Motiva online monitoring and optimization energy system
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The document outlines the online monitoring and optimization of the energy system at the Motiva Port Arthur refinery, detailing its application of Visual Mesa EMS technologies. It highlights the refinery's operational capacity, optimization strategies for utilities, and implementation cases demonstrating significant cost savings. Future developments include enhancements to KPI calculations and the integration of hydrogen networks to further optimize energy management.
Motiva online monitoring and optimization energy system
- 1. ONLINE MONITORING AND OPTIMIZATION OFTHE ENERGY SYSTEM AT MOTIVA PORT ARTHUR REFINERY KBC USERS CONFERENCE 2018 Motiva Enterprises Robert Aegerter, Jake Lam, Raul Adarme KBC Jorge Mamprin, Carlos Ruiz, Pablo Montagna
- 2. AGENDA Company Overviews Visual MESA EMSTechnologies Motiva Port ArthurVisual MESA Model Optimization Actions Example Future developments Conclusions
- 3. COMPANY OVERVIEW: MOTIVATODAY An investment-grade, self-sufficient, entrepreneurial enterprise – steered by leadership team in Houston and supported by owner, Saudi Aramco North America’s largest refinery -- 635,000 barrels a day Largest base oil lubricants plant in the western hemisphere Marketer and distributor of two fuel brands: Shell and 76, supplying more than 5,000 retail gas stations 26 product loading racks in 20 markets
- 4. COMPANY OVERVIEW: SOTEICAVISUAL MESA (SVM),YOKOGAWA & KBC SVM, since 1985 Software Solution Provider for the Hydrocarbon Industry More than 140 applications on sites worldwide Most widely used ERTO system: +90 Energy Site Wide Optimizers around the world 2016Yokogawa acquires 100% of SVM 2017 SVM integration in KBC Integrated automation solutions Best-in-class automation technology KBC All about EXCELLENCE Proven Operational Excellence and Profit improvement consulting Leading simulation technology for hydrocarbon industry Soteica Visual MESA Industrial Knowledge Secure cloud services for DaaS Supplier / customer collaboration Leading provider of energy real time optimization
- 5. AGENDA Companies Overview Visual MESA EMSTechnologies Motiva Port ArthurVisual MESA Model Optimization Actions Example Future developments Conclusions
- 6. • External Utilities Contracts • Forecasts Emissions Regulations Measurements OPEN-LOOP advisory reports to operators Control System / Historian Process (Utilities Consumers and Generators) VM EMS TECHNOLOGIES: ON-PREMISE FUNCTIONALITY Operators Energy Related Reports and Dashboard Energy and Emissions KPIs Monitoring Energy Use and Account Optimum Energy System Operation Report EnPIs, Streams and Equipment Calcs. Hydrogen Fuel Steam Electricity Water Energy and Utilities System (Degrees of freedom in Generation and Distribution) Motiva’s model scope
- 7. VM EMS TECHNOLOGIES: UTILITY OPTIMIZATION CAPABILITIES (VM-ERTO) 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? Target is the minimization of total operating cost (Fuel+Power+BFW+Others) Customized or pre-defined Excel based reports provide operating guidance What-if capabilities
- 8. AGENDA Companies Overview Visual MESA EMSTechnologies Motiva Port ArthurVisual MESA Model Optimization Actions Example Future developments Conclusions
- 9. VM EMS TECHNOLOGIES: ERTO / EM ON-PREMISE IT ARCHITECTURE
- 10. VISUAL MESA MODEL: MOTIVA PORT ARTHUR REFINERY Fired boilers GTG’s with HRSG’s STG’s TM pairs/groups Internal power generation Steam generation Main View PS4 Utilities Area 0 0 0 0 999 999 999 999 999999999
- 11. VISUAL MESA MODEL: MOTIVA PORT ARTHUR REFINERY Visual MESA Software application Online Open-Loop Operational targets provided by Operation Reports Runs every 30 minutes Over 4400 input tags Optimization Handles – Actionable items GTG’s Load STG’s Load Boiler’s Load Duct Firing T/M Swaps PS3 Utilities Area Delta = Optimization - Simulation
- 12. VISUAL MESA MODEL: MOTIVA PORT ARTHUR REFINERY Constraints Equipment limits Steam reserve Monitoring and Accounting Over 7600 output tags KPIs: Efficiency of boilers, STGs and GTs,Total Energy Use, Imbalances Historization of streams Historization of optimum values and incremental costs On-the-fly mass balances
- 13. VISUAL MESA MODEL: MOTIVA PORT ARTHUR REFINERY DashboardKPIs Calculation Mass Balance Reports 12341234 1234 1234 1234 1234 1234 1234 12341234 123412341234 12341234 12341234 1234 1234 1234 1234 1234 12341234 1234 1234 12341234 1234 1234 1234 KPI 1234 1234 1234 1234 1234 1234 KPI KPI Description KPI KPI Description KPI Description 123 123 123 123 123 123 123 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 123 KPI 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant Plant
- 14. AGENDA Companies Overview Visual MESA EMSTechnologies Motiva Port ArthurVisual MESA Model Optimization Actions Example Future developments Conclusions
- 16. IMPLEMENTATION CASE BLRs 34, 35 and 46 were reduced Reversed later (savings increased) BLR 46 BLR 34 BLR 35 Energy Gap
- 17. IMPLEMENTATION CASE Recommendations for STG 33 were partially implemented STG34 inlet Energy Gap STG 34 steam flow was decreased
- 18. IMPLEMENTATION CASE Letdowns react to changes in steam production Energy Cost Gap was reduced 1500#/900# 900#/600# 600#/150# 150#/15# Significant savings were captured
- 19. AGENDA Companies Overview Visual MESA EMSTechnologies Motiva Port ArthurVisual MESA Model Optimization Actions Example Next Steps Conclusions
- 20. NEXT STEPS Improvement of KPI calculations and balances Addition of hydrogen network and its integration to the steam, power and fuel existing networks Lost Benefit Analysis: Evaluate the potential lost benefit by running in parallel an unconstrained model to compare with current case Based on the “original” ERTO model, no additional configuration needed Historize savings and optimization solution Compare constrained versus unconstrained savings to analyze and decide if worthwhile the expansion of certain optimizer limits and availability Additional unconstrained scenarios Analysis of the impact on savings of a given set of Individual optimization variables
- 21. AGENDA Companies Overview Visual MESA EMSTechnologies Motiva Port ArthurVisual MESA Model Optimization Actions Example Next Steps Conclusions
- 22. CONCLUSIONS The integrated steam, power and fuel network of the Motiva Port Arthur site have been modeled inVisual MESA Energy Real Time Optimizer. The system is running unattended every 30 minutes generating a list of recommendations for operations to reduce the utilities' costs. Significant savings were captured. The model is also used to evaluate “what-if” cases such as turnaround planning and investment planning.