Technology based energy management information system
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The document summarizes a workshop presented by KBC Energy Services on their energy management information system (EMIS) and tools. It discusses barriers to effective EMIS, including the interaction between energy and production systems and the challenges of integrated site-wide energy. KBC presents their EMIS toolset, including real-time optimization, integrated process and utility modeling, and cloud-based expert support, to help customers overcome these challenges, achieve 3-8% energy savings with no capital cost, and increase production 1-2% without investment. Case studies demonstrate annual savings of $20-30 million from improved energy efficiency.
Technology based energy management information system
- 1. KBC/Petronas Technology Session and Round Table Workshop Proprietary Information 16-17 January 2018 Confidential Information Technology Based Energy Management Information System (EMIS) Seamlessly Integrating Energy Supply and Demand Improvements KBC Energy Services
- 2. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Agenda • Introduction • Benefits from energy management • Challenges • Overcoming the challenges • What the future of EMIS looks like • Case studies
- 3. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Supply Re-UseDemand Energy CO2 Utilities System 1981-1989 MESA Simulator 1992-1998 G2-MESA Visual MESA™ (VM-ERTO) 1998-2000 Closed Loop Optimisation (VM- ECLRTO) 2000-2012 Fuels Hydrogen UI & Excel® Energy KPIs 2012-Present Web Browser Client Multi Period Optimisation (VM-EMPO) Energy Balances and EnKPIs Dashboarding (VM-EM)Superior energy optimisation 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 and Utility Modelling BT Correlations Energy recovery & heat exchange consulting and software Linnhoff March acquired by KBC in 2002 Over 1000 energy consulting studies KBC unitesthe worldleadersin optimisingenergysupply, demand and re-useto provide a completesolution 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
- 4. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Energyefficiencyofferslargesavingsof directcostsandemissionsofCO2 – Energyimprovementsovercome constraintsonproductionandyield • Energy is the largest controllable operating cost: Typical refinery/petchem energy cost is $200-300m/y • Energy saving always makes money – it is a less risky investment than adding capacity or changing product mix. • Even where energy is “free” e.g. upstream it has a cost in terms of bringing forward drilling or other capex. • Energy systems often constrain processes (e.g. major compressors limited by turbine drives, unit throughput limited by process furnace). Energy related bottlenecks typically constrain throughput of high margin processes by 2-3%. • Even the best performers use significantly more energy than KBC’s Best Technology Benchmark. • Upstream and Refining are significantly worse than Petrochemicals. • Even a top performer can economically save 10-15% of energy use worth $20-30 million per year. • Similar percentage reduction in CO2.0 50 100 150 200 250 300 350 KBCBestTechnologyIndex Site Best Technology Benchmarking Upstream Refinery Petrochemicals 100 = Optimum performance
- 5. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Barriers To Effective Energy Management Information Systems 1. Energy and production/yield affect each other 2. Energy systems are highly integrated and changes impact whole site 3. Human behaviour is key to making it happen • Skills being lost “great shift change” • Lack of people – leaner operation • Digital maturity gap • Work processes and practices need to catch up with technology Typical EMIS Today Challenges 1. KPI Dashboards 2. Equipment KPIs and analytics 3. Simulation and utility models and tools 4. Reports • Focus on supply side • EnPIs don’t reflect severity/feedstock effects • Monitor machine performance • Miss chance to switch it off • Get out of date and dis-used • New staff fail to exploit full value • Not always acted upon • Irrelevant for frontline staff
- 6. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Challenge 1: Process/Energy Interactions • In the past… Simulation and modelling tools for energy and process are independent, making it difficult to determine the common optimum. Simplistic Energy KPIs defined such as specific energy consumption. Better yield or quality results in worse energy index. • Now… World class supply side optimisation based on visual Mesa technology. Integrated with demand side modelling based on Petro-SIM with energy analytics. Delivering Smart energy KPIs based on KBCs Best Technology approach to drive the optimum overall performance. Case Study: FCCLimitedbySteamTurbine driving amajorcompressor. Improvements toturbineand coolingwatersystem worth $0.08m/yenergy. Howeverre-optimisingtheunitto takeadvantage ofenergy bottleneckremoval wasworth $10m/yinYieldincrease.
