An introduction to energy management

KBC/Petronas Technology Session
and Round Table Workshop
Proprietary Information
16-17th January 2018
Confidential Information
An Introduction to Energy Management
What’s new in KBC
Carlos Ruiz, Product Manager
Energy Management Visual MESA
carlos.ruiz@kbcat.com

& Round Table Workshop
Proprietary Information 16-17th January 2018
Agenda
• Introduction
• Visual MESA Energy Management System (VM-EMS) Applications
• Visual MESA EMS Architecture: traditional versus integrating supply &
demand
• Visual MESA EMS functionalities description
• Visual MESA Demonstration
• Case Studies

Visual MESATechnologies
• VISUAL MESA Energy Management System (EMS)
Real time online energy and emissions Management System that assists companies in their
SEP/ISO 50001 initiatives
 VM-ERTO: Real Time, Mixed Integer Non Linear Optimization, either open loop or closed loop
 VM-EM: Energy Key Performance Indicators Calculation and Monitoring, including emissions
 VM-EMPO: Optimal Energy Systems Multi-Period Planning
• VISUAL MESA Hydrocarbon Management Solutions (HMS)
 VM-PA: Next generation of Production / Yield Accounting and Data Reconciliation system
which assists users with the calculation of their site-wide daily mass balances, on a tank-by-
tank and unit-by-unit level. It serves as the foundation of the facility’s loss control initiatives
 VM-SCS: Hybrid continuous and discrete events simulation application to support the
management of operations in refinery and petrochemical processes. It provides future visibility
thorough detailed simulation models of both logistic and unit operations, keeping constantly
updated projections of inventories and material properties

AComplete Solution for Energy Optimisation
Supply
Re-UseDemand
Energy
CO2
Utilities System
1981-1989
MESA
Simulator
1992-1998
G2-MESA
Visual
MESA
(VM-ERTO)
1998-2000
Closed Loop
optimization
(VM-
ECLRTO)
2000-2012
Fuels
Hydrogen
UI & Excel
Energy
KPIs
2012-Present
Web Browser
Client
Multi Period
Optimization
(VM-EMPO)
Energy Balances
and EnKPIs
Dashboarding
(VM-EM)Superior energy optimization technology
Over 90 installed real time optimizers
Heat Recovery
1984-1986
Linnhoff March
Pinch
Consulting
1986-2011
SuperTarget
pinch software
TotalSite
1991-1997
ProSteam released
1998-2012
HX Monitor
within Petro-SIM 4.1
2016-Present
Petro-SIM 6.2
Fully integrated process
+utility modelling
BT correlations
Energy recovery & heat
exchange consulting and
software
Linnhoff March acquired
by KBC in 2002
Over 1000 energy consulting studies
Process Units1979-1988
KBC
yield &
energy
studies
1988-1998
Petrofine
Profimatics
simulation
software
1998-2004
HYSYS.
refinery
collaboration
Petro-SIM
launched
2004-2016
TTS
acquisition
human
performance
improvement
2016-Present
Petro-SIM 6
launched
Maximus
pipeline
simulator
Infochem
thermo-
dynamics
Process and energy consulting and
software, underpinned by human
performance improvement

1981-1989
MESA
Simulator
1989-1992
MESA with
SQP and MI
Optimizer
1992-1998
G2-MESA
Visual
MESA
(VM-ERTO)
1998-2000
Closed Loop
ERTO and
Cogeneration
Modeling
(VM-ECLRTO)
2000-2003
Fuel
Systems and
Emissions
calculations
2003-2006
Microsoft
Visio based
GUI and MS
Excel reporting
2006-2008
Energy Key
Performance
Indicators
(EnKPIs)
Plant Energy
Cost Block
2008-2010
Applied to
Ethanol
Production
2010-2012
Applied to
District Cooling
and Heating
Applied to
Hydrogen
Systems
2012-present
Internet Web
Browser Client
Multi Period
Optimization
(VM-EMPO)
Energy
Balances and
EnKPIs
Dashboarding
(VM-EM)
VM-ERTO VM-ECLRTO VM-EMPO
VM-EM
Modular
Energy
System
Analyzer
Visual MESAEMS Timeline: VM-ERTO, VM-ECLRTO, VM-EM and VM-EMPO

