Solution Provider for the Hydrocarbon Industry • HQ in Houston & Offices in Barcelona, Buenos Aires, Santa Fe and Rosario • More than 140 applications on site world wide • Most widely used ERTO system: +90 References World Wide Houston, USA Barcelona, Spain Buenos Aires, Argentina KBC Executive Symposium Japan 2018 April 19, 2018
Proven Operational Excellence and Profit improvement consulting Leading simulation technology for hydrocarbon industry Secure cloud services for DaaS Supplier/ customer collaboration Leading provider of energy real time optimization SVM Company Overview –Soteica Visual MESA (SVM), Yokogawa & KBC • 2013 Partnership agreement between SVM & Yokogawa • 2016 Yokogawa acquires 100% of SVM • Joint Projects SVM & Yokogawa since 2013 18 world wide (9 in APAC) • 2017 SVM integration in KBC KBC Executive Symposium Japan 2018 April 19, 2018
Energy Management Solutions (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 KBC Executive Symposium Japan 2018 April 19, 2018
Complete Solution for Energy Optimization Supply Re-Use Demand 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 optimisation technology over 90 installed real time optimisers Process Units 1979-1988 KBC Yield & Energy Studies 1988-1998 Petrofine Profimatics Simulation Software 1998-2004 HYSYS. Refinery Collaboration Petro-SIM Launched 2004-2016 TTS Acquisition Human Performance Improvemen t 2016-Present Petro-SIM 6 Launched Maximus pipeline simulator Infochem Thermo- dynamics Process and energy consulting and software, underpinned by human performance improvement 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 KBC Executive Symposium Japan 2018 April 19, 2018
Applications • VM-ERTO / ECLRTO • Visual MESA Energy Real Time Optimizer (open or closed loop) is the leading real-time solution for modeling and optimization of energy systems • VM-EM • Visual MESA Energy Monitor offers a feature set specifically built for the monitoring of energy systems (KPIs Calculation, balances, etc.) • VM-EMPO • Visual MESA Energy Multi-Period Optimizer is the energy management tool for the optimal planning and scheduling of utility assets Visual MESA EMS Suite VM-ERTO VM- ECLRTO VM-EM VM- EMPO KBC Executive Symposium Japan 2018 April 19, 2018
Energy Co-Pilot 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 Cogeneratio n Modeling (VM- ECLRTO) 2000- 2003 Fuel Systems and Emissions calculatio ns 2003-2006 Microsoft Visio based GUI and MS Excel reporting 2006-2008 Energy Key Performan ce Indicators (EnKPIs) Plant Energy Cost Block 2008-2010 Applied to Ethanol Productio n 2010-2013 Applied to District Cooling and Heating Applied to Hydrogen Systems 2013-2016 Internet Web Browser Client Multi Period Optimizatio n (VM- EMPO) Energy Balances and EnKPIs Dashboardin g (VM-EM) VM-ERTO VM-ECLRTO VM-EMPO VM-EM Modular Energy System Analyzer SVM Company Overview –Visual MESA EMS Development Timeline KBC Executive Symposium Japan 2018 April 19, 2018
& Recent Projects 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 (2016 – VM-ERTO) Singapore site (2016 – VM-ERTO) 2 sites (2011 and 2017 – VM-ERTO) PetroVietnam BSR site (2017 – VM-EM) 3 sites (2006, 2014 and 2018 – VM-ERTO) KBC Executive Symposium Japan 2018 April 19, 2018
Measurements Optimum Set Points CLOSED-LOOP signals to control systems OPEN-LOOP advisory reports to operators Control System / Historian Process (Utilities Consumers and Generators) VM EMS Technologies –VM-EMS On-Premise General Functionality Operators Energy Related Reports and Dashboard Energy and Emissions KPIs Monitoring Energy Use and Account Optimum Energy System Operation Report EnPIs, Streams and Equipment Calcs. Optimum Multi Period Planning Hydrogen Fuel Steam Water Electricity Energy and Utilities System (Degrees of freedom in Generation and Distribution) KBC Executive Symposium Japan 2018 April 19, 2018
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 • Visual MESA provides our customers with the following capabilities for improving energy performance: • Utilities Supply & Distribution Optimization (VM-ERTO/ECLRTO) • Case Studies / What-if tool (VM-ERTO) • Monitoring / Auditing / Accounting/ Key Performance Indicators calculation (VM-EM) • Energy Management - ISO 50001(VM-ERTO/EM) • Optimal Planning & Scheduling of Utility Assets (VM-EMPO) • Corporate Fleet Energy Management (VM-ERTO/ECLRTO/EM) KBC Executive Symposium Japan 2018 April 19, 2018