- 7. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Challenge2: Site-wideEnergyIssues– Overcome withAutomated Site-wideOptimisationandMonitoringTool VM-EM Visual MESA Energy Monitor Platform VM-ERTO Site wide Real Time Utility Optimisation VM-ECLRTO Closed Loop Optimiser Automation VM-EMPO Multi-period Optimiser Planning Petro-SIM Demand Side Energy Management HX-Monitor Heat Exchanger Cleaning Complex interactions mean that changes and improvements need to be considered in the context of the whole utility system. Steam Balance Fuel Balance Power Balance Pricing
- 8. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 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) Optimu m 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-EnergyRealTime Optimizer/ Monitorand Petro-SIM IntegratedUtilities and ProcessArchitecture Optimum Energy System Operation Report
- 9. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Example Economic Results Source: 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. With 2003 costs! 20 USD/barrel Medium Size Refinery- Olefins Complex in Tarragona (Spain) Reference: ERTC Computing 2004 4% energy reduction cost in utilities system, and consistently smaller gap to optimum operation
- 10. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Challenge3: Sustainmentand SkillsGaps OvercomewithCloudBasedModelAssurance andExpertSupport 10 Just as the co-pilot of an aircraft is there to assist the pilot with additional knowledge and to step in and help at times of intense activity, KBC’s Co- Pilot is there to remotely support an asset with expertise and insight supplementing the asset’s own capabilities and resources, therefore assuring that it achieves its full potential. • Remotely ensure the technology and tools your business relies on are always correct and up to date. • Collaborate in real time with your people, to enhance your knowledge, build up skills. • Provide world class expertise to ensure that your energy efficiency is always optimum. Client has hands on the controls KBC as a second pair of expert eyes
- 11. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 SharedDigitalTwinintheCloudConnectsyou toaWorldOf Expertise– Co-PilotEmphasisesSharingandCollaboration,ratherthan Outsourcing Customer Facility Physical Assets Your People Digital Twin In the Cloud Collaboration Portal Data Questions Economics Advice & Capabilities Assured Models Data Update Models Questions Advice & Capabilities Plant Insights Plant Insights KBC Co-Pilot Connected Experts 3rd parties Data & Insights Suppliers and manufacturers • Equipment supplier monitoring • Catalyst vendors • Chemical suppliers
- 12. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Energy OpX Sustains Top Performance • Clear Link between energy management maturity (right scale) and energy use (bottom axis). • 1 Point increase in Energy OpX maturity leads to 18.5% energy reduction on average. • Co-Pilot delivers and sustains excellence on a fast-track timetable – Operational Excellence as a Service.
- 13. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Energy Systems KBC Tools Energy Supply Utility Systems Steam, Fuel, Power, Hydrogen, Water Fired Equipment Furnaces, Boilers, Incinerators Energy Demand Process Systems Reactors, Distillation, Rotating Equipment Energy Recovery & Re-Use Energy Recovery Heat Exchangers Low Grade Heat Recovery Barriers To Effective Energy Management Information Systems 1. Energy and production/ yield affect each other 2. Energy systems are highly integrated and changes impact the whole site 3. Human behaviour is key to making it happen • Skills being lost “great shift change” • Lack of people – leaner operation • Digital maturity gap • Work processes and practices need to catch up with technology Challenges to Overcome TodaysEMIS BT Benchmarks HX Monitor KBC Toolset for Future EMIS Cloud Based Real-Time Support • 3-8% energy savings with zero capital cost 1-5% utilities 1-3% Process 1-3% Exchangers • 1-2% production increase without investment • Reduce maintenance costs and improve availability by 1-2% Benefits
- 14. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 BuildingaWorldClassEMISRequiresaRigorousandStructuredApproach HumanandTechnicalPerformancemustbeAddressed InParallel DEVELOPDISCOVER DELIVERDEFINE SUSTAIN • Asses against Best Technology benchmarking • Provide high level gap analysis and recommendations • Recommend Energy Supply improvements • Utility Systems • Fired Equipment • Optimise process energy use • Maximise heat recovery • Design for Reliability/Safety/Process • Codify work processes and procedures • Ensure organisational alignment • Design competency development programme • Construct Investment Roadmap • Execute Implementation plans and test runs • Conduct Energy Operational Excellence Benchmarking CO-PILOT • Capture Quick wins – Tracked via cloud ProfitTracker™ • Provide Benchmark KPIs • Utilise Visual MESA and Petro-SIM used for study • Monitor economic performance • Provide recommendations via dashboard • Foster cloud KBC/client collaboration, dialogue & support • Provide continuous audit & governance • Adapt to changing situations • Leverage Visual MESA & Petro-SIM models • Execute implementation plans • Provide management of change • Assure results and value capture TechnicalHuman
