Service, Customization, Innovation NovaTech EAMS The Role of Advanced Process Control in your Energy Management Solution IETC Conference May 2010
Service, Customization, Innovation
NovaTech EAMSThe Role of Advanced Process
Control in your Energy Management Solution
IETC ConferenceMay 2010
Presentation titleService, Customization, Innovation
NovaTech @ a Glance
Three Primary Business Units: NovaTech Process Solutions—Owings Mills, MD NovaTech Utility Communications –Kansas City, KS Bitronics Measurement and Metering –Bethlehem, PA
Over 25 years of Automation Industry Experience
Fortune 500 customer base with over 500 customers worldwide
Who is NovaTech
Presentation titleService, Customization, Innovation
NovaTech @ a Glance
Agro Processing
Brewing
Food & Beverage
Energy/Utilities
Heavy Industry
Pharmaceutical
Specialty Chemical
NovaTech’s Industry Focus
Presentation titleService, Customization, Innovation
Strategic Partnership Approach
NovaTech - World Class D/3® DCS Process Control Expertise Electrical Metering/Interface (Orion & Bitronics) EAMS and Project Services (Chemical Engineers) Aspentech Partner
BluESP - Global leader in Metals, Mining, Materials Aspentech Partner/Integrator Proven track record on energy and emissions Application Services Aspentech - Global leader in Advanced Process Control Process Optimization InfoPlus21® – Relational Database Historian DMCPlus® – Multivariable Model Predictive
control
Presentation titleService, Customization, Innovation
The Problem
No Single version of the truth
Islands of Automation
Silos of Information
No common HMI
Minimum or no data verification/reconciliation
Current Reality for many Industrial / Commercial Operations
Presentation titleService, Customization, Innovation
The Opportunity
The Opportunity
• Communication & Data Exchange - Multiple Automation Systems (PLCs, Skid Mounted OEM, DCS, Etc.) throughout the plant.
• Develop Integrated System for Information Sharing.• Intranet• Internet
• Increase Confidence in the Quality of Data currently being collected.• Verification• Validation• Repeatability
• Establish a Common HMI – Plant Smartboard displaying Key Performance Indicators needs to be developed.
Presentation titleService, Customization, Innovation
EAMS Site Assessment Report
The Objectives
• Efficient & Informed Commodity Procurement
• Quicker Response to Energy Deviations and Identification of Potential Problems within the Utilities Infrastructure
• Management and Production Decisions based on Actual Production/Product Cost Data
• Continuous Improvement for the utilities consumers Plan vs. Actual
• Achievement of environmental goals: Monitoring and Reduction of Emissions
• Maximizing use of most energy-efficient equipment
Presentation titleService, Customization, Innovation
Energy and Asset Management Solution
EAMS is an integrated solution that will allow an organization to monitor, measure and control energy usage in terms of: Energy Efficiency Asset Utilization Production Optimization
It consists of an collection of four solution modules: Assessment and Analysis Data Integration Key Performance Indicator Dashboards Advanced Process Control
Introduction – What is EAMS
Presentation titleService, Customization, Innovation
What does EAMS enable you to do?
Collect utility / energy data from plant equipment and utility processes
Monitor utility and energy usage, rates and equipment performance
Turning data into useful information Display real-time operating conditions Analyze utility and energy consumption trends and assist energy
managers to reduce facility energy costs. Simulate “what if” and predictive scenarios Report upset conditions and utilization efficiencies – baseline and
results Control and implement changes related to utility utilization to
reduce energy consumption in harmony with the production process
EAMS Functions
Presentation titleService, Customization, Innovation
Operational Benefits of EAMS
Manufacture at lowest energy contribution cost per unit of production
Efficiently allocate equipment and capital resources
Better manage utility premiums and avoid penalties
Replace time-based maintenance with condition-based maintenance
Establish baseline operating conditions in terms of energy, promote “best practices” and behavior modification.
