers, turbinesand other equipment)Allocate loading of boilers and turbines for optimumtig poperationsDevelop process models• So that the control strategies “know” each asset, what they’recapable of, and how they interact with each otherFeed steam and electricity use information to the plantenergy system for predictive controlEstablish automated, real-time connections withelectricity providersy p• To include electricity buy and sell factors into the energymanagement modelsAdjust process setpoints to least, but safe, costImplement Tie-Line ControlImplement Tie Line Control• For prioritized load shedding and purchased power optimization• Real-time price schedules35© ARC Advisory GroupSource: Emerson ProcessManagement
    • How Optimization and APC Results in EnergySavingsHow Optimization and APC Results in EnergySavingsLoop optimization study at Lubrizol Deer Parkp p yfacility resulted in $45,000 per year energysavings in 2004 dollars.36© ARC Advisory Group
    • APC Provides Energy Efficiency for Pulp MillAPC Provides Energy Efficiency for Pulp MillThe recovery boiler in a pulp mill is a dynamic process andsensitive to disturbances and instability caused by a varietyof reasons, such as the varying quality of black liquor, loadchanges, and different operating methods. Obviously,improving the operation and efficiency of a recovery boilerimproving the operation and efficiency of a recovery boilerwill have a substantial impact on a mill’s overall operationsand finally the mill’s bottom line.A pulp mill in India realized a saving of more than $60,000p p g $ ,per year with a payback period of 1.15 years only becausethey deployed advanced technology though plant was alreadycontrolled by DCS. The oxygen level which was varyingbetween 3 0 - 8 0 percent earlier confined to 3 - 3 6 percentbetween 3.0 - 8.0 percent earlier confined to 3 - 3.6 percentpost APC installation. This improved the thermal efficiency,resulting in reduced purchase of coal steam and stable boileroperation.37© ARC Advisory Group
    • Production ManagementProduction ManagementEnergy OptimizationEnergy OptimizationProductionManagement38© ARC Advisory Group
    • Major Refiner Implements OperationsManagement Platform to Save $$$Major Refiner Implements OperationsManagement Platform to Save $$$Major refiner draws process water from a nearby river to producet i t t t ti d t ti th l fsteam in two steam stations and an automatic thermal reformer(ATR) area that is used for internal and external consumerconsumption.As the demand for coal decreased and imported natural gasincreased, steam demand declined, shifting the strategy frommaximizing output to minimizing cost.Steam stations are contractually obligated to operate with 160 tonsper hour of spare steam, which is approximately equal to the steamper hour of spare steam, which is approximately equal to the steamoutput from one boiler. If plants cannot meet the demand for steam,they must reduce supply to the electrical generation customers, whobuy electricity directly from the grid.Implementation of performance measures and good baseline withImplementation of performance measures and good baseline withoperations management system, taking data from multiple DCSs.39© ARC Advisory Group
    • Refiner Implements Operations ManagementPlatformRefiner Implements Operations ManagementPlatformSavings of 6% in energy and 4% in electricitycosts within the first monthSaved $400,000 (USD) within the first 2 monthsfrom two out of the five targeted plants and over$1M during the course of the year$ du g e cou se o e yeaOver 2% reduction in variable costs associatedwith energy feedstocks and electricity40© ARC Advisory Group
    • Knowledge Management IssuesKnowledge Management IssuesMore information for the operatorpMore information for MaintenanceHow to use this information effectively?Do you have an accurate picture of yourplant’s energy usage?D h th i h tiDo you have the in house expertisenecessary to provide you with a goodbaseline?Work practices must be changed to adapt41© ARC Advisory Group
    • Thank YouThank YouFor more information, contact the author atlobrien@arcweb.comor visit our web pages at www arcweb com42© ARC Advisory Groupor visit our web pages at www.arcweb.com