- 15. 1516-17 January 2018 KBC/Petronas Technology Session & Round Table Workshop Proprietary Information Questions? KBC Energy Services
- 16. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Annex 1 Examples of Benefits Obtained in KBC EMIS Projects
- 17. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 The KBC ENgage programmeis proven to deliver significantand sustainedbenefitsfor top industryperformers Year Client Scope of Work DELIVERED 2007 to 2010 Refining • Multi-site EMS & technical benchmarking & gap analysis • Development of energy metrics for all site processes • Delivery of site specific tools & RoadMap $37m/a 2007 to 2011 Refining & Petrochemicals • EMS benchmarking and gap analysis • Development of corporate wide masterplan for gap closure • Multi-phase rollout to deliver site specific tools & RoadMaps $74m/a 2005 to 2008 Petrochemicals • EMS benchmarking and design • Development of energy metrics for all site processes • Delivery of RoadMap for energy improvement $50-55m/a 2010 to 2014 Refining & Petrochemicals • Developed EMS to industrial best practice specification • Work processes, best practices, organisation, capabilities • Multi-phase rollout to deliver tools & RoadMaps to sites $270m/a 2014 to 2017 Petrochemicals • EMS benchmarking and gap analysis • Capability development for corporate Energy Management team • Multi-phase rollout to deliver site specific tools & RoadMaps $180m/a DEVELOP DELIVERDISCOVERDEFINE SUSTAIN
- 18. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 European Energy Improvement Project – ENgage KBCEnergyServices–RefiningSectorCaseStudy Client Situation European Conversion Refinery, 100KBPD with 2nd Quartile Energy Efficiency Performance. The client desired a phased approach of energy improvement focusing on process energy, utility optimisation and energy management systems / metrics. Project Implementation Approach • To achieve the clients desired improvements a program was designed including the following elements: 1. Profit Improvement Program (PIP) with focus on non-investment opportunities in yield and energy 2. A Strategic Energy Review (SER) with focus on energy efficiency improvement projects 3. A Utility System Optimiser implementing on-line (open loop) optimisation of the utility system 4. An Energy Management System with metric identification / updates to implement an appropriate set of energy metrics to monitor performance cascaded through the organisation • The client and KBC team worked collaboratively to implement all improvements. • The project was specifically designed to meet the clients implementation ability and budget. Faster improvement is possible if resources are available. Key Findings and Recommendations • The specific results and findings were: 1. The PIP identified operational / process energy savings worth 2.7% across the site 2. The SER identified projects (with a payback < 4 years) worth 11.9% across the site 3. The utility optimiser resulted in savings of up to 4% based on comparison with operation previously 4. The improved energy metrics monitoring saved 1% Results The net impact of the project was a reduction in EII of around 20%, with equivalent reductions in energy costs. The client is now sustainably a solid first quartile performer in industry benchmarking studies.
- 19. KBC/Petronas Technology Session & Round Table Workshop Proprietary Information 16-17 January 2018 Middle East Energy Improvement Program KBCEnergyServices–PetrochemicalsSectorCaseStudy Client Situation A Middle East petrochemicals company has an initiative to reduce its energy use at its production sites by 25% by 2025. This program, carried out with KBC, involved studies on ten production sites over a three year period. Project Implementation Approach • A joint project with the client’s energy team • Best Technology (BT) Benchmarking and Gap Analysis – quantify reasons for poor performance • Investment RoadMap of non-investment and investment projects produced for each site • Technology transfer to client’s project team done via on-the-job training and training courses. • Client licensed KBC software Petro-SIM, VisualMESA and SuperTarget™. Key Findings and Recommendations • A total of more than 150 energy-saving projects have been included the ten investment RoadMaps. • These projects will make a major contribution to helping the client meet his energy saving target. • The relatively low fuel price made some investment projects uneconomic. However, these projects were also evaluated based on a higher “sensitivity” fuel price which made them attractive. The client now has a list of “opportunity” projects for implementation in the future when the fuel price is forecast to increase significantly. • The client’s energy team is now fully trained and equipped to execute energy studies. Results • Energy improvement projects identified to save 180 MM USD/year. • This included “quick wins” and minor investment projects worth 140 MM USD/year.