ECLRTO) • 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 guidance • With model, optimization solution and reports fully accessible from within a web browser. KBC Executive Symposium Japan 2018 April 19, 2018
(VM-ERTO/ECLRTO) • Investment Planning and Basic Engineering: • Plant Expansions, new equipment or replacement • Change of Configuration in the Energy System • Utilities Planning and Scheduling: • Effect of Production Plans on the Energy System • Planning of Shutdowns • Export/Import Nominations; multi cases. • Utilities contracts evaluation: • Assess Contract Terms • Negotiate Better Contracts KBC Executive Symposium Japan 2018 April 19, 2018
Ad-hoc RTDB for massive historization of results (internal historian) • 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 • Equation block for custom calculations (i.e., BT index), 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” • Balance report boundaries chosen from the VM-EM web GUI, Site, Area or Unit wise • KPIs KBC Executive Symposium Japan 2018 April 19, 2018
• 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 KBC Executive Symposium Japan 2018 April 19, 2018
Facility 4 Facility 5 Facility 6 Target & Actions Audit and Accounting Energy Indicators Integrated Operations WATER CARBON ENERGY • 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 VM EMS Technologies –Corporate Fleet Energy Management (VM-ERTO / ECLRTO / EM) KBC Executive Symposium Japan 2018 April 19, 2018
5% savings depending on the site complexity 0.0 1.0 2.0 3.0 4.0 5.0 6.0 0 50 100 150 Energy Cost Savings (%) Number of Decision Variables KBC Executive Symposium Japan 2018 April 19, 2018
& Support • 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 written by themselves • Customers with references list KBC Executive Symposium Japan 2018 April 19, 2018
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! 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 KBC Executive Symposium Japan 2018 April 19, 2018
Refinery • Challenge • Reduce the total cost of the energy • 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 • Engineers and operators training • Solution sustainability services • 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 KBC Executive Symposium Japan 2018 April 19, 2018
Services • Provides Software Helpdesk, Updates and Enhancements of the Solution • Sustainability Service Program • Designed to help clients to sustain the benefit captured by VM and to ensure the site-specific model is always up to date KBC Executive Symposium Japan 2018 April 19, 2018
Operations involvement and buy-in during model Development • Validation and ongoing review of solutions • Model Owner • Management of Change • Track utilization factor • Keep benefits and Lost Opportunity in front of Management • Optimization failure response procedures • Training and documentation Source: Maurie Laurenz, ExxonMobil presentation about Energy Real Time Optimizer at Baytown Refinery/Chemical Complex, IETC, May 2009. KBC Executive Symposium Japan 2018 April 19, 2018
as the co-pilot of an aircraft is there to assist the pilot with additional knowledge and to step in and help at times of intense activity, KBC’s Co-Pilot is there to remotely support an asset with expertise and insight. • Supplementing the asset’s own capabilities and resources to assure that it achieves its full potential. • Remotely ensure the technology and tools our customer’s business relies on are always correct and up to date • Collaborate in real-time with our customer’s people, to enhance your knowledge, build up skills • Provide world class expertise to ensure that our customer’s energy efficiency is always optimum. Overcome with cloud-based model assurance and expert support KBC Executive Symposium Japan 2018 April 19, 2018
through a shared Digital Twin in the Cloud, connected to a world of expertise Energy Co-Pilot –Shared Digital Twin in the Cloud Connected experts Customer facility KBC Executive Symposium Japan 2018 April 19, 2018 KBC Executive Symposium Japan 2018
