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30 July 2015 1PROPRIETARY INFORMATION
We are waiting on others to join. Thank you for your patience!
The webinar will begi...
Before We Begin…
> This webinar is being recorded for future reference.
> Questions can be asked in the chat box and will ...
© 2015 KBC Advanced Technologies plc. All Rights Reserved.
Benefits of Modelling Steam &
Power Systems
KBC Webinar
30 July...
Agenda
• Introduction
• Modelling
• What needs to be included?
• What can we do with it?
• Hidden benefits?
• On-line opti...
Steam and Power Systems
> Energy is typically highest controllable cost in process plants
> Steam and power systems offer ...
Typical Steam and Power System
> Boilers
> WHBs
> Headers
> Consumers
> Steam
Turbines
> Gas turbines
> Letdowns
> Flash d...
What Needs to be Modelled?
> Boilers
– Excess air, stack temperature, efficiency, blowdown
– Optimise use of boilers
> Ste...
What Needs to be Modelled?- Modelling Boiler House Area
30 July 2015 PROPRIETARY INFORMATION 8
What Needs to be Modelled? - Modelling Process Units Area
30 July 2015 PROPRIETARY INFORMATION 9
Things You Can Do with a Model
> Rigorous heat balances
around headers
> Multiple scenarios (fixed
power generation, seaso...
Things You Can Do with a Model (cont’d)
30 July 2015 PROPRIETARY INFORMATION 11
Offline Study
Models
Efficiency Studies
Ev...
Hidden Benefits of Developing a Model
30 July 2015 PROPRIETARY INFORMATION 12
> During Building Stage
– Better understandi...
Selecting the Modelling Approach
30 July 2015 PROPRIETARY INFORMATION 13
KBC’s Modelling Products
30 July 2015 PROPRIETARY INFORMATION 14
ProSteam
Excel Add-In
Any size model from 1 piece
of equi...
Expected Benefits
30 July 2015 PROPRIETARY INFORMATION 15
Case Study: Ethylene Complex
30 July 2015 PROPRIETARY INFORMATION 16
Case Study: Complex-wide Utility System Optimisation
30 July 2015 PROPRIETARY INFORMATION 17
Case Study: Petrochemical Site
30 July 2015 PROPRIETARY INFORMATION 18
Closing
> Questions?
> Future webinar topics in energy:
– Review of utility-related equipment in Petro-SIM v6 and ProSteam...
Questions
> Can you elaborate on what type of projects you expect to find when you talk about 2 to 4%
operational savings?...
Questions (cont’d)
> How many man hours were spent creating the model on
Slide 18?
– It varies from site to site, but typi...
Questions (cont’d)
> you mentioned that a significant amount of savings can be
achieved by an off-line model, so, when wou...
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KBC IoE Webinar - Benefits of Modelling Steam and Power Systems

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During this webinar, KBC discusses the benefits of modelling steam and power systems.

The webinar discussion includes:
• Components of a typical steam system
• What needs to be included on a steam model?
• Benefits of having a steam model
• Modelling approaches to get the best results from your steam model
• Case Studies

Although a site may already be effectively managed by equipped staff, or seem too simple to benefit from modelling its utility (steam) system, the truth is there is always something that isn’t being considered and complexities of the site are often underestimated. If we consider all factors that affect the running of a utility system, such as planned and unplanned process changes, seasonal variations, equipment constraints (e.g. boiler and turbine limits), changing fuel costs and availability, complex power tariff structures, etc., it becomes clear that, without the proper tools, finding the best operating mode at any time is a daunting task.

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KBC IoE Webinar - Benefits of Modelling Steam and Power Systems

