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Texas Technology 2003 Showcase

Plant Energy Optimization

Tony DafftPrincipal EngineerRohm and Haas Company

Deer Park Site

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Simplified Plant Steam System Three Main Header

Systems 600 psig

150 psig

75 psig

Other Local

Pressures

Process

Steam

Generators

Boiler

Furnace

Boiler

Drum

Process

Steam

Generators

Process

Steam

Generators

Process

Steam

Generators

600#

150#

75#

Vent

Vent

L/D

L/D

Process

Steam

Users

Process

Steam

Users

Process

Steam

Users

Process

Steam

Users

Process

Steam

Users

Process

Steam

Users

Process

Steam

Generators

Process

Steam

Generators

Cond.

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Plant Steam System Particulars

u 1,000,000 to 2,000,000 pounds per hour

average steam generationuGeneration and consumption vary depending

on unit rates

uOver 20 waste heat boilers

uOver 60,000hp of steam turbines

uOne Gas Turbine with HRSG

u 2 Natural Gas Fired Boilers to maintainheader pressure

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Visual MESA Selected for

Plant Implementation

u

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

uOptimizes the entire steam & electrical

systemu Evaluates What If cases

u

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

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Visual MESA Particulars for

the Deer Park Plant

u

Reads over 1000 tags every 3 minutesuOptimizer runs hourly

u

Resides on stand alone serveruAccessible from any desktop computer

u

Plant data feeds from 9 separateDistributed Control Systems

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Plant Energy Optimization

Benefitsu Letting down and venting significantly

reduced with 24/7 attention.uMonitoring condensate return allows more to

be returned. Diversions have to be manually

switched back and this is sometimesforgotten.

u Turbine vs motor switching can be called

correctly much sooner with better cost data.u The lost opportunity trend tracked hourly

will give increased attention by all to the

overall energy system.

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Plant Energy Optimization

Benefits

u

Corrective actions to the system that havebeen difficult to fund in the past have a muchbetter basis for funding.

u The graphical representation of the steamsystem allows a much larger group of peopleto gain familiarity with the system.

uMeter inaccuracies can be identified andscheduled for corrective action.

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Plant Energy Optimization

Benefits

u

Detailed balances within each unit can beunderstood and corrected with potentialenergy improvement projects resulting.

u Shutdown and production planning can beevaluated from an energy perspective.

u The effect of rapidly changing natural gasand energy costs can easily be quantified.

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Example of Turbine/Motor

Switch Showing Savings

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Plant Optimization System

Operational in June 2000

Boiler House Steam Production to Balance Plant

(Avg. Lb/Hr)

0

50,000100,000

150,000

200,000

250,000300,000

350,000

400,000

450,000

Dec-

96

Sep-

97

Jul-98 May-

99

Mar-

00

Jan-

01

Nov-

01

Sep-

02

Jun-

03

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Fired Steam Production Drops

After June 2002 ImplementationBoilerhouse Steam Production

0

50,000

100,000150,000

200,000

250,000

300,000

350,000

400,000

450,000

500,000

Aug-99 Mar-00 Oct-00 Apr-01 Nov-01

pph

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150# Header Narrow Band of

Pressure Control

150# L/D Set

165# RV Set

Time

Vac. Jet Low Press.

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Customized Report Selection

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ChallengesuDeveloping master flow diagrams of

the steam system from the thousands ofProcess & Instrument Diagrams

u

Keeping network connectivity reliableuDetermining how to respond to

recommended changes

uGetting and keeping meters working primary element and

configurations/spans/tag id

s/etc.

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Obstacles & Lessons Learnedu Its more complicated than it appears.u If you do not have the appropriate

handwheels, you cant respond to every

opportunity.

u Fixing one problem can create another

problem due to equipment/process inter-relationships and constraints in the system.

uMakes an excellent learning tool for the steam

system.uCore group of people need to understand the

software - They must take on communicating

and training of others.

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Obstacles & Lessons Learned

u

The effort must be supported by managementand have a champion

uCertain items will need to be purchased

above and beyond the software keyflowmeters on letdowns, vents, andimport/export to complex areas.

u Interface with IT department is mandatory

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Future Plans

u

Build Natural Gas model into Steam modeluConnect production planning to the model

uAdd other Utilities like nitrogen and

instrument air to the modeluConvert data server to Aspen IP-21

u

Configure more detail into the modelu Provide graphical interface to DCS system to

put information in front of operators