30 July 2015 1 PROPRIETARY INFORMATION

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Before We Begin… > This webinar is being recorded for future reference. > Questions can be asked in the chat box and will be

answered at the end during Q&A. > An email will be sent within 24 hours with download details

of the webinar materials.

30 July 2015 PROPRIETARY INFORMATION 2

© 2015 KBC Advanced Technologies plc. All Rights Reserved.

Benefits of Modelling Steam & Power Systems KBC Webinar

30 July 2015

Agenda

• Introduction • Modelling

• What needs to be included? • What can we do with it? • Hidden benefits? • On-line optimiser vs off-line modelling • Typical benefits

• Case Studies 30 July 2015 4 PROPRIETARY INFORMATION

Steam and Power Systems > Energy is typically highest controllable cost in process plants > Steam and power systems offer great scope for energy saving

– These systems are large consumers of energy and have many degrees of operational freedom:

– Typically 2-4% can be saved without capital investment • They need to be optimised on a daily basis.

– Typically 50% of a site’s gap to “Best Technology” Energy performance is attributable to utility system

• Energy projects in utilities can lead to dramatic savings > Steam and power generation are inseparably linked

– Because all on-site power is produced either in steam turbines, or in gas turbines that are, generally, attached to the steam system

– This interaction must be modelled accurately to take advantage of the synergies

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Typical Steam and Power System > Boilers > WHBs > Headers > Consumers > Steam

Turbines > Gas turbines > Letdowns > Flash drums > Deaerators

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What Needs to be Modelled? > Boilers

– Excess air, stack temperature, efficiency, blowdown – Optimise use of boilers

> Steam header conditions (reflecting system layout) > Steam turbines

– Isentropic efficiency – Optimise the use of turbines

• Which turbines to run? • motor/turbine flexibility.

> Power generation and its efficiency – Mostly in order to maximise backpressure power

> Other system components – Deaerators, flash drums, condensate return

> System controls – Actual marginal mechanisms

• Enables calculation of steam values

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What Needs to be Modelled?- Modelling Boiler House Area

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What Needs to be Modelled? - Modelling Process Units Area

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Things You Can Do with a Model > Rigorous heat balances

around headers > Multiple scenarios (fixed

power generation, seasonal variations)

> Additional logic, for example, to use the most efficient equipment

> Operating curves for turbines, boilers, etc.

> Gas turbine models > Optimisation > Models can be set up to use

real time plant data > Key Performance Indicators

sent back to plant data historian.

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Things You Can Do with a Model (cont’d)

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Offline Study Models

Efficiency Studies

Evaluate Energy Saving Options (what-if)

Predict future steam/fuel/power scenarios

Back of Envelope Calculations

Energy Balances

Determine steam marginal value

Training

On-Line Monitoring & Optimisation

Equipment Monitoring

KPI Generation & Tracking (incl. lost opportunity cost)

Real Time Optimisation

Performance Reporting & Dashboards

Design

Size New Equipment

Evaluate Multiple Design Cases

Configuration Decisions

Hydraulics

Hidden Benefits of Developing a Model

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> During Building Stage – Better understanding of the utility system for operators and

engineers • Connectivities and interactions • Operating strategies

– Quick-win ideas usually come to light during this review

Selecting the Modelling Approach

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KBC’s Modelling Products

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ProSteam

Excel Add-In

Any size model from 1 piece of equipment to whole site

Custom and flexible header logic (built by user)

Freeform Models

Connection to data historian can be created

Energy-SIM

Based on Prosteam Functions

Standard, Structured Workbook - maintainable

Standard performance reports

Databridge and SQL database for data handling

Corporate Viewer

In-built Logic

Petro-SIM V6

Rigorous GT Model

Process & Utility in 1 Single Model

Hydraulics can be added (Maximus, Network Solver)

Easy to connect to data historian

Expected Benefits

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Case Study: Ethylene Complex

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Case Study: Complex-wide Utility System Optimisation

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Case Study: Petrochemical Site

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Closing > Questions? > Future webinar topics in energy:

– Review of utility-related equipment in Petro-SIM v6 and ProSteam – Steam modelling in Petro-SIM v6 and ProSteam – Energy-SIM demonstration – HX Monitor and fouling studies – Dashboards – Using the data from your historian in your model – Petro-SIM GT model

> We welcome suggestions for future topics – please email kbc-marketing@kbcat.com

> Next webinar information will go out shortly. > Thank you for joining us!

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Questions > Can you elaborate on what type of projects you expect to find when you talk about 2 to 4%

operational savings? It depends on the site, but I would expect projects such as: – Switching turbines if a letdown is more than the minimum required – Try and reducing power generation of condensing turbines and to review the vacuum

level that is achieved – Try to maximise steam generation on GT’s HRSGs (if available) – Whether or not you should import or export power will depend on the power tariff (it

might be profitable to export power during the day and import power at night), with a model you will be able to establish the optimum operation and how the balance will look like

– Also, you can review benefits of changing your deaerator pressure. Typically you would try to reduce it, but in some cases you might want to increase it. For instance if you are venting steam

– if there is a vent on LP, on top of the changing pressure of deaerators, another option you can look at is to decrease the pressure of the LP header, in this way the turbines will need less steam to generate the required power and this will reduce the excess steam

These are the kind of projects you can easily spot during the review and analyse once you have a model

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Questions (cont’d) > How many man hours were spent creating the model on

Slide 18? – It varies from site to site, but typically ~2months for an off-line model

and between 6 to 9 months for a full blown optimiser

> My question is about heat losses in pipes – the steam used in the turbines needs to be superheated in order to avoid condensing in the turbine. Does the model make any calcs regarding the heat losses in the pipes? – It can be done, but the logic (heat losses, pressure losses) has to be

defined by the user

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Questions (cont’d) > you mentioned that a significant amount of savings can be

achieved by an off-line model, so, when would you suggest using an on-line optimiser? In our opinion an optimiser is mainly needed when there are frequent and significant variations to steam demand/generation, or very complex power tariffs, like the type we find in places like Japan; where prices change not just per time of the day, but day of the week, seasonal, etc. In these cases an optimiser would make sense as it would, otherwise, be very difficult to establish an action plan for all situations beforehand.

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