EAU901.088.01 Virtual

Energy Management: Optimizing
Site Wide Utilities to Save Energy

using Aspen Utilities Planner
AspenTech Customer Education
Training Manual
Application Workshop Number: EAU901.088.01
Copyright 2015 by Aspen Technology, Inc. 20 Crosby Drive, Bedford, Massachusetts 01730,
USA. All rights reserved. This document may not be reproduced or distributed in whole or part
in any form or by any means without the prior written permission of Aspen Technology, Inc.
The information contained herein is subject to change without notice, and Aspen Technology
assumes no responsibility for any typographical or other errors that may appear.
Aspen Technology may provide information regarding possible future product developments
including new products, product features, product interfaces, integration, design, architecture,
etc. that may be represented as product roadmaps. Any such information is for discussion
purposes only and does not constitute a commitment by Aspen Technology to do or deliver
anything in these product roadmaps or otherwise. Any such commitment must be explicitly set
forth in a written contract between the customer and Aspen Technology, executed by an
authorized officer of each company.
EAU 901 Application Workshop
2015 AspenTech. All Rights Reserved
Energy Management - Aspen Utilities Planner
1-1
Aspen Technology, Inc.
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1 - 10
1 - 11
1 - 12
1 - 13
1 - 14
1 - 15
1 - 16
1 - 17
1 - 18
1 - 19
1 - 20
1 - 21
1 - 22
Energy Management: Optimizing Site Wide

Utilities to Save Energy using
Aspen Utilities Planner
EAU901
Application Workshop Instructions
EAU901 Application Workshop
Energy Management Aspen Utilities Planner
Introduction
The provision of an adequate and reliable supply of Utilities (fuel, steam and power)
represents a significant operating cost for many industrial companies. For many
industries, the energy/utilities cost is the largest operating expense after the purchase of
raw materials.
Aspen Utilities PlannerTM explores the flexibility inherent in the purchase, generation,
use and distribution of utilities on industrial sites and advises on the optimum choice
available to the user. Issues such as different tariffs, alternative fuels, optimum loading
of boilers and turbines, choice of equipment, import, self-sufficiency or export of
electricity, choice of drives (motor or turbine) etc. are all taken into account in the
optimization.
Aspen Utilities provides a model-centric approach whereby a single rigorous model of
the utilities system is used to address all the important business processes related to
energy management.
This workshop demonstrates how the most common energy management business
processes can be performed with Aspen Utilities PlannerTM to substantially improve
financial performance.
Objective
In this workshop, we will use a pre-build model of a utilities system which is based
on a real application.
First we shall review the model to familiarize with the utilities system and its
equipment.
Then we shall show to enter inputs, run the model and view results.
Then we shall use the model to perform various energy management business
processes :
Optimize Utility Plant Operation: Obtain advice on the optimum load
allocation in boilers and turbines and optimum choice of drives (motor/turbine),
to minimize operating cost.
Manage New Natural Gas Contract: Evaluate optimum choice of fuels with
multi-tier pricing.
Forecast Power and Gas Demands to Provide Nominations: Optimize in
advance, internal power generation vs. import, depending on the power price
during peak and off peak times. Make realistic and optimal nominations to
your suppliers, which you can fulfill, to avoid penalties.
Convert Production Plan to Utilities Plan: Transfer the weekly production plan
into Aspen Utilities and convert this into utility demands using demand
2015 AspenTech. All Rights Reserved.
1 - 24
forecasting correlations. Based on these, produce a utilities production plan,

allowing for a turbine to be brought down for maintenance during that week.
Evaluate Capital Investment : Assess the potential cost savings from
investment in a new steam turbo-generator and calculate ROI.
We shall provide instructions how to execute each step.

We shall review and comment on the solutions found.
Description
This workshop includes the following tasks:
Task 1 Open and review the Aspen Utilities model

Task 2 Link the model to an Excel Interface file
Task 3 How to run the model
Task 4 Optimize Utility Plant Operation
Task 5 Manage New Natural Gas Contract
Task 6 Forecast Power and Gas Demand to Provide Nomination
Task 7 Convert Production Plan to Utility Plan
Task 8 Evaluate Capital Investment
Before starting the workshop, you need to copy the following files from the
Databases2periods folder:
ProfileData.mdb
DemandData.mdb
TariffData.mdb
Interface.mdb
Paste the files into the following path:

C:\ProgramData\AspenTech\Aspen Utilities Planner V8.8\Example Databases
1 - 25
Task 1 Open and Review the Aspen Utilities Model
Open the Aspen Utilities Planner file titled Model.auf.
This model represents a typical utilities system.