  1. 1. 30 July 2015 1PROPRIETARY INFORMATION We are waiting on others to join. Thank you for your patience! The webinar will begin shortly.
  2. 2. Before We Begin… > This webinar is being recorded for future reference. > Questions can be asked in the chat box and will be answered at the end during Q&A. > An email will be sent within 24 hours with download details of the webinar materials. 30 July 2015 PROPRIETARY INFORMATION 2
  3. 3. © 2015 KBC Advanced Technologies plc. All Rights Reserved. Benefits of Modelling Steam & Power Systems KBC Webinar 30 July 2015
  4. 4. Agenda • Introduction • Modelling • What needs to be included? • What can we do with it? • Hidden benefits? • On-line optimiser vs off-line modelling • Typical benefits • Case Studies 30 July 2015 4PROPRIETARY INFORMATION
  5. 5. Steam and Power Systems > Energy is typically highest controllable cost in process plants > Steam and power systems offer great scope for energy saving – These systems are large consumers of energy and have many degrees of operational freedom: – Typically 2-4% can be saved without capital investment • They need to be optimised on a daily basis. – Typically 50% of a site’s gap to “Best Technology” Energy performance is attributable to utility system • Energy projects in utilities can lead to dramatic savings > Steam and power generation are inseparably linked – Because all on-site power is produced either in steam turbines, or in gas turbines that are, generally, attached to the steam system – This interaction must be modelled accurately to take advantage of the synergies 30 July 2015 PROPRIETARY INFORMATION 5
  6. 6. Typical Steam and Power System > Boilers > WHBs > Headers > Consumers > Steam Turbines > Gas turbines > Letdowns > Flash drums > Deaerators 30 July 2015 PROPRIETARY INFORMATION 6
  7. 7. What Needs to be Modelled? > Boilers – Excess air, stack temperature, efficiency, blowdown – Optimise use of boilers > Steam header conditions (reflecting system layout) > Steam turbines – Isentropic efficiency – Optimise the use of turbines • Which turbines to run? • motor/turbine flexibility. > Power generation and its efficiency – Mostly in order to maximise backpressure power > Other system components – Deaerators, flash drums, condensate return > System controls – Actual marginal mechanisms • Enables calculation of steam values 30 July 2015 PROPRIETARY INFORMATION 7
  8. 8. What Needs to be Modelled?- Modelling Boiler House Area 30 July 2015 PROPRIETARY INFORMATION 8
  9. 9. What Needs to be Modelled? - Modelling Process Units Area 30 July 2015 PROPRIETARY INFORMATION 9
  10. 10. Things You Can Do with a Model > Rigorous heat balances around headers > Multiple scenarios (fixed power generation, seasonal variations) > Additional logic, for example, to use the most efficient equipment > Operating curves for turbines, boilers, etc. > Gas turbine models > Optimisation > Models can be set up to use real time plant data > Key Performance Indicators sent back to plant data historian. 30 July 2015 PROPRIETARY INFORMATION 10
  11. 11. Things You Can Do with a Model (cont’d) 30 July 2015 PROPRIETARY INFORMATION 11 Offline Study Models Efficiency Studies Evaluate Energy Saving Options (what-if) Predict future steam/fuel/power scenarios Back of Envelope Calculations Energy Balances Determine steam marginal value Training On-Line Monitoring & Optimisation Equipment Monitoring KPI Generation & Tracking (incl. lost opportunity cost) Real Time Optimisation Performance Reporting & Dashboards Design Size New Equipment Evaluate Multiple Design Cases Configuration Decisions Hydraulics
  12. 12. Hidden Benefits of Developing a Model 30 July 2015 PROPRIETARY INFORMATION 12 > During Building Stage – Better understanding of the utility system for operators and engineers • Connectivities and interactions • Operating strategies – Quick-win ideas usually come to light during this review
  13. 13. Selecting the Modelling Approach 30 July 2015 PROPRIETARY INFORMATION 13
  14. 14. KBC’s Modelling Products 30 July 2015 PROPRIETARY INFORMATION 14 ProSteam Excel Add-In Any size model from 1 piece of equipment to whole site Custom and flexible header logic (built by user) Freeform Models Connection to data historian can be created Energy-SIM Based on Prosteam Functions Standard, Structured Workbook - maintainable Standard performance reports Databridge and SQL database for data handling Corporate Viewer In-built Logic Petro-SIM V6 Rigorous GT Model Process & Utility in 1 Single Model Hydraulics can be added (Maximus, Network Solver) Easy to connect to data historian
  15. 15. Expected Benefits 30 July 2015 PROPRIETARY INFORMATION 15
  16. 16. Case Study: Ethylene Complex 30 July 2015 PROPRIETARY INFORMATION 16
  17. 17. Case Study: Complex-wide Utility System Optimisation 30 July 2015 PROPRIETARY INFORMATION 17
  18. 18. Case Study: Petrochemical Site 30 July 2015 PROPRIETARY INFORMATION 18
  19. 19. Closing > Questions? > Future webinar topics in energy: – Review of utility-related equipment in Petro-SIM v6 and ProSteam – Steam modelling in Petro-SIM v6 and ProSteam – Energy-SIM demonstration – HX Monitor and fouling studies – Dashboards – Using the data from your historian in your model – Petro-SIM GT model > We welcome suggestions for future topics – please email kbc-marketing@kbcat.com > Next webinar information will go out shortly. > Thank you for joining us! 30 July 2015 PROPRIETARY INFORMATION 19
  20. 20. Questions > Can you elaborate on what type of projects you expect to find when you talk about 2 to 4% operational savings? It depends on the site, but I would expect projects such as: – Switching turbines if a letdown is more than the minimum required – Try and reducing power generation of condensing turbines and to review the vacuum level that is achieved – Try to maximise steam generation on GT’s HRSGs (if available) – Whether or not you should import or export power will depend on the power tariff (it might be profitable to export power during the day and import power at night), with a model you will be able to establish the optimum operation and how the balance will look like – Also, you can review benefits of changing your deaerator pressure. Typically you would try to reduce it, but in some cases you might want to increase it. For instance if you are venting steam – if there is a vent on LP, on top of the changing pressure of deaerators, another option you can look at is to decrease the pressure of the LP header, in this way the turbines will need less steam to generate the required power and this will reduce the excess steam These are the kind of projects you can easily spot during the review and analyse once you have a model 30 July 2015 PROPRIETARY INFORMATION 20
  21. 21. Questions (cont’d) > How many man hours were spent creating the model on Slide 18? – It varies from site to site, but typically ~2months for an off-line model and between 6 to 9 months for a full blown optimiser > My question is about heat losses in pipes – the steam used in the turbines needs to be superheated in order to avoid condensing in the turbine. Does the model make any calcs regarding the heat losses in the pipes? – It can be done, but the logic (heat losses, pressure losses) has to be defined by the user 30 July 2015 PROPRIETARY INFORMATION 21
  22. 22. Questions (cont’d) > you mentioned that a significant amount of savings can be achieved by an off-line model, so, when would you suggest using an on-line optimiser? In our opinion an optimiser is mainly needed when there are frequent and significant variations to steam demand/generation, or very complex power tariffs, like the type we find in places like Japan; where prices change not just per time of the day, but day of the week, seasonal, etc. In these cases an optimiser would make sense as it would, otherwise, be very difficult to establish an action plan for all situations beforehand. 30 July 2015 PROPRIETARY INFORMATION 22

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