Energy Re-use) Emissions Regulations Measurements CLOSED-LOOP signals to control systems OPEN-LOOP advisory reports to operators Operators Optimu m Energy System Operatio n Report Process Models Measurements Control System / Historian EnPIs, Streams and Equipment Calcs. Energy Related Reports and Dashboard Energy and Emissions KPIs Monitoring Energy Use and Account Optimum Energy System Operation Report Energy Co-Pilot –Foundation: VM EMS + Petro-SIM Utilities / Process Functionality Optimum Multi Period Planning • External Utilities Contracts • Forecasts Hydrogen Fuel Steam Water Electricity Energy and Utilities System (Degrees of freedom in Generation and Distribution) KBC Executive Symposium Japan 2018 April 19, 2018
Energy Co-Pilot –Portal Elements • Overall portal • Single point of entry to all tools and models Visual MESA Utilities Model Energy Dashboards and actions Click Through Model to KPI dashboard Collaboration space • Discussion Board • Actions Other cloud hosted Tools • Unit Performance Co-Pilot • Petro-SIM Models • Petro-SIM Database • HX-Monitor • Application Workbook • Metric calculations Application outputs viewed in dashboard KBC Executive Symposium Japan 2018
process, quality, economic and planning data to KBC’s private cloud • Build and calibration (as necessary) of a base-case process simulation model/s using Petro-SIM, and utility model using VM- ERTO/EM/EMPO • Automated rigorous VM-ERTO/EM model simulations in the cloud to validate input data, quantify its quality and continuously monitor and optimize energy performance • Optimum energy multi-period planning using VM-EMPO • Petro-SIM model/s to consider process side, e.g. Unit Performance, HXs Monitoring, Process KPIs, etc.) • Other third parties collaborative tools • Daily, weekly and / or monthly analysis, insight, recommendations, reporting and stewardship by KBC experts • Reactive Service – KBC ensure the model is always accurate and available, Customer interprets results • Proactive Service – KBC provide OaaS – Outcome as a service, interpreting model/s and providing insights KBC Executive Symposium Japan 2018 April 19, 2018
Designed to Deliver Value Quickly • Typical EMS projects • 6-9 months to deliver IT system. • Supplier focus on completing model build to hit payment milestones • Sustainment and value comes late in the process • Energy Co-Pilot agile approach • 3 months to start delivering value from a simplified model • Focus efforts where most valuable • May be implementing value already found • May be developing additional model detail or capabilities • Flexible scope to suit evolving needs • Focus is on maximizing customer value, not delivering a model • Customer value achieved much faster 3 month: 80:20 model 6-9 month model development phase Sprint 1 DEVELOP DELIVER DEFINE SUSTAIN DEFINE DEVELOP DELIVER SUSTAIN DEVELOP Typical EMS Project Linear Delivery Energy Co-Pilot Agile Delivery DISCOVER DISCOVER $ $ DELIVER DISCOVER DISCOVER DEVELOP DEVELOP DELIVER DELIVER Adopts an agile philosophy to focus on value, not on IT systems KBC Executive Symposium Japan 2018
Constant monitoring of IT systems • Daily monitoring of data and model issues to ensure optimizer is always running and solving Enhanced model assurance • Update model in response to changes in physical hardware on site • Update correlations and performance curves • Monthly reports and recommendations on model condition Energy performance and equipment assurance • Review success in implementing optimizer recommendations • Ensure full range of degrees of freedom exploited • Review equipment trends & degradation, make recommendations on operation, cleaning & maintenance • Support troubleshooting Strategic energy assurance • Carry out energy forecasts and look ahead scenarios • Review and analyze energy performance gaps across site • Recommend minor / major investment projects to debottleneck and improve energy efficiency • Review progress vs recommendations and quantify value of Co-Pilot KBC Executive Symposium Japan 2018 April 19, 2018
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