Applying Sigmafine & Thermodynamics Extension for Energy Balance and Performance MonitoringCody Drake - Sigmafine Specialist

Houston – 18th September 2018Pimsoft

Topics

Sigmafine inEnergy domain(utilitynetworks,LNG,power…)

EquipmentKPIevaluationand

performancemonitoring

CompliancetoISO50001for

energyefficiency

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Sigmafine in EnergyUses and benefits

Company Challenges in Energy Domain

Energy cost fluctuations of last years have affected companystrategies:

Need of verified and auditable data to all trading partnersOperate with environmental permit limitsProfit maximization based on energy balance (heat, power and steam)

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LNGproductionandregassification

Energyintensiveprocesses(furnaces,compressors,distillation columns)

Utilitynetworks Powergeneration

Sigmafine in Energy Domain

Sigmafine provides trustable data based on validated quantities, toperform energy calculations and KPIs.• Energy accounting (utility balance)

üFuel gas networküSteam networküElectricity network

•

• Performance monitoringüModel based data reconciliationüProvide reliable KPIs based on reconciled data

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Reconciled energy production and consumption

Equipment performance

Applying Sigmafine beyond production accounting

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ValidatedKPIsRawdata

RECRAW

Reconcileddata(massandenergy)

SF Balance Analysis

• Sigmafine balance (linear)• Energy balance (non-linear)

SF Extensions• Steam Tables• Thermodynamics• LNG calculations

Sigmafine in Energy Domain

Sigmafine can merge Accounting and

Engineering targets in one scenario

Fuel Gas Network

Combine mass flow meters with analyzers to evaluate LHV/HHV

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Energy balance of thenetwork• Sources: natural gas, fuel gas,

etc.• Destinations: all the consumers

(process units, flares, boilers,etc.)

Model’sassets

Graphicalrepresentationofelementsandconnectivity

Steam Network and Energy Balance

One model with coupled mass and energy balance

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Advantages• Higher redundancy• Rigorous data reconciliation

(allows calculation of bothmaterial and energy relatedindicators)

Disadvantages• Higher model complexity• Non-linear model requiring

iterative solutionMass Enthalpy

Usage of Sigmafine in LNG

• Data validationü verify custody transfers and other measurementsüdetermine the state of the terminal in near real-

timeü early warning of unexpected imbalances or lossesü identify less accurate measurements (meter

maintenance)

• Best estimate of unmeasured valuesü estimate component dataü verify equipment performance

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Energy Content Estimation in LNG

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• Sigmafine LNG extension:üLiquid/gas flows energy calculation (heating calculation)

üCompressibility factorüMass calorific valueüLNG tank density

• Sigmafine analyses:üMass and Component balanceüEnergy balance

Sigmafine in Power Generation

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Benefits with Sigmafine:Power industry needs:

Transparency and auditabilityof the entire business process

Manage huge amounts of information (frequent data)

Data consistency

Automatic validation of regulatory emission parameters

Hourly production balancingo near real-time target assessment

Accurate monitoring of implemented production and environmental strategieso validation of regulatory emission parameterso support product distribution optimization (heat,

steam, electricity, water, etc.)o loss estimation and monitoring

Business accounting automation and validationo validate unit production efficiencieso automatic data transfer to business systemso auditability compliance

Thermodynamics extensionand KPI calculationUses and benefits

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Sigmafine Thermodynamics Extension

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Conventionally, operators and process engineers monitorthe status of the plant by looking at measured data viatrends and displays to understand process performance.

For the process information that cannotbe directly seen in measured data, theThermodynamics Extension provides anaccurate estimation using equations ofstate.

Heat exchanged?Efficiency?

Sigmafine Thermodynamics Extension

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Evaluation of stream properties through theSigmafine Thermodynamics Extension:

• Consider the composition of flow

• Perform the equilibrium calculation basedon equations of state (e.g. Peng-Robinson) todetermine unmeasured vapor&liquid flowrate

• Calculate accurate estimates of propertiesof the vapor and liquid flows

Multi-Stage Gas Compressor Model Empowered by Thermodynamics Extension

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Estimation of composition

after knock-out drum

Reconciled Data Improve KPI AccuracyCase study: reboiler duty of styrene purification column

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Can you really trust your KPIs?

uncertainty: 3,0% uncertainty: 2,7%

Difference: 45,6 kcal/kg

~2000€/dayofhiddenoperatingcosts!

üProduce KPIs based onreconciled data

üKeep product in spec reducingsteam consumption

Correlation between flue gas oxygen, efficiency and crude batches

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Raw data show poor correlation Reconcileddataallowtocorrelateequipmentperformancewithcrudetype

Reconciled Data Improve KPI AccuracyCase study: industrial furnace

Sigmafine App for Thermodynamics

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The thermodynamics calculations are also available for the OSIsoft® PISystem® via Sigmafine App, a derivative product of Sigmafine Serverextensions.ü Advanced analytics capability of Sigmafine

without model buildingü Make complex engineering calculations

accessible, consistent and easy to manageü Empower the PI AF Analyticsü Support the process engineers in monitoring

plant performance almost real - time

Compliance to ISO 50001Sigmafine supports the standard ISO 50001 for Energy Efficiency

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Sigmafine Supports Energy Management

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«Using energy efficiently helps organizations save money as well as helping to conserve resources andtackle climate change. ISO 50001 supports organizations to use energy more efficiently, through thedevelopment of an energy management system (EnMS).»

• Monitoring and measuring• Compliance with legal requirements• Internal audit• Evaluation and investigation of non-

conformities (e.g. non-achievementof target values)

• Controls of records

Do

Check

Act

PlanMassivequantityofdatatobehandled

Sigmafine Model Based Process Monitoring

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Sigmafine supports activities within the ISO 50001 frameworkproviding:ü Accurate estimation of

flow properties

ü Trustable data for the analyses

ü Key process unmeasuredparameters (e.g. energy duty and efficiency of equipment)

Integrated Energy and Mass balance

(system runs unattended)

powered by the Thermodynamics extension

Sigmafine Results Automatically Aggregated on PowerBI Dashboard

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ü Improve real-time operations in the control room

ü Support energymanager dailyactivities

ü Data accessibleon-line and by mobile

Conclusions

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• Sigmafine energy balance to validate the quality of process data:üAll data sources (PI and external) considered in modelüData validation and filteringüAccurate reporting

• Accurate estimation of properties with Sigmafine advanced energycalculations to support operational challenges:üBetter process insightüKPIs calculated on reconciled data are more accurate improving decision making processüUnderperforming production can be easily identified

• Sigmafine supports the standard ISO 50001 for energy efficiency:üPerformance monitoring for near-real time balance

Online Resources

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• Technical reference• https://sigmafinesupport.com/• Register as “Customer”

• Sigmafine website• https://sigmafine.pimsoftinc.com

Presenter

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CodyDrakeSigmafine SpecialistPimsoftcody.drake@pimsoftinc.com

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