Visual MESAEnergy Management System Applications
Visual MESA
EMS Suite
VM-ERTO
VM-ECLRTO
VM-EMVM-EMPO
VM-ERTO / ECLRTO
VM-EM
VM-EMPO
Visual MESA Energy Monitor offers a feature set
specifically built for the monitoring of energy
systems (KPIs Calculation, balances, etc.)
Visual MESA Energy Real Time Optimizer (open
or closed loop) is the leading real-time solution
for modeling and optimization of energy systems
Visual MESA Energy Multi-Period Optimizer is
the energy management tool for the optimal
planning and scheduling of utility assets

Visual MESAEMS Overview
• Leading Real-Time EMS solution for Modeling, Monitoring, Optimization and
Planning of steam/water, fuel/emissions, power and hydrogen systems
 Ability to quickly configure mass and energy balance models
 Mature models and solution engine
 Simple, graphical interface to construct energy models
• Mature modeling and industry leading real time optimization engine
 Robust real-time modeling and optimization
 Real-time calculation server supporting closed-loop
 Appropriate data error handling
 Easy/fast connection to real-time data via OPC
• Easy to use, graphical interface – Web GUI and MS Visio
 Windows service, web browser based GUI (thin client)

External Utilities
Contracts
Emissions
Regulations
Hydrogen Fuel Steam Water Electricity
Energy and Utilities System
Measurements
Optimum
Set Points
CLOSED-LOOP
signals to
control systems
OPEN-LOOP
advisory reports to
operators
Control System / Historian
Operators
Process (Utilities Consumers and Generators)
(Degrees of freedom in Generation and Distribution)
Optimum
Energy
System
Operatio
n Report
Optimum
Energy
System
Operation
Report
VM-Energy Real Time Optimizer / VM-Energy CLRTO
Traditional Architecture

External Utilities
Contracts
Emissions
Regulations
Measurements
EnPIs, Streams
and Equipment
Calcs.
Energy System visibility and
accounting for
operators and engineers
Operators
Energy and
Emissions
KPIs
Monitoring
Energy Use
and Account
Energy
Related
Reports and
Dashboard
VM-Energy Monitor

External Utilities
Contracts
Emissions
Regulations
Fuel Steam Water Electricity
Energy Scheduling
and Planning
Operators
Data
Visualization
and Custom
Reports
Optimal
Allocation
of Utility
Assets
VM-Energy Multi Period Optimizer
Measurements Forecasts

Optimum
Set Points
Process
(Utilities
Consumers)
External Utilities
Contracts
Emissions
Regulations
Measurements
CLOSED-LOOP
signals to
control systems
OPEN-LOOP
advisory reports to
operators
Operators
(Degrees of freedom in Generation and Distribution)
Optimum
Energy
System
Operatio
n Report
Process Models
Measurements
EnPIs, Streams
and Equipment
Calcs.
Energy
Related
Reports and
Dashboard
Energy and
Emissions
KPIs
Monitoring
Energy Use
and Account
VM-Energy Real Time Optimizer / Monitor and Petro-SIM
Integrated Utilities + ProcessArchitecture
Optimum
Energy
System
Operation
Report

What Does Energy Real Time Optimization (VM-ERTO / ECLRTO)
Provide?
• 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?
• A Utilities Real Time Optimizer that ensures Operations is doing the best it can
with the utilities assets it has available in this moment and with the current operating
conditions.
• It gives Operations a Real Time Target for producing and distributing the utilities at
the minimum Site-Wide overall Energy System cost.
• Customized or pre-defined Excel based reports provide operating actionable
items guidance
• With model, optimization solution and reports fully accessible from within a
web browser.

