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An introduction to energy management

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An introduction to energy management

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An introduction to energy management

  1. 1. KBC/Petronas Technology Session and Round Table Workshop Proprietary Information 16-17th January 2018 Confidential Information An Introduction to Energy Management What’s new in KBC Carlos Ruiz, Product Manager Energy Management Visual MESA carlos.ruiz@kbcat.com
  2. 2. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Agenda • Introduction • Visual MESA Energy Management System (VM-EMS) Applications • Visual MESA EMS Architecture: traditional versus integrating supply & demand • Visual MESA EMS functionalities description • Visual MESA Demonstration • Case Studies
  3. 3. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESATechnologies • VISUAL MESA Energy Management System (EMS) Real time online energy and emissions Management System that assists companies in their SEP/ISO 50001 initiatives  VM-ERTO: Real Time, Mixed Integer Non Linear Optimization, either open loop or closed loop  VM-EM: Energy Key Performance Indicators Calculation and Monitoring, including emissions  VM-EMPO: Optimal Energy Systems Multi-Period Planning • VISUAL MESA Hydrocarbon Management Solutions (HMS)  VM-PA: Next generation of Production / Yield Accounting and Data Reconciliation system which assists users with the calculation of their site-wide daily mass balances, on a tank-by- tank and unit-by-unit level. It serves as the foundation of the facility’s loss control initiatives  VM-SCS: Hybrid continuous and discrete events simulation application to support the management of operations in refinery and petrochemical processes. It provides future visibility thorough detailed simulation models of both logistic and unit operations, keeping constantly updated projections of inventories and material properties
  4. 4. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 AComplete Solution for Energy Optimisation Supply Re-UseDemand Energy CO2 Utilities System 1981-1989 MESA Simulator 1992-1998 G2-MESA Visual MESA (VM-ERTO) 1998-2000 Closed Loop optimization (VM- ECLRTO) 2000-2012 Fuels Hydrogen UI & Excel Energy KPIs 2012-Present Web Browser Client Multi Period Optimization (VM-EMPO) Energy Balances and EnKPIs Dashboarding (VM-EM)Superior energy optimization technology Over 90 installed real time optimizers Heat Recovery 1984-1986 Linnhoff March Pinch Consulting 1986-2011 SuperTarget pinch software TotalSite 1991-1997 ProSteam released 1998-2012 HX Monitor within Petro-SIM 4.1 2016-Present Petro-SIM 6.2 Fully integrated process +utility modelling BT correlations Energy recovery & heat exchange consulting and software Linnhoff March acquired by KBC in 2002 Over 1000 energy consulting studies Process Units1979-1988 KBC yield & energy studies 1988-1998 Petrofine Profimatics simulation software 1998-2004 HYSYS. refinery collaboration Petro-SIM launched 2004-2016 TTS acquisition human performance improvement 2016-Present Petro-SIM 6 launched Maximus pipeline simulator Infochem thermo- dynamics Process and energy consulting and software, underpinned by human performance improvement
  5. 5. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 1981-1989 MESA Simulator 1989-1992 MESA with SQP and MI Optimizer 1992-1998 G2-MESA Visual MESA (VM-ERTO) 1998-2000 Closed Loop ERTO and Cogeneration Modeling (VM-ECLRTO) 2000-2003 Fuel Systems and Emissions calculations 2003-2006 Microsoft Visio based GUI and MS Excel reporting 2006-2008 Energy Key Performance Indicators (EnKPIs) Plant Energy Cost Block 2008-2010 Applied to Ethanol Production 2010-2012 Applied to District Cooling and Heating Applied to Hydrogen Systems 2012-present Internet Web Browser Client Multi Period Optimization (VM-EMPO) Energy Balances and EnKPIs Dashboarding (VM-EM) VM-ERTO VM-ECLRTO VM-EMPO VM-EM Modular Energy System Analyzer Visual MESAEMS Timeline: VM-ERTO, VM-ECLRTO, VM-EM and VM-EMPO
