Sie sind auf Seite 1von 17
Texas Technology 2003 Showcase Plant Energy Optimization Tony Dafft Principal Engineer Rohm and Haas Company

Texas Technology 2003 Showcase Plant Energy Optimization

Tony Dafft Principal Engineer Rohm and Haas Company Deer Park Site

Technology 2003 Showcase Plant Energy Optimization Tony Dafft Principal Engineer Rohm and Haas Company Deer Park
Simplified Plant Steam System Three Main Header Systems • 600 psig • 150 psig •

Simplified Plant Steam System

Three Main Header Systems

600 psig

150 psig

75 psig

Other Local Pressures

Process Process Steam Steam Generators Generators Process Process 600# Steam Steam Users Users L/D Vent
Process Process
Steam Steam
Generators Generators
Process
Process
600#
Steam
Steam
Users
Users
L/D
Vent
Cond.
Process
Process
150#
Steam
Steam
Users
Users
L/D
Vent
Boiler
Drum
Process
Process
75
#
Steam
Steam
Boiler
Users
Users
Furnace
Process
Process
Process
Process
Steam
Steam
Steam
Steam
Generators
Generators
Generators
Generators
Furnace Process Process Process Process Steam Steam Steam Steam Generators Generators Generators Generators
Plant Steam System Particulars u 1,000,000 to 2,000,000 pounds per hour average steam generation u

Plant Steam System Particulars

u

1,000,000 to 2,000,000 pounds per hour average steam generation

u

Generation and consumption vary depending on unit rates

u

Over 20 waste heat boilers

u

Over 60,000hp of steam turbines

u

One Gas Turbine with HRSG

u

2 Natural Gas Fired Boilers to maintain header pressure

of steam turbines u One Gas Turbine with HRSG u 2 Natural Gas Fired Boilers to
Visual MESA Selected for Plant Implementation u Continually Monitors the entire Steam, BFW and Condensate

Visual MESA Selected for Plant Implementation

u

Continually Monitors the entire Steam, BFW and Condensate systems and flags problems

u

Optimizes the entire steam & electrical system

u

Evaluates What If cases

u

Auditing and Accounting. Validates your data and helps you with trouble shooting, auditing and accounting.

u Auditing and Accounting . Validates your data and helps you with trouble shooting, auditing and
Visual MESA Particulars for the Deer Park Plant u Reads over 1000 tags every 3

Visual MESA Particulars for the Deer Park Plant

uReads over 1000 tags every 3 minutes uOptimizer runs hourly uResides on stand alone server uAccessible from any desktop computer uPlant data feeds from 9 separate Distributed Control Systems

alone server u Accessible from any desktop computer u Plant data feeds from 9 separate Distributed
Plant Energy Optimization Benefits u Letting down and venting significantly reduced with 24/7 attention. u

Plant Energy Optimization Benefits

u

Letting down and venting significantly reduced with 24/7 attention.

u

Monitoring condensate return allows more to be returned. Diversions have to be manually switched back and this is sometimes forgotten.

u

Turbine vs motor switching can be called correctly much sooner with better cost data.

u

The lost opportunity trendtracked hourly will give increased attention by all to the overall energy system.

The “ lost opportunity trend ” tracked hourly will give increased attention by all to the
Plant Energy Optimization Benefits u Corrective actions to the system that have been difficult to

Plant Energy Optimization Benefits

u

Corrective actions to the system that have been difficult to fund in the past have a much better basis for funding.

u

The graphical representation of the steam system allows a much larger group of people to gain familiarity with the system.

u

Meter inaccuracies can be identified and scheduled for corrective action.

to gain familiarity with the system. u Meter inaccuracies can be identified and scheduled for corrective
Plant Energy Optimization Benefits u Detailed balances within each unit can be understood and corrected

Plant Energy Optimization Benefits

u

Detailed balances within each unit can be understood and corrected with potential energy improvement projects resulting.

u

Shutdown and production planning can be evaluated from an energy perspective.

u

The effect of rapidly changing natural gas and energy costs can easily be quantified.

an energy perspective. u The effect of rapidly changing natural gas and energy costs can easily
Example of Turbine/Motor Switch Showing Savings

Example of Turbine/Motor Switch Showing Savings

Example of Turbine/Motor Switch Showing Savings
Example of Turbine/Motor Switch Showing Savings
Plant Optimization System Operational in June 2000 Boiler House Steam Production to Balance Plant (Avg.