Steam is generated at high pressure in the BOILER and also in a heat recovery
steam generator HRSG, which takes exhaust from a gas turbine GTG.
Power is generated on site in the gas turbine GTG and also in the condensing
steam turbine STG.
There are 2 steam distribution headers : high pressure HPHDR and low pressure
LPHDR
The usage of steam in the process units at each header pressure is modelled using
steam demand blocks HPUSE and LPUSE
There is also steam generation from waste heat in the process units (from column
pumparounds and exothermic reaction), modelled as steam supply blocks
HPGEN and LPGEN.
Between the HP header and the LP header, there is a LETDOWN.
1 - 26
There is also a steam turbine drive, between the HP and LP headers, which drives
the boiler feed water pump BFWPUMP. The turbine is modelled using a drive list
block PUMPDRV. There is an alternative motor driven pump, which is also
modelled inside the drive list block.
The model includes a DEAERATOR which receives: condensate return from the
STG and from the process units COND, make up water MKUP and LP steam.
The DEAERATOR provides boiler feed water to BOILER, to HRSG and also to
the process units BFWPROC.
Two fuels are used: Natural Gas is used in the GTG, HRSG and BOILER. Butane
can be used in the BOILER only. The flowsheet also includes block NGASCONS
which represents natural gas consumption by the process units.
The block SITEPOW represents the total power demand of the site. The overall
sites power balance has been modelled using the power header POWERHDR.
The model calculates how much power needs to be imported from the GRID to
make up for any shortfall.
Note that the model also shows a steam turbine generator between the HP and LP
headers (TURBINE). This equipment is not physically in place at the plant, but
has been added in the model to evaluate a future potential investment.
Task 2 Link the Model to an Excel Interface File

To run the model and to view results from the model, we need to link the flowsheet to a
Microsoft Excel Interface file using an Aspen Utilities Add-in.
To activate the add-in, the steps are explained below:
Open the Excel Interface file Task1Starter.xlsm.
Select File | Options
1 - 27
Select Add-Ins | Manage :Excel Add-Ins | Go
In the Add-ins window, select Aspen Utilities v8.4 Add-in

Browse to the folder
C:\Program Files(x86)\AspenTech\Aspen Utilities Planner V8.4\bin
And select the Utilities 300.xla file
Once selected, the following Aspen Utilities menu will appear in Excel.
You have now completed the activation of the Aspen Utilities Excel Add-in.
1 - 28
Next you will link Excel to the Aspen Utilities model file, using the following steps:
From the Aspen Utilities Add-In menu, select Open Aspen Utilities
Point to the model model.auf and select Open.
When prompted with the following question, press Cancel
The Excel file and the Aspen Utilities model are now linked.
Select Show Aspen Utilities, to make the model visible
The Aspen Utilities icon should appear and the model is now visible
1 - 29
Task 3 How to Run the Model

The Excel Interface file has some preconfigured tabs that allow the user to send inputs
into the model, run optimization and view optimization results.
These tabs will be explained below.
Use the Demand tab to enter the utility demands of the process units.
The Demand tab contains a list of all the utility demands of the flowsheet. The inputs
for each demand are the Min value and the Max value. Because the demands are fixed
the Min and Max values should be specified to be equal.
The results of the optimizer are reported in the next two columns: The optimized value is
written by the optimizer in column Value and the marginal cost for each demand is
written by the optimizer in the Shadow Price column.
Note that the Demand tab contains data for two periods, 1 and 2. This allows the user
to enter inputs for 2 cases, the inputs can be the same between the cases or different.
1 - 30
Use the Availability tab to enter the equipment availability and capacity limits.
For each utility equipment type (i.e. BOILER, HRSG, STG, GTG etc.) the list contains
typically two items:
Availability
Limits on capacity (Min and Max values)
Availability is specified as follows:
Available
This equipment is available for use if it is economical to do so. It need not
necessarily be used
Not Available
This equipment is not available, e.g., it is down for maintenance
Must be on
This equipment must be used even if it is uneconomic to do so
1 - 31
Use the Energy Cost Summary tab to enter the contract information and
prices
The Energy Cost Summary tab is where the user enters prices and limits for the
various contracts and the total operating cost is being calculated.
For every contract, the user has to enter the Fixed Cost, the Variable cost, the Min limit
and the Max limit. Columns Flow and TotCost are used by the optimizer to report the
optimum flow of the corresponding utility and its cost.
Our site has the following contracts:
A contract for Power Import from the GRID.
A contract for the Butane fuel used in the BOILER
A contract for the Natural Gas. This contract has two tiers. Tier pricing allows the
user to define multiple prices within the same contract, depending on the usage.
In the current screen you can see that Tier1price applies for the first 250 GJ/hr of
gad usage, and any usage above this will use Tier 2 pricing.
1 - 32
To run optimization, select Optimize Flowsheet from the Aspen Utilities menu
When the following optimization window appears, press OK
1 - 33
When optimization is completed, go to the Flowsheet tab to view the

