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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
AGENDA
 Company Overviews
 Visual MESA EMSTechnologies
 Motiva Port ArthurVisual MESA Model
 Optimization Actions Example
 Future developments
 Conclusions
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
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
AGENDA
 Companies Overview
 Visual MESA EMSTechnologies
 Motiva Port ArthurVisual MESA Model
 Optimization Actions Example
 Future developments
 Conclusions
• 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
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
AGENDA
 Companies Overview
 Visual MESA EMSTechnologies
 Motiva Port ArthurVisual MESA Model
 Optimization Actions Example
 Future developments
 Conclusions
VM EMS TECHNOLOGIES:
ERTO / EM ON-PREMISE IT ARCHITECTURE
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
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
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
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
AGENDA
 Companies Overview
 Visual MESA EMSTechnologies
 Motiva Port ArthurVisual MESA Model
 Optimization Actions Example
 Future developments
 Conclusions
IMPLEMENTATION CASES
IMPLEMENTATION CASE
 BLRs 34, 35 and 46 were reduced
 Reversed later (savings increased)
BLR 46
BLR 34
BLR 35
Energy Gap
IMPLEMENTATION CASE
 Recommendations for STG 33
were partially implemented
STG34 inlet
Energy Gap
 STG 34 steam flow was decreased
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
AGENDA
 Companies Overview
 Visual MESA EMSTechnologies
 Motiva Port ArthurVisual MESA Model
 Optimization Actions Example
 Next Steps
 Conclusions
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
AGENDA
 Companies Overview
 Visual MESA EMSTechnologies
 Motiva Port ArthurVisual MESA Model
 Optimization Actions Example
 Next Steps
 Conclusions
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.
Motiva online monitoring and optimization energy system

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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.