What Does Energy Monitor (VM-EM) Provide?
• Ad-hoc RTDB for massive historization of results (Shistorian)
 Historization of all the modeled streams and equipment results., calculated KPIs, limits and alarming, etc.
 Internal tags automatically created and updated based on model topology
• Key Performance Indicators (KPIs) Alarming
 All built on the site model to provide consistent data
 Alarming capabilities, also integration with existing Company Standard KPIs visualization dashboard
 Built in KPI calculators to swiftly configure
- Plant Energy use and cost per unit of plant production, equipment efficiencies (i.e., boilers, heaters, GTs, turbines,
etc.), bias from performance curves, etc.
 Equation block for custom calculations (i.e., BT index, EII), using current and/or historical data
• Excel style reports on any time-frame
 Steam / Fuels / Hydrogen / Electricity balances of a plant or sub plant over any time period  Monthly or
Periodical Balances for accounting are produced “on the fly”, with boundaries chosen from the web
GUI either Site, Area or Unit wise
 KPIs

What Does Energy Multi-Period Optimizer (VM-EMPO) Provide?
• Visual MESA Energy Multi-Period Optimizer (VM-EMPO) allows scheduling
engineers and operators to find the optimal operation of the utility plants on a
time horizon when dealing with time dependent constraints (i.e., planned out-
of-service periods, caps on emissions, fuel tank farms management,
minimum/maximum start/stop time of equipment, thermal energy storage
management, etc.)
• Energy System Optimum Planning, taking into account multi-period optimization
handles and constraints
 Including forecasting of prices, weather conditions, equipment availability, energy storage, fuels storage and
availability, etc.
 Constraints to be imposed on certain periods or integrated (i.e., totalized) variables, like emissions cap or
total fuel consumption
 Solution presented in user configurable Gantt and bar charts.
• Excel style reports for the Planning Periods
 Multi-period energy, emissions and KPIs reports

Facility 1 Facility 3Facility 2 Facility NFacility 4 Facility 5 Facility 6
Targets &
Actions
Audit and
Accounting
Energy
Indicators
Integrated
Operations
WATER
CARBONENERGY
• Site wide real-time energy
optimization
• Validated and consistent
measurements and
• Calculation of Energy
Balances & KPIs
• Published to Corporate
Energy Portal for site and fleet
evaluation
• Presented in a Dashboard
Visual MESAEMS: Fleet Energy Management

Direct connection for closed loop
Visual MESAEMS: VM-ERTO/EM/ECLRTO ITArchitecture

Visual MESAEMS: ERTO/ECLRTO/EM Server
• The server is where Visual MESA ERTO/ECLRTO and/or EM are automatically
executed as a service

Visual MESAEMS: VM-ERTO Online and Offline Use
• The Visual MESA model can be used in Open loop with a
flexibility for Online and Offline data fetching.
 During Online mode, it will fetch the input data from system for the period selected by the user
with an option of average data or current data
 Then user can take the model Offline and manually overwrite inputs, as needed
- Visual MESA Excel Add-In is available to manage the what-if optimization cases from within Excel
(write and read to/from the model)
Client-Server / Web browser access Standalone use (model building and what-if studies)

Structural
Model
External
Multi-period
Constraints
Forecast
Data
UserInterface
Optimal
Schedule
UserInterface
Calculation
Engine
Through the user interface, the user
can define the scheduling problem by
providing three major inputs.
Namely, the structural model of the
utility plant, the forecasted data of
future conditions of the plant and an
appropriate set of multi-period
constraints.
The calculation engine uses the
inputs to generate the optimal
schedule.
Input-output structure
Visual MESAEMS: VM-EMPO DataArchitecture

Visual MESAEMS: VM-EMPO Operational Procedure
STEP 1: Build Utilities
Model
STEP 2: Set-Up Forecast
and Constraints
STEP 3: Define Schedule
Horizon
Set-UpRunVisualize

Visual MESAEMS: VM-ERTO/EM Project Schedule

Visual MESAEMS: VM-ERTO/EM Project Typical Client Personnel
Requirements
• Total: ~10 weeks for Project Owner and ~12 weeks for Engineering
Designate
• Before and During KOM
 2 weeks for Project Owner
 4 weeks for Engineering Designate who can obtain required information
• Model, Optimization, and KPIs
 Project Owner and Engineering Designate available as needed to answer questions and clarify data or assumptions
• Training and Model Review
 1 week for Project Owner; 1 week for Engineering Designate
• Commissioning
 1 week for Project Owner; 1 week for Engineering Designate
• Formal Training for Operators (by Client)
 1 day per shift plus 2 days of course preparation time, such preparation with the assistance of Soteica
• For implementing optimization recommendations in operations
 3 weeks for Project Owner and 2 weeks for Engineering Designate