optimized results for Period 1
You can view results for Period 2 by typing number 2 next to the PERIOD cell
In the Production Plan tab you can view and compare the results for all
periods.
1 - 34
Task 4 Optimize Utility Plant Operation

Objective of Task 4
First we shall use the model to set up a Base Case that represents the current
operation of the utility system and calculate the current operating cost. We will use
Period 1 for this case
Then we shall perform optimization to find out the Optimized operation. We will use
Period 2 for this
Finally we shall compare the Base Case and the Optimized Case to conclude what
changes to make to the plant operation and how much savings this will bring.
For this task open Task4Starter.xlsm. Once opened, it will automatically link to
model.auf.
Enter in Period 1 the current utility demands

From plant measurements, we have obtained the current demands of the process units for
steam, power, fuel and water:
Utility Demand
Unit of
measure
GJ/hr
MW(e)
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
Natural Gas Consumption

Site Power Demand
HP Steam Use
HP Process Steam Generation
Recovered Condensate
LP Steam Use
LP Process Steam Generation
Process BFW Demand
Value
40.00
31.90
130.00
53.00
33.00
52.00
32.00
85.00
In the Demand tab, in Period 1, enter the current values for each utility demand in
the Min and Max columns. The same value should be entered for both Min and Max.
Demand
Legend
Period 1
Area Units
Min

Site Power Demand
HP Steam Use
LP Steam Use
Process BFW Demand
Area1
Area2
Area2
Area2
Area2
Area3
Area3
Area3
GJ/hr
MW(e)
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
1 - 35
40
31.9
130
53
33
52
32
85
Max Value Shadow Price
40
31.9
130
53
33
52
32
85
Enter in Period 1 the current equipment loads

From plant measurements, we have obtained the current loads of the utility equipment.
Equipment
Unit of
measure
MW(e)
MW(e)
MW(e)
tonne/hr
GJ/hr
New Turbine Power output

STG Power Generation
GTG Power Generation
BOILER Steam Generation
Butane Availability
Value
0
4
17.5
35
0
We also know that:

The Motor driven boiler feed water pump PUMPDRV.Motor is currently
being used.
The turbine driven pump PUMPDRV.Turbine is switched off.
In the Availability tab, in Period 1, enter the current loads of the equipment. The
same value should be used for both Min and Max.
For the HRSG Supplementary Firing and HRSG steam generation we dont have
measurements of the current loads, so we enter their capacity limits (0 300 and 0-200
respectively). The model will be able to calculate their loads based on the steam balance.
For each item of equipment, enter its availability, i.e. if the equipment is currently
running set it to Must Be On, if its load is zero, then set it to Not Available.
Availability
Legend
Period 1
Area Units
Min
HRSG Supplementary Firing

New Turbine Power Out
New Turbine Status
STG Availability
PUMPDRV.Turbine
PUMPDRV.Motor
HRSG Availability
GTG Availability
Boiler Availability
HRSG Steam Generation
Boiler Steam Generation
BUTANE Availability
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area2
Max
GJ/hr
0.00 300.00
MW(e)
0.00
0.00
MW(e)
4.00
4.00
MW(e)
17.50 17.50
Not Available
none
Must Be On
none
Not Available
none
Must Be On
none
Must Be On
none
Must Be On
none
none
Must Be On
tonnes/hr 0.00 200.00
tonnes/hr 35.00 35.00
GJ/hr
0.00
0.00
1 - 36
Enter in Period 1 the utility prices

The prices for the purchased utilities - power, natural gas and butane - are provided
below. Note that currently natural gas has the same price for both tiers.
Contract
Unit of
measure
Power Import
Butane
Natural Gas Tier 1
Natural Gas Tier 2
MWh
GJ
GJ
GJ
Variable
Cost
$/unit
40
6
1.5
1.5
In the Energy Cost Summary tab, enter the prices of the contracts in Period 1 in the
Variable Cost column J
Energy Cost Summary