  6. 6. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEnergy Management System Applications Visual MESA EMS Suite VM-ERTO VM-ECLRTO VM-EMVM-EMPO VM-ERTO / ECLRTO VM-EM VM-EMPO Visual MESA Energy Monitor offers a feature set specifically built for the monitoring of energy systems (KPIs Calculation, balances, etc.) Visual MESA Energy Real Time Optimizer (open or closed loop) is the leading real-time solution for modeling and optimization of energy systems Visual MESA Energy Multi-Period Optimizer is the energy management tool for the optimal planning and scheduling of utility assets
  7. 7. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS Overview • Leading Real-Time EMS solution for Modeling, Monitoring, Optimization and Planning of steam/water, fuel/emissions, power and hydrogen systems  Ability to quickly configure mass and energy balance models  Mature models and solution engine  Simple, graphical interface to construct energy models • Mature modeling and industry leading real time optimization engine  Robust real-time modeling and optimization  Real-time calculation server supporting closed-loop  Appropriate data error handling  Easy/fast connection to real-time data via OPC • Easy to use, graphical interface – Web GUI and MS Visio  Windows service, web browser based GUI (thin client)
  8. 8. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 External Utilities Contracts Emissions Regulations Hydrogen Fuel Steam Water Electricity Energy and Utilities System Measurements Optimum Set Points CLOSED-LOOP signals to control systems OPEN-LOOP advisory reports to operators Control System / Historian Operators Process (Utilities Consumers and Generators) (Degrees of freedom in Generation and Distribution) Optimum Energy System Operatio n Report Optimum Energy System Operation Report VM-Energy Real Time Optimizer / VM-Energy CLRTO Traditional Architecture
  9. 9. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 External Utilities Contracts Emissions Regulations Hydrogen Fuel Steam Water Electricity Energy and Utilities System Measurements EnPIs, Streams and Equipment Calcs. Energy System visibility and accounting for operators and engineers Control System / Historian Operators Process (Utilities Consumers and Generators) Energy and Emissions KPIs Monitoring Energy Use and Account Energy Related Reports and Dashboard VM-Energy Monitor Traditional Architecture
  10. 10. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 External Utilities Contracts Emissions Regulations Fuel Steam Water Electricity Energy and Utilities System Energy Scheduling and Planning Operators Process (Utilities Consumers and Generators) Data Visualization and Custom Reports Optimal Allocation of Utility Assets VM-Energy Multi Period Optimizer Traditional Architecture Measurements Forecasts
  11. 11. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Optimum Set Points Process (Utilities Consumers) External Utilities Contracts Emissions Regulations Hydrogen Fuel Steam Water Electricity Energy and Utilities System Measurements CLOSED-LOOP signals to control systems OPEN-LOOP advisory reports to operators Operators (Degrees of freedom in Generation and Distribution) Optimum Energy System Operatio n Report Process Models Measurements Control System / Historian EnPIs, Streams and Equipment Calcs. Energy Related Reports and Dashboard Energy and Emissions KPIs Monitoring Energy Use and Account VM-Energy Real Time Optimizer / Monitor and Petro-SIM Integrated Utilities + ProcessArchitecture Optimum Energy System Operation Report
  12. 12. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 What Does Energy Real Time Optimization (VM-ERTO / ECLRTO) Provide? • Whatever utilities the process needs, the process gets. • How can we get those utilities needs to the process in the cheapest possible way…  within emissions constraints…  within current operating constraints, and  within contractual constraints? • A Utilities Real Time Optimizer that ensures Operations is doing the best it can with the utilities assets it has available in this moment and with the current operating conditions. • It gives Operations a Real Time Target for producing and distributing the utilities at the minimum Site-Wide overall Energy System cost. • Customized or pre-defined Excel based reports provide operating actionable items guidance • With model, optimization solution and reports fully accessible from within a web browser.