Reduce Carbon footprint by managing CO2, SOx and NOx emissions
To be competitive in this climate energy efficiency needs to be driven to new levels
What it Does for You
Presentation titleService, Customization, Innovation
The Role of APC in an EAMS Solution
TypicalOperating
Region
Pressure
Tem
pera
ture
CompressorSpeed
Colum
n dP
Qualities
Motor Amps
OptimalConstrainedOperation
Operate process against many simultaneous constraints.
Stabilize the process through disturbances
Presentation titleService, Customization, Innovation
APC Technology
What is Advanced Process Control (APC) A model based control technology. That moves independent process handles (such as feed rates,
product rates, utility rates). To control key process dependent variables (such as
temperature, pressure, conversion, yield).
Objectives of APC Reduce overall variability in the process. Improve operating consistency, stability, and reliability. Increase unit throughput and yield of key products. Reduce operating costs: raw materials, energy, catalysts. Infer product qualities between lab measurements. Automate – lock in operator Best Practice.
Presentation titleService, Customization, Innovation
Fired Heater Example
FiredHeater
F
P
QFeed Flow
Fuel Gas Flow
Fuel Gas Pressure
Temperature
Duty
Presentation titleService, Customization, Innovation
Fired Heater Example
14
FiredHeater
F
P
QFeed Flow
Fuel Gas Flow
Fuel Gas Pressure
Temperature
Duty
Independents Dependents
Presentation titleService, Customization, Innovation
APC Logic
Achieve These Objectives:
Maximize feed Maintain outlet temperature at target value
While Satisfying All Constraints:
Keep heater duty below maximum limit
Move Feed and Fuel Gas Together
Compensate for All Disturbances
Presentation titleService, Customization, Innovation
Models from Plant Tests
Process
2
1. Step the Independents 2. Observe the Dependents
3. Identify the Models
Presentation titleService, Customization, Innovation
Benefits of APC
Limit
Target
= Profit
APC Reduces Variation
Reduced Variation Allows Operation Closer to Limit
No APC
Operating Margin
Reduce Variability
Presentation titleService, Customization, Innovation
Typical Benefits of APC
Quality standard deviation
Unit energy consumption
Product yield
Manufacturing Capacity
Reliability
Reduce by up to 50 %
Reduce by up to 10 %
Increase by up to 3 %
Increase by average of 4%
Increase by average of 4%
Presentation titleService, Customization, Innovation
Using Visualization to facilitate Optimal Plant Operation
Up-to-date online information - steam, power demands, electricity price, gas price etc. change continuously
Up-to-date online advice (Real Time Decision Support) – How should the utilities be set up to achieve lowest costs
Can close the loop
Presentation titleService, Customization, Innovation
Visualization -- Operations Response and Agility
The value of the decision to an organization is directly related to the speed with which the right decision is made and action taken.
•This assumes:
1. The right data are present to support a decision
2. The event is made visible to the right person
3. The person making the decision has all the relevant inputs - DM Review, January 2004, by R. Hackathorn
ValueGained
Performance Monitoring
Performance Management
Shorter Delay
Presentation titleService, Customization, Innovation
Presentation titleService, Customization, Innovation
Role Based Visualization – Configurable Dashboards
Role-Based Visualization also has connections to
relational databases, XML, and InfoBus messages.