Legend
Units Min
Period 1
Max
Fixed Cost Var. Cost Flow Total Cost

Elec
Power Import
MWh
0.00
9999.00
$0.00
$40.00
Elec Sub Total
0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
$0.00
Total Cost
$0
Fuel
Butane
GJ
Natural Gas Tier 1 GJ
0.00
0.00
0.00
9999.00
250.00
9999.00
$0.00
$6.00
$0.00
$1.50
$0.00
$1.50
Fuel Sub Total
Run optimization for Period 1
Run Optimization for period 1 only, by changing the ending period to be 1
Although we have run optimization, because we restricted the loads of the equipment to
their current values, the model has actually reproduced the current operation. View the
mass and energy balance for the current operation in the Flowsheet tab and make a
note of the hourly operating cost 1282 $/h.
1 - 37
Next we shall use Period 2 to optimize the operation.

Enter in Period 2 the utility demands
In the Demand tab in Period 2, copy and paste the Min/Max values from Period 1.
Enter in Period 2 the equipment availability and capacity limits

The capacity of the utility equipment is provided in the table below.
Equipment
Butane Availability
Unit of
measure
GJ/hr
MW(e)
MW(e)
MW(e)
tonne/hr
tonne/hr
GJ/hr
Min
Max
0
0
3.5
8
0
20
0
300
0
7
20
200
200
9999
In the Availability tab, in Period 2, enter the equipment capacity limits.
Make all equipment Available, except the New Turbine, which should be set to
Not Available and the BOILER which should be set to Must Be On
1 - 38
Enter in Period 2 the utility prices
In the Energy Cost Summary tab make sure the prices for Period 2 are the same as
for Period 1
Run optimization
Run Optimization for period 1 and 2, by changing the ending period to be 2
Task 4 - Solution
Availability
Legend
Period 1
Area Units
Min

New Turbine Status
STG Availability
PUMPDRV.Turbine
PUMPDRV.Motor
HRSG Availability
GTG Availability
Boiler Availability
BUTANE Availability
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area2
GJ/hr
MW(e)
MW(e)
MW(e)
none
none
none
none
none
none
none
tonnes/hr
tonnes/hr
GJ/hr
Max
Period 2
Value Shadow Price
0.00 300.00 184.72

0.00
0.00
0.00
4.00
4.00
4.00
17.50
17.50 17.50
Off
Not Available
On
Must Be On
Off
Not Available
On
Must Be On
On
Must Be On
On
Must Be On
On
Must Be On
0.00 200.00 109.30
35.00
35.00 35.00
0.00
0.00
0.00
Min
Max
Value
Shadow Price
0.00 0.00 300.00 264.05

40.00 0.00
0.00
0.00
16.28 3.50
7.00
7.00
30.18 8.00
20.00 20.00
0.00 Not Available
Off
0.00
On
Available
0.00
On
Available
0.00
Off
Available
0.00
On
Available
0.00
On
Available
0.00
On
Must Be On
0.00 0.00 200.00 142.72
1.22 20.00 200.00 20.00
1.50 0.00 9999.00
0.00
0.47
0.00
8.81
31.33
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Demand
Legend
Period 1
Area Units
Min

Site Power Demand
HP Steam Use
LP Steam Use
Process BFW Demand
Area1
Area2
Area2
Area2
Area2
Area3
Area3
Area3
Max Value Shadow Price
GJ/hr
40.00 40.00 40.00
MW(e)
31.90 31.90 31.90
tonnes/hr 130.00 130.00 130.00
tonnes/hr 53.00 53.00 53.00
tonnes/hr 33.00 33.00 33.00
tonnes/hr 52.00 52.00 52.00
tonnes/hr 32.00 32.00 32.00
tonnes/hr 85.00 85.00 85.00
Period 2
1 - 39
Min
Max Value
1.50 40.00 40.00 40.00

40.00 31.90 31.90 31.90
5.83 130.00 130.00 130.00
5.83 53.00 53.00 53.00
0.42 33.00 33.00 33.00
5.83 52.00 52.00 52.00
5.83 32.00 32.00 32.00
0.70 85.00 85.00 85.00
Shadow Price
1.50
40.00
5.83
5.83
0.42
5.83
5.83
0.70
Energy Cost Summary

