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“Energy fluid”
• Multiple pressure levels
• Multiple producers and consumers
• Complex dynamics
• Interaction with various systems
Steam generation accounts for approximately 30% of the total energy used in industries
Goal of Steam Network
• Safely
– Ensure header pressure and steam velocity are within design limits
• Efficiently
– Minimize vent to atmosphere and steam consumption
• Without interruption
– Effective control/operating policy to ensure emergency situation such as loss of boiler can be handled properly
Schneider Electric Products
Dynamic Simulation
– Control and trip logic
– Header geometry
– Valve trim and open/close times
– Boiler ramp up/down times
Boilers
Fuel / Water Piping
Volume
DYNSIM
Back Pressure
Turbines
Turbine De-aerators
Performance Pressure Letdown
Curves Stations/ De-super Heaters
Study Approach
• P&ID, PFD • Heat / Mass balance • Validating transient • Sensitivity study • Recommendations
• Control files • Data recon behavior with and • What-if scenarios
• Control Narratives • Two or more without control
conditions actions
• Pipe geometry
• Kick off meeting
Design # 1
Design # 2
HP Pressure response at control point after the trip of 1 Oil fired Boiler
Critical Equipments trip at 41.6 barg
Benefits
• Prevented tripping of critical Instrument Air and CW pump turbines on low HP header pressure
• Achieved tighter control of the critical HP steam header
HP header response at control point after the trip of 2 Fuel Oil fired Boilers
Option 3 Option 4
MP header response at control point after the trip of 2 Fuel Oil fired Boilers
Benefits
• Ensured stable steam system operation in the event of loss of major steam producers
Ex-2 Integrated Refinery and Petrochemical Complex
Representation of the HP steam network Bottleneck Discovered
(Remove)
Normal Steam
Polymers Flow
Check valve
Existing
Tanks Utility Island
Olefins Refinery
A B New Aromatics
Refinery
C
Light Ends Alternate
Normal Steam Route?
Flow
4000 meters
A - VHP Auxiliary Boiler 1 (Oil Fired)
Case - Trip of Boiler C
B - VHP Auxiliary Boiler 2 (Gas Fired)
C - HP Auxiliary Boiler (Gas Fired)
Ex-3 Refinery Site
Key Objective
1 Normal operating conditions Increase the line size between Hydrocracker and Sulfur Recovery Unit
2 Planned shutdown #1 Change control strategy to incorporate high pressure protection to avoid lifting relief valve
7 Unplanned shutdown of DCU Strategy to provide steam to be made gradual in order to control HP pressure
21 General power failure LP steam distribution exceeds design limit and additional safety valves can be installed
HP header low pressure clamp remains in operation.MP Header pressure increases and
26 Control Failure - HP-MP Let down
additional relief valves in MP header are recommended.
Summary
• Dynamic simulation is quickly becoming acceptable tool for in-depth steam system analysis
• Such a tool can be useful in various phase from design to training
• Typical users of steam system dynamic simulation models are process/utility engineers,
design engineers, control engineers and operators
• Model can easily extended to understand the impact on process
Experience in Dynamic Simulation
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