Dashboard Editor enables users to create
dashboards using “drag and drop”
visualization objects
Presentation titleService, Customization, Innovation
Typical User Interface
Hierarchical navigation simplifies
access to key information
Resource links in context to a maintenance for a particular
unit
Dynamic updates from real-time
historians
Presentation titleService, Customization, Innovation
Presentation titleService, Customization, Innovation
Presentation titleService, Customization, Innovation
KPI Dashboards
Presentation titleService, Customization, Innovation
Forward projection and decision analyses
Presentation titleService, Customization, Innovation
Solution Development Methodology
• Pre-Site Assessment Report (10-30pg)• Potential areas for improvement• Estimate of potential savings per area
InterviewsProcess Analysis
Identification of potential savings
• Detailed Site Assessment Report (80-120pg)• Benefits qualified by area• Benefits quantified by area• ROI / Payback• Solution proposal• Quotation for solution implementation
InterviewsBusiness Process Analysis
Production Process AnalysisData Collection
• Working solution• Trained users• KPI dashboards• Solution support
Conceptual Design Functional Design
FATImplementation
SATOffline simulation and Testing
Commissioning
Pre-Site Assessment
Detailed Site Assessment
Implementation
Deliverables
Deliverables
Deliverables
• 1 week• 1-2
engineers• Plant
personnel available for 1 hour interviews
• 1-2 weeks• 2-4 engineers• Plant
personnel available for 1 hour interviews
• 10-24 weeks• 4-8 engineers• Plant
engineers involved in implementation
Presentation titleService, Customization, Innovation
Solution Approach
1. Behavior Modification If you do not need it, do not use it
Usually 0 – 30% potential savings
Not always sustainable
2. Operational efficiency Match usage to requirement
Usually 10 – 40% potential savings
Need to be sustained
3. Equipment efficiency Improve component efficiency
Usually 5 – 10% potential savings
Sustainable on its own
4. Improved Technology New Improved process
Save up to 60%
Sustainable
Presentation titleService, Customization, Innovation
Areas Of Opportunity
Where you Consume Energy
Furnaces, boilers, re-boilers, motors, steam/gas turbines
Reduce cost of purchased fuels, steam, power, plant produced energy consumed
Where you Recover Energy
Exchangers, waste heat boilers, economizers, expanders, insulation
Where to apply EAMS / APC Solutions
Presentation titleService, Customization, Innovation
Areas Of Opportunity
Where you Distribute Energy
Natural gas, fuel oil, fuel gas, steam, electric power
Where you Remove Energy
Cooling tower recirculation water, once through water systems, air fin/fan coolers, condensers
Optimization of Emissions
CO2, NOx, SOx, (and other VOCs)
Where to apply EAMS / APC Solutions
Presentation titleService, Customization, Innovation
How EAMS ties into existing infrastructure
Open, Scalable and Highly Configurable Architecture
Integrate process, electrical, steam, gas and other utility data using open standards and existing equipment, or augment your measurement network with best-in-class NovaTech components.
Not tied to any particular brand of valves or field devices
EAMS is deployable in any automation environment
Share data with ERP, MES and other enterprise data systems
Can start in one process unit and expand to additional phases as cost savings are proven
Custom application development and protocol emulation services are available
Presentation titleService, Customization, Innovation
Typical System Architecture
DCS/PLC/OPC L1 Interface
DCSManualEntry
ASCIIfiles
OthercomputersPLC
Process Lan
RDBMSLIMSOther
OPC Server Direct
Interface
SCADACustom
ApplicationSystems
ERP
WEB ServerRBV
Corporate WAN
EAMSServer & Historian
Plant LAN
LAB
Presentation titleService, Customization, Innovation
Benchmark against your own best performance
Develop equations between production rate / yields and energy requirements
Compare the actual daily performance with the best possible performance
Highlight deviations
Visualization tools
Proactive responses to deviations
Production
2,000
4,000
6,000
8,000
10,000
12,000
14,000
0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Rate
Eff
icie
ncy
Btu
/lb
Presentation titleService, Customization, Innovation
Components of a successful EAMS solution
Visualization
APC
Real-time Database
Integration
Reporting
Hardware
Training
Support
Instrumentation
Presentation titleService, Customization, Innovation
NovaTech’s EAMS
For More Information Contact:
NovaTech Process Solutions, LLC
11500 Cronridge Drive, Suite 110
Owings Mills, MD 21117 USA+1.410.753.8300+1.800.253.3842
www.novatechweb.com
Kevin Johnson [email protected]
Allen [email protected]