Legend
Units Min
Period 1
Max
Period 2
Fixed Cost Var. Cost Flow Total Cost Fixed Cost Var. Cost Flow Total Cost
Elec
Power Import
MWh
0.00
9999.00
$0.00
$40.00
Elec Sub Total
0.00
0.00
0.00
9999.00
250.00
9999.00
10.81
10.81
$432.34
$432.34
$0.00
$0.00
$6.00
0.00
$0.00
$1.50
0.00
$0.00
$1.50 566.35
Fuel Sub Total 566.35
$0.00
$0.00
$849.52
$849.52
$0.00
$0.00
$0.00
Total Cost
$1,282
$40.00
4.91
4.91
$196.59
$196.59
$6.00
0.00
$1.50
0.00
$1.50 619.08
619.08
$0.00
$0.00
$928.62
$928.62
Fuel
Butane
GJ
$1,125
UTILITY PRODUCTION PLAN

Power
generation
Steam
Generation
Fuel
Steam
Power
Block
GTG
STG
BOILER
HRSG
BUTANE
NATGAS
GTG
HRSG
Natural Gas Header
BOILER
LPUSE
HPUSE
HPGEN
LPGEN
BFWPROC
LETDOWN
VENT
COND
DEARATOR
STG
PUMPDRV
PUMPDRV
GRID
SITEPOW
STGPUMP
PUMPDRV
BFWPUMP
TURBINE
MKUP
AnnCost
Description
Power from Gas Turbine
Power from Cond Steam Turbine
Steam Generation from Boiler
Steam Generation from HRSG
Butane
Natural Gas
GTG - Natural Gas In
HRSG - Natural Gas In
BOILHDR - Natural Gas In
Boiler Fuel
LP Steam Use
HP Steam Use
HP Steam Generation
LP Steam Generation
BFW Steam Generation
LETDOWN - Steam In
VENT - Steam Out
CONDENSATE Return
DEAREATOR - Steam In
HP Steam In
Steam Into Turbine Driven BFW pump
Shaftwork from Turbine Driven BFW pump
Power Import from Grid
Site Power Demand
Power to STG condensate pump
Power in Motor Driven BFW pump
BFW Pump Power In
Power from the new turbine MPtoLP
Make up Water
Hourly Cost
2
17.50
4.00
35.00
109.29
0.00
566.35
217.50
184.69
124.16
124.16
52.00
130.00
53.00
32.00
85.00
44.41
0.00
33.00
24.41
22.88
0.00
0.00
10.81
31.90
0.01
0.40
0.36
0.00
155.83
1282
20.00
7.00
20.00
142.70
0.00
619.08
242.00
263.99
73.09
73.09
52.00
130.00
53.00
32.00
85.00
30.67
0.00
33.00
25.67
40.03
15.00
0.40
4.91
31.90
0.01
0.00
0.39
0.00
157.13
1125
The current hourly operating cost is $1282. This can be reduced to $1125, if we optimize
the operation. The changes recommended by the optimizer are:
To increase GTG power generation from 17.5 to 20 MW
To increase STG power generation from 4 to 7 MW
To reduce steam production from BOILER from 35 to 20 t/h
To increase steam production from HRSG from 109 to 142 t/h
To switch on the BFW Steam driven pump and switch off the Motor pump
Save the Excel Interface File under the name Task4.xlsm
1 - 40
Task 5 Manage New Natural Gas Contract

Objective of Task 5
Our gas contract has expired and our gas supplier has put forward a new contract.
We can take up to 250 GJ/hr of natural gas at $1.5/GJ and any usage above the 250 is
charged at $7.5/GJ.
We have a supply of butane available at $6/GJ.
We need to decide if we should take both tiers of natural gas, or only take the cheaper
tier and top up our fuel requirements with butane.
We shall use the model to evaluate the two options. We shall use Period 1 to evaluate
option 1 (no Butane available), and period 2 to evaluate option 2 (with Butane
available).
We will prepare the data for both periods and run optimization of both cases in one
optimization run.
You can continue to use the excel file from Task4. If you have not finished Task 4, load
Task4Solution.xlsm to use as the starting file for Task 5
Enter utility demands
The utility demands are the same as in the previous task, so there is no need to change
them.
Enter equipment availability
Enter in both periods the equipment Min and Max capacity limits
Equipment
Unit of
measure
GJ/hr
MW(e)
MW(e)
MW(e)
tonne/hr
tonne/hr
Min
Max
0
0
3.5
8
0
20
300
0
7
20
200
200
For the availability of Butane, in Period 1 set its Max to be 0, in Period 2 set its Max
to be 9999 (unlimited).
Set all equipment to Available with the following exceptions:

NEW TURBINE should be Not Available
BOILER should be Must Be On
1 - 41
Availability
Legend
Period 1
Area Units
Min