Plant Optimization System Operational in June 2000

Boiler House Steam Production to Balance Plant (Avg. Lb/Hr) 450,000 400,000 350,000 300,000 250,000 200,000
Boiler House Steam Production to Balance Plant
(Avg. Lb/Hr)
450,000
400,000
350,000
300,000
250,000
200,000
150,000
100,000
50,000
0
Dec-
Sep- Jul-98
May-
Mar-
Jan-
Nov- Sep-
Jun-
96 97
99
00
01 01
02 03
200,000 150,000 100,000 50,000 0 Dec- Sep- Jul-98 May- Mar- Jan- Nov- Sep- Jun- 96 97
Fired Steam Production Drops After June 2002 Implementation Boilerhouse Steam Production 500,000 450,000 400,000

Fired Steam Production Drops After June 2002 Implementation

Boilerhouse Steam Production 500,000 450,000 400,000 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0
Boilerhouse Steam Production
500,000
450,000
400,000
350,000
300,000
250,000
200,000
150,000
100,000
50,000
0
Aug-99
Mar-00
Oct-00
Apr-01
Nov-01
pph
400,000 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0 Aug-99 Mar-00 Oct-00 Apr-01 Nov-01 pph
150# Header Narrow Band of Pressure Control 165# RV Set 150# L/D Set Vac. Jet

150# Header Narrow Band of Pressure Control

150# Header Narrow Band of Pressure Control 165# RV Set 150# L/D Set Vac. Jet Low
150# Header Narrow Band of Pressure Control 165# RV Set 150# L/D Set Vac. Jet Low

165# RV Set

150# L/D Set

Vac. Jet Low Press. Time

150# Header Narrow Band of Pressure Control 165# RV Set 150# L/D Set Vac. Jet Low
150# Header Narrow Band of Pressure Control 165# RV Set 150# L/D Set Vac. Jet Low
Customized Report Selection

Customized Report Selection

Customized Report Selection
Customized Report Selection
Challenges u Developing master flow diagrams of the steam system from the thousands of Process

Challenges

uDeveloping master flow diagrams of the steam system from the thousands of Process & Instrument Diagrams uKeeping network connectivity reliable uDetermining how to respond to recommended changes uGetting and keeping meters working primary element and configurations/spans/tag ids/etc.

changes u Getting and keeping meters working – primary element and configurations/spans/tag id ’ s/etc.
Obstacles & Lessons Learned u It ’ s more complicated than it appears. u If

Obstacles & Lessons Learned

u

Its more complicated than it appears.

u

If you do not have the appropriate handwheels, you can t respond to every opportunity.

u

Fixing one problem can create another problem due to equipment/process inter- relationships and constraints in the system.

u

Makes an excellent learning tool for the steam system.

u

Core group of people need to understand the software - They must take on communicating and training of others.

u Core group of people need to understand the software - They must take on communicating
Obstacles & Lessons Learned u The effort must be supported by management and have a

Obstacles & Lessons Learned

u

The effort must be supported by management and have a champion

u

Certain items will need to be purchasedabove and beyond the software key flowmeters on letdowns, vents, and import/export to complex areas.

u

Interface with IT department is mandatory

flowmeters on letdowns, vents, and import/export to complex areas. u Interface with IT department is mandatory
Future Plans u Build Natural Gas model into Steam model u Connect production planning to

Future Plans

u

Build Natural Gas model into Steam model

u

Connect production planning to the model

u

Add other Utilities like nitrogen and instrument air to the model

u

Convert data server to Aspen IP-21

u

Configure more detail into the model

u

Provide graphical interface to DCS system to put information in front of operators

more detail into the model u Provide graphical interface to DCS system to put information in