  13. 13. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 What Does Energy Monitor (VM-EM) Provide? • Ad-hoc RTDB for massive historization of results (Shistorian)  Historization of all the modeled streams and equipment results., calculated KPIs, limits and alarming, etc.  Internal tags automatically created and updated based on model topology • Key Performance Indicators (KPIs) Alarming  All built on the site model to provide consistent data  Alarming capabilities, also integration with existing Company Standard KPIs visualization dashboard  Built in KPI calculators to swiftly configure - Plant Energy use and cost per unit of plant production, equipment efficiencies (i.e., boilers, heaters, GTs, turbines, etc.), bias from performance curves, etc.  Equation block for custom calculations (i.e., BT index, EII), using current and/or historical data • Excel style reports on any time-frame  Steam / Fuels / Hydrogen / Electricity balances of a plant or sub plant over any time period  Monthly or Periodical Balances for accounting are produced “on the fly”, with boundaries chosen from the web GUI either Site, Area or Unit wise  KPIs
  14. 14. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 What Does Energy Multi-Period Optimizer (VM-EMPO) Provide? • Visual MESA Energy Multi-Period Optimizer (VM-EMPO) allows scheduling engineers and operators to find the optimal operation of the utility plants on a time horizon when dealing with time dependent constraints (i.e., planned out- of-service periods, caps on emissions, fuel tank farms management, minimum/maximum start/stop time of equipment, thermal energy storage management, etc.) • Energy System Optimum Planning, taking into account multi-period optimization handles and constraints  Including forecasting of prices, weather conditions, equipment availability, energy storage, fuels storage and availability, etc.  Constraints to be imposed on certain periods or integrated (i.e., totalized) variables, like emissions cap or total fuel consumption  Solution presented in user configurable Gantt and bar charts. • Excel style reports for the Planning Periods  Multi-period energy, emissions and KPIs reports
  15. 15. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Facility 1 Facility 3Facility 2 Facility NFacility 4 Facility 5 Facility 6 Targets & Actions Audit and Accounting Energy Indicators Integrated Operations WATER CARBONENERGY • Site wide real-time energy optimization • Validated and consistent measurements and • Calculation of Energy Balances & KPIs • Published to Corporate Energy Portal for site and fleet evaluation • Presented in a Dashboard Visual MESAEMS: Fleet Energy Management
  16. 16. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Direct connection for closed loop Visual MESAEMS: VM-ERTO/EM/ECLRTO ITArchitecture
  17. 17. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: ERTO/ECLRTO/EM Server • The server is where Visual MESA ERTO/ECLRTO and/or EM are automatically executed as a service
  18. 18. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: VM-ERTO Online and Offline Use • The Visual MESA model can be used in Open loop with a flexibility for Online and Offline data fetching.  During Online mode, it will fetch the input data from system for the period selected by the user with an option of average data or current data  Then user can take the model Offline and manually overwrite inputs, as needed - Visual MESA Excel Add-In is available to manage the what-if optimization cases from within Excel (write and read to/from the model) Client-Server / Web browser access Standalone use (model building and what-if studies)
  19. 19. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Structural Model External Multi-period Constraints Forecast Data UserInterface Optimal Schedule UserInterface Calculation Engine Through the user interface, the user can define the scheduling problem by providing three major inputs. Namely, the structural model of the utility plant, the forecasted data of future conditions of the plant and an appropriate set of multi-period constraints. The calculation engine uses the inputs to generate the optimal schedule. Input-output structure Visual MESAEMS: VM-EMPO DataArchitecture
  20. 20. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: VM-EMPO Operational Procedure STEP 1: Build Utilities Model STEP 2: Set-Up Forecast and Constraints STEP 3: Define Schedule Horizon Set-UpRunVisualize
  21. 21. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: VM-ERTO/EM Project Schedule