Visual MESAEMS: VM-ERTO Work Flow (Open Loop Optimization)
Production/Energy Meeting (weekdays)
EMC presents and discuss Energy Cost Gap and
main Energy KPIs for previous 24 hours
EMC communicates direction to Operations,
as Energy Cost Gap or Energy KPIs warrants
Real-Time PI Data
Operators Implement Visual MESA Recommendations on a daily or shift basis
Also, periodically as alerted for an increase in Energy Cost Gap
via the Reports or by having the PI tag Energy Cost Gap
or Energy KPIs trends on a screen
Operating Actions:
Turbine/Motor Swaps, STGs / GTs power, Boilers balancing,
Boilers/Furnaces firing efficiency improvement
Visual MESA runs automatically with real-time PI data (every 30 minutes)
Rigorous solver optimizes discrete
and continuous variables
Calculates Optimization Opportunity
or “Energy Cost Gap” and other
Energy KPIs
Creates Report with Operator
Recommendations for Capturing
Energy Cost Gap
Optimization and KPIs are pushed
back to PI and in Excel, .pdf, and
.html Reports
Operators verify/update main constraints, as well as Turbine/Motor swapping availability
and report to Energy Management Coordinator (EMC) as needed
Operators update optimizer and also update EMC if any T/M swap can’t be performed
(i.e., due to an equipment out of service , on maintenance, etc.).
Also, if a previously unavailable equipment is on service again.
EMC updates optimizer status,
prices and/or constraints

Visual MESAEMS: Software Maintenance and Sustainability Services
• Following commissioning and start-up, the Software Maintenance Services starts,
designed to deliver both updates and enhancements to the software, and which includes:
 Access to improvements or changes to the software designed to update operating performance;
 Access to functionalities, functional attributes, or interface enhancements that did not previously exist in the initial Software
version sold;
 Technical services regarding the use of the software and its enhancements and modifications.
 Remote installation of the latest Software versions, including adaptation and testing of the model and customized Excel
reports.
• The Sustainability Program are proactive services delivered to ensure adoption and sustainability of the
software solution at our clients’ sites. Provided remotely through a secure VPN, these services include:
 Discussion and answers to questions relating to design and implementation of the software site-specific model;
 Supervision and validation of Customer’s modifications to the software site-specific model;
 Advice on how the Customer may modify, or implement new elements within, the software site-specific model;
 Discussion and answers to questions regarding interpretation of the results produced by the software site-specific model;
 Support of the Customers’ development of an energy system performance improvement plan including, but not limited to;
(i) specifying additional metering and (ii) equipment performance audits; and
 Supervision of Customers’ studies for steam system modifications, projects and shutdown maintenance.

Visual MESA EMS Demonstration

VM-ERTO Screenshots

VM-EM Screenshots

VM-EMPO Screenshots

Annex 1
Examples of Benefits Obtained in Visual
MESAEMS Projects

Visual MESAEMS Case Studies:
Reference Papers Documents
• Extensive library with Reference Papers:
 Document with all References and papers indexed by year and industry
 Vast majority of the papers co-authored with our customers or even written by themselves
• Customers with references list

Jamnagar site (2016 – VM-ERTO, Phase 2 in execution)
Corporate Standard for Utilities RTO (multiple sites)
Corporate Standard for Utilities RTO (multiple sites)
Corporate Standard for Utilities RTO (3 sites)
Corporate Standard for Utilities RTO (7 sites)
Port Arthur site (2017 – VM-ERTO)
Singapore site (2016 – VM-ERTO)
2 sites (2011 and 2017 – VM-ERTO)
Chiba site (2017 – VM-ERTO)
3 sites (2006, 2014 and 2018 – VM-ERTO)
Visual MESAEMS Case Studies:
Selected Customer Base & Recent Projects