New Turbine Status
STG Availability
PUMPDRV.Turbine
PUMPDRV.Motor
HRSG Availability
GTG Availability
Boiler Availability
BUTANE Availability
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area1
Area2
Period 2
Max Value dow P Min
GJ/hr
0.00 300.00
MW(e)
0.00
0.00
MW(e)
3.50
7.00
MW(e)
8.00 20.00
Not Available
none
Available
none
Available
none
Available
none
Available
none
Available
none
none
Must Be On
tonnes/hr 0.00 200.00
tonnes/hr 20.00 200.00
GJ/hr
0.00
0.00
Max
Valueadow Pr
0.00 300.00
0.00
0.00
3.50
7.00
8.00
20.00
Not Available
Available
Available
Available
Available
Available
Must Be On
0.00 200.00
20.00 200.00
0.00 9999.00
Enter Prices
In the Energy Cost Summary change the Tier 2 price for Period 1 Natural gas to 7.5
($/GJ). This is automatically applied to Period 2 also.
Energy Cost Summary

Legend
Units Min
Period 2
Period 1
Max
Elec
Power Import
MWh
0.00
9999.00
$0.00
$40.00
Elec Sub Total
$0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
$0.00
Total Cost
$0
$40.00
0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
$0.00
Fuel
Butane
GJ
0.00
0.00
0.00
9999.00
250.00
9999.00
$0.00
$6.00
$0.00
$1.50
$0.00
$7.50
Fuel Sub Total
$6.00
$1.50
$7.50
$0
Run optimization
Run Optimization for period 1 and 2, by setting the ending period to be 2:
1 - 42
Task 5 - Solution
The cost for Period 2 is lower than Period 1. Hence it is more cost effective to only take
Tier 1 natural gas (250 GJ/h) and top up with butane.

Power
generation
Steam
Generation
Fuel
Steam
Power
Block
GTG
STG
BOILER
HRSG
BUTANE
NATGAS
GTG
HRSG
Natural Gas Header
BOILER
LPUSE
HPUSE
HPGEN
LPGEN
BFWPROC
LETDOWN
VENT
COND
DEARATOR
STG
PUMPDRV
PUMPDRV
GRID
SITEPOW
STGPUMP
PUMPDRV
BFWPUMP
TURBINE
MKUP
AnnCost
Description
Butane
Natural Gas
Boiler Fuel
LP Steam Use
HP Steam Use
HP Steam Generation
LP Steam Generation
LETDOWN - Steam In
VENT - Steam Out
CONDENSATE Return
HP Steam In
Site Power Demand
BFW Pump Power In
Make up Water
Hourly Cost
1 - 43
1
MWe
MWe
tonnes/hr
tonnes/hr
GJ/hr
GJ/hr
GJ/hr
GJ/hr
GJ/hr
GJ/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
MWe
MWe
MWe
MWe
MWe
MWe
MWe
tonnes/hr
$/hr
2
8.00
0.00
20.00
99.85
0.00
434.19
130.00
191.09
73.09
73.09
52.00
130.00
53.00
32.00
85.00
27.85
0.00
33.00
22.85
0.00
15.00
0.40
23.90
31.90
0.00
0.00
0.32
0.00
154.87
2712
16.00
0.00
81.03
38.63
262.50
250.00
204.00
6.00
0.00
262.50
52.00
130.00
53.00
32.00
85.00
27.67
0.00
33.00
22.67
0.00
15.00
0.40
15.90
31.90
0.00
0.00
0.32
0.00
153.54
2586
Period 1 Results No Butane Available
Period 2 Results Butane Available
Compare the loads of equipment between the two cases:

If Tier 2 gas is used (period 1), the load of GTG is reduced to 8 MW, to try and
minimize gas usage.
In period 2, steam generation is shifted from HRSG to Boiler (due to Butane
being cheaper than Tier 2 gas), freeing Tier 1 gas to be used for more GTG power
generation (16 MW). Save the Excel Interface File under the name Task5.xlsm.
1 - 44
Task 6 Forecast Power and Natural Gas Demands to

Provide Nomination
Objective of Task 6
We need to nominate to our gas and electricity suppliers how much gas and
electricity we plan to take the following day.
There are two price zones for electricity :
o Day time - 7:00 to 24:00 - Power Price = 40 $/MWH
o Night time - 00:01 to 7:00 - Power Price = 20 $/MWH
The gas price is flat (1.5 $/GJ) for both tiers
The utility demands as the same as in the previous task
