Service, Customization, Innovation NovaTech EAMS The Role of Advanced Process Control in your Energy...

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


NovaTech @ a Glance

Agro Processing

Brewing

Food & Beverage

Energy/Utilities

Heavy Industry

Pharmaceutical

Specialty Chemical

NovaTech’s Industry Focus


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


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


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.


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


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


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


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


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


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.


Fired Heater Example

FiredHeater

F

P

QFeed Flow

Fuel Gas Flow

Fuel Gas Pressure

Temperature

Duty


Fired Heater Example

14

FiredHeater

F

P

QFeed Flow

Fuel Gas Flow

Fuel Gas Pressure

Temperature

Duty

Independents Dependents


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


Models from Plant Tests

Process

2

1. Step the Independents 2. Observe the Dependents

3. Identify the Models


Benefits of APC

Limit

Target

= Profit

APC Reduces Variation

Reduced Variation Allows Operation Closer to Limit

No APC

Operating Margin

Reduce Variability


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%


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


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


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


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


KPI Dashboards


Forward projection and decision analyses


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


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


Need to be sustained

3. Equipment efficiency Improve component efficiency


Sustainable on its own

4. Improved Technology New Improved process

Save up to 60%

Sustainable


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


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


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


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


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


Components of a successful EAMS solution

Visualization

APC

Real-time Database

Integration

Reporting

Hardware

Training

Support

Instrumentation


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]

mailto:[email protected]

mailto:[email protected]

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