Visual MESAEMS Case Studies
Case 1: REPSOL Tarragona Refinery
• Challenge
 Reduce the total cost of the energy
 Coordinate optimization actions to be taken at the
different Units of the site
• Solution
 Visual MESA Energy Real Time Optimizer
(VM-ERTO)
 Model, optimization and reports setup
 Engineers and operators training
 Solution sustainability services
• Benefits1
 Energy cost reduction of 4% (in the order of 2 MM€/y)
due to optimization
 Additional, non quantified benefits, were obtained by
energy performance monitoring
With 2003 costs of
20 USD/barrel
1 Energy Costs Reduction By Using An On Line Utilities Optimization Tool, Diego Ruiz Massa, Carlos Ruiz García, David
Nelson, Gary Roseme, Manuel Lázaro Meléndez, María Sartaguda Pardos, European Refining Technology Conference
(ERTC) Computing, London, UK, June 2004

Case 2: KNPC, MAARefinery
• Challenge
 Generate operational recommendations in order to help
engineers and plant operators in the decision making
process
 Calculate and track several Energy KPIs
• Solution
 Visual MESA Energy Real Time Optimizer (VM-ERTO)
 Model, optimization and reports setup
• Benefits1
 Savings of 4.4 MM$/y
 CO2 emission reduction of 27,600 tons per year were
reported
 What-If case example with 2 MM$/y of potential savings
was presented 1 Online Energy Management System Implementation in KNPC Mina Al-Ahmadi Refinery, M. Ershaid, A. Al-Tarkeet, D.
Periyasamy, N. Visuara, C. Ruiz, S. Cúneo, Middle East Process Engineering (MEPEC), Bahrain, September 2013

Case 3: SABIC Saudi Kayan Petchem Complex
• Challenge
 Implement a Real Time Online Energy Management System
• Solution
 Visual MESA Energy Real Time Optimizer and Monitor (VM-
ERTO and VM-EM)
 Model, optimization, Energy KPIs calculation, dashboard and
reports setup
• Benefits1
 Energy cost reduction in the order of 3.42 MM$/year
 Additional savings were obtained from:
- Online Energy Monitoring, Auditing and Accounting
- Online Energy KPIs Dashboard
 What-if studies:
- Capital Project Opportunities
- Planning / Scheduling of Utilities
Before implementing recommendations:
Average potential savings: 390 $/h
After implementing recommendations:
Average potential savings: 270 $/h
Captured Savings: 120$/h (1.05 MM$/year)
Example of an optimization action in which Visual MESA recommendations
were partially applied and, as a consequence, 1.05 MM $/year of savings
where achieved
1 Real Time Online Energy Management System Implemented at SABIC Saudi Kayan Petrochemical Company, M.
Al-Shehri, T. Khan, A. Salem, C. Ruiz, M. Reinaldi, S. Cúneo, Middle East Process Engineering (MEPEC), Bahrain,
September 2013

VM EMS Case Studies
Case 4: TECO District Heating & Cooling, Houston TX, USA
• Challenge
 Reduce the total cost of the energy to produce chilled water and
steam for the Houston Medical Center
 Have an optimum planning for the site, including Thermal
Energy Storage (TES) and Combined Heat and Power (CHP)
• Solution
 Visual MESA Energy Real Time Optimizer and Multi-Period
Optimizer (VM-ERTO and VM-EMPO)
 Model, optimization, planning and reports setup
• Benefits1
 Improved total energy efficiency by real-time optimization
 Multi-period energy optimization used for day ahead schedule,
taking into account demand, weather and power prices forecasts
1 Multi-Period Optimization of District Energy Supply, Development of Day-Ahead Scheduling to Supplement
Real-Time Optimization at TECO, J. Garcia, J. Ruiz, T. Reitmeier, International District Energy Association
(IDEA) Annual Conference, Miami, USA, June 2013

Questions?

Thank you!

An introduction to energy management

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to An introduction to energy management

Similar to An introduction to energy management (20)

More from KBC (A Yokogawa Company)

More from KBC (A Yokogawa Company) (20)

Recently uploaded

Recently uploaded (20)

An introduction to energy management