Grangemouth Utilities Optimiser

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Grangemouth Utilities Optimiser Powered By Docstoc
					On-line Optimisation of an
Integrated Petrochemicals
Facility
Glyn Westlake, Emerson
Mark Brewer, Emerson
Tim Desmond, BP
   Overview
                  The Grangemouth site.

                  On-line optimisation.
                       – Types of optimisation.

                       – Why use optimisation here?

                  The implemented system.




[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 2
   BP Grangemouth
       Large integrated site.
       Processing facilities for Forties pipeline system.
          – Approx 1 million barrels per day.
       Major Fuels Refinery.
          – Annual capacity approx 10 million tonnes.
       Major petrochemical producer.
          – Annual capacity approx 1.2 million tonnes.
       Large energy user.
          – Steam.
          – Electricity.


[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 3
   Grangemouth Utilities Plant
       8 Boilers.
       7 Steam Turbines.
       1 Gas Turbine/Heat Recovery Steam Generator.
          – GT/HRSG run by separate company.
          – Contracts for exchange of fuel/steam between BP and
            “CHP”.




[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 4
   Grangemouth Utilities Plant
 Fuel Gas

 Fuel Oil




                       Blr                Blr        Blr   Blr   Blr                 Blr   Blr   Blr
                        8                  9         10    11    12                  13    14    15

 EHP
 Steam
 Users



                                          TA         TA    TA    TA                  TA    TA    TA
                                           5          6     7     8                   9    10    11

 MP
 Steam
 Users

 Electricity
 Users


                                                GT




                                                                       Natural Gas
                       Electricity Grid




[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 5
Types of Optimiser
   OPTIMISER
                 • Plant data entered manually.
     Off-Line    • Model tuned manually.
     PLANT       • Results implemented manually.


   OPTIMISER     • Plant data entered automatically.
   Open-Loop     • Model tuned automatically.
                 • Results implemented manually.
    PLANT



   OPTIMISER
                 • Plant data entered automatically.
   Closed-Loop   • Model tuned automatically.
    PLANT        • Results implemented automatically.
   Real-Time Optimisation - Criteria
                Problem complexity
                   – Is “the answer” obvious?
                   – Can the system be simulated?
                Degrees of freedom
                   – Is there any scope for optimisation?
                   – Will the optimiser generate a large number of
                     small set point changes?
                Amount of change in the problem
                   – Can “the answer” be worked out once and then
                     kept?
                   – Can the system cope with process
                     disturbances?

[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 7
   Why Use Optimisation Here?
                Complexity
                  – Individual unit performance can be found from historic data.
                  – Units change performance gradually due to fouling etc.
                  – Optimal operation requires trade off between different units
                Degrees of freedom
                  – Boiler rates.
                  – Turbine rates.
                Change
                  – Steam demands.
                  – Indigenous fuel availability.
                  – Prices.
                  – Unit performance.
[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 8
   Why Use Optimisation Here?
                Site-wide push to reduce energy usage.
                Desire to improve
                  – Instantaneous operation. How should we currently
                    be running to minimise costs?
                  – Planning. What equipment configuration would be
                    best during the expected plant start-up?




[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 9
   What does the optimiser do?

         For the given total steam and power demand:
            – Minimise total operating cost (including CHP
              streams).
         By
            – Choosing individual boiler steam generation rates.
            – Choosing individual T/A electricity generation rates.




[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 10
Project Components
On-line Optimiser    Off-line Optimiser




    Control Room           Offices
   On-line/Off-line Optimiser
       On-line optimiser
          – Results every few minutes displayed on DCS screens.
          – Operators use the advice to set up the plant for best economic
            operation.
       Off-line Optimiser
          – Uses same model as on-line optimiser, tuned to current
            performance.
          – Allows office based staff to run operating scenarios to evaluate
            alternatives.
          – Automated comparison of different equipment configurations.
          – Used by Optimisation Engineers/Planners/Technical Engineers.
          – Intended for day by day use for short term planning.



[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 12
   System Components

                       Models       Optimisers   Estimators




                                  Shared Data




                                Data Conditioning




                                      DCS

[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 13
   Project Status/Conclusion

       System successfully implemented.

       Benefits audit ongoing.

       On track to exceed guaranteed 1% benefits.

       System intended to provide basis of closed-loop
        optimiser.

       Good candidate for on-line optimisation.


[File Name or Event]
Emerson Confidential
27-Jun-01, Slide 14

				
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