Real Time Efficiency Based Energy Optimization

Abstract This paper is based on successful implementation of dynamic efficiency-based optimisation in Habshan-5 Utility Boilers Objective was to Minimize Loss Opportunities in optimal Fuel Gas Consumption in Boilers while maintaining steam balance across Habshan-5 Utility Steam network. Thus, scope was To Implement efficiency-based optimizer that allocate load among boilers based on their dynamic efficiency instead of equal allocation To Minimize letdown between STS and STL to minimum allowable while ensuring stability of both STS & STL headers Maintaining header balance across steam system accounting all consumers and producers Original Method Original Operation was Equal allocation based on STS header pressure. Hi Selector based PID controls the letdown. Drawback Package Boilers though identical, differ in efficiency due to various reasons. Similarly, WHRB also differ in steam generation efficiency from duct firing. There is a significant efficiency difference between WHRB and Package boilers & respective fuel consumptions. Also, variation existed in let-down opening with scope for optimisation. Advanced Energy Solution (AES) To meet the improvement needs, M/s Honeywell Advanced Energy Solution coupled with Honeywell APC was used. Economic Load Allocation of boilers based on cost curve generated from reconciled efficiency (calculated dynamically using ASME method) curve. Non-linear economic load allocation of boilers considering all constraints & efficiency curves are reconciled at every execution. Multivariable Predictive Controller APC minimise Letdown opening. Project Outcome First of its kind in ADNOC, this real time dynamic efficiency-based optimisation resulted in significant reduction in Fuel Gas consumption & equivalent amount of GHG 24.7K Tons. Apart from this, the implementation completed in record low time (6 months) with payback period less than 4 months