  22. 22. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: VM-ERTO/EM Project Typical Client Personnel Requirements • Total: ~10 weeks for Project Owner and ~12 weeks for Engineering Designate • Before and During KOM  2 weeks for Project Owner  4 weeks for Engineering Designate who can obtain required information • Model, Optimization, and KPIs  Project Owner and Engineering Designate available as needed to answer questions and clarify data or assumptions • Training and Model Review  1 week for Project Owner; 1 week for Engineering Designate • Commissioning  1 week for Project Owner; 1 week for Engineering Designate • Formal Training for Operators (by Client)  1 day per shift plus 2 days of course preparation time, such preparation with the assistance of Soteica • For implementing optimization recommendations in operations  3 weeks for Project Owner and 2 weeks for Engineering Designate
  23. 23. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: VM-ERTO Work Flow (Open Loop Optimization) Production/Energy Meeting (weekdays) EMC presents and discuss Energy Cost Gap and main Energy KPIs for previous 24 hours EMC communicates direction to Operations, as Energy Cost Gap or Energy KPIs warrants Real-Time PI Data Operators Implement Visual MESA Recommendations on a daily or shift basis Also, periodically as alerted for an increase in Energy Cost Gap via the Reports or by having the PI tag Energy Cost Gap or Energy KPIs trends on a screen Operating Actions: Turbine/Motor Swaps, STGs / GTs power, Boilers balancing, Boilers/Furnaces firing efficiency improvement Visual MESA runs automatically with real-time PI data (every 30 minutes) Rigorous solver optimizes discrete and continuous variables Calculates Optimization Opportunity or “Energy Cost Gap” and other Energy KPIs Creates Report with Operator Recommendations for Capturing Energy Cost Gap Optimization and KPIs are pushed back to PI and in Excel, .pdf, and .html Reports Operators verify/update main constraints, as well as Turbine/Motor swapping availability and report to Energy Management Coordinator (EMC) as needed Operators update optimizer and also update EMC if any T/M swap can’t be performed (i.e., due to an equipment out of service , on maintenance, etc.). Also, if a previously unavailable equipment is on service again. EMC updates optimizer status, prices and/or constraints
  24. 24. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS: Software Maintenance and Sustainability Services • Following commissioning and start-up, the Software Maintenance Services starts, designed to deliver both updates and enhancements to the software, and which includes:  Access to improvements or changes to the software designed to update operating performance;  Access to functionalities, functional attributes, or interface enhancements that did not previously exist in the initial Software version sold;  Technical services regarding the use of the software and its enhancements and modifications.  Remote installation of the latest Software versions, including adaptation and testing of the model and customized Excel reports. • The Sustainability Program are proactive services delivered to ensure adoption and sustainability of the software solution at our clients’ sites. Provided remotely through a secure VPN, these services include:  Discussion and answers to questions relating to design and implementation of the software site-specific model;  Supervision and validation of Customer’s modifications to the software site-specific model;  Advice on how the Customer may modify, or implement new elements within, the software site-specific model;  Discussion and answers to questions regarding interpretation of the results produced by the software site-specific model;  Support of the Customers’ development of an energy system performance improvement plan including, but not limited to; (i) specifying additional metering and (ii) equipment performance audits; and  Supervision of Customers’ studies for steam system modifications, projects and shutdown maintenance.
  25. 25. KBC/Petronas Technology Session and Round Table Workshop Proprietary Information 16-17th January 2018 Confidential Information Visual MESA EMS Demonstration
  26. 26. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 VM-ERTO Screenshots
  27. 27. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 VM-EM Screenshots
  28. 28. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 VM-EMPO Screenshots
  29. 29. KBC/Petronas Technology Session and Round Table Workshop Proprietary Information 16-17th January 2018 Confidential Information Annex 1 Examples of Benefits Obtained in Visual MESAEMS Projects
  30. 30. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS Case Studies: Reference Papers Documents • Extensive library with Reference Papers:  Document with all References and papers indexed by year and industry  Vast majority of the papers co-authored with our customers or even written by themselves • Customers with references list
  31. 31. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Jamnagar site (2016 – VM-ERTO, Phase 2 in execution) Corporate Standard for Utilities RTO (multiple sites) Corporate Standard for Utilities RTO (multiple sites) Corporate Standard for Utilities RTO (3 sites) Corporate Standard for Utilities RTO (7 sites) Port Arthur site (2017 – VM-ERTO) Singapore site (2016 – VM-ERTO) 2 sites (2011 and 2017 – VM-ERTO) Chiba site (2017 – VM-ERTO) 3 sites (2006, 2014 and 2018 – VM-ERTO) Visual MESAEMS Case Studies: Selected Customer Base & Recent Projects
  32. 32. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS Case Studies Case 1: REPSOL Tarragona Refinery • Challenge  Reduce the total cost of the energy  Coordinate optimization actions to be taken at the different Units of the site • Solution  Visual MESA Energy Real Time Optimizer (VM-ERTO)  Model, optimization and reports setup  Engineers and operators training  Solution sustainability services • Benefits1  Energy cost reduction of 4% (in the order of 2 MM€/y) due to optimization  Additional, non quantified benefits, were obtained by energy performance monitoring With 2003 costs of 20 USD/barrel 1 Energy Costs Reduction By Using An On Line Utilities Optimization Tool, Diego Ruiz Massa, Carlos Ruiz García, David Nelson, Gary Roseme, Manuel Lázaro Meléndez, María Sartaguda Pardos, European Refining Technology Conference (ERTC) Computing, London, UK, June 2004
  33. 33. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS Case Studies Case 2: KNPC, MAARefinery • Challenge  Reduce the total cost of the energy  Generate operational recommendations in order to help engineers and plant operators in the decision making process  Calculate and track several Energy KPIs • Solution  Visual MESA Energy Real Time Optimizer (VM-ERTO)  Model, optimization and reports setup  Engineers and operators training  Solution sustainability services • Benefits1  Savings of 4.4 MM$/y  CO2 emission reduction of 27,600 tons per year were reported  What-If case example with 2 MM$/y of potential savings was presented 1 Online Energy Management System Implementation in KNPC Mina Al-Ahmadi Refinery, M. Ershaid, A. Al-Tarkeet, D. Periyasamy, N. Visuara, C. Ruiz, S. Cúneo, Middle East Process Engineering (MEPEC), Bahrain, September 2013
  34. 34. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Visual MESAEMS Case Studies Case 3: SABIC Saudi Kayan Petchem Complex • Challenge  Reduce the total cost of the energy  Implement a Real Time Online Energy Management System • Solution  Visual MESA Energy Real Time Optimizer and Monitor (VM- ERTO and VM-EM)  Model, optimization, Energy KPIs calculation, dashboard and reports setup  Engineers and operators training  Solution sustainability services • Benefits1  Energy cost reduction in the order of 3.42 MM$/year  Additional savings were obtained from: - Online Energy Monitoring, Auditing and Accounting - Online Energy KPIs Dashboard  What-if studies: - Capital Project Opportunities - Planning / Scheduling of Utilities Before implementing recommendations: Average potential savings: 390 $/h After implementing recommendations: Average potential savings: 270 $/h Captured Savings: 120$/h (1.05 MM$/year) Example of an optimization action in which Visual MESA recommendations were partially applied and, as a consequence, 1.05 MM $/year of savings where achieved 1 Real Time Online Energy Management System Implemented at SABIC Saudi Kayan Petrochemical Company, M. Al-Shehri, T. Khan, A. Salem, C. Ruiz, M. Reinaldi, S. Cúneo, Middle East Process Engineering (MEPEC), Bahrain, September 2013
  35. 35. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 VM EMS Case Studies Case 4: TECO District Heating & Cooling, Houston TX, USA • Challenge  Reduce the total cost of the energy to produce chilled water and steam for the Houston Medical Center  Have an optimum planning for the site, including Thermal Energy Storage (TES) and Combined Heat and Power (CHP) • Solution  Visual MESA Energy Real Time Optimizer and Multi-Period Optimizer (VM-ERTO and VM-EMPO)  Model, optimization, planning and reports setup  Engineers and operators training  Solution sustainability services • Benefits1  Improved total energy efficiency by real-time optimization  Multi-period energy optimization used for day ahead schedule, taking into account demand, weather and power prices forecasts 1 Multi-Period Optimization of District Energy Supply, Development of Day-Ahead Scheduling to Supplement Real-Time Optimization at TECO, J. Garcia, J. Ruiz, T. Reitmeier, International District Energy Association (IDEA) Annual Conference, Miami, USA, June 2013
  36. 36. KBC/Petronas Technology Session and Round Table Workshop Proprietary Information 16-17th January 2018 Confidential Information Questions?
  37. 37. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17th January 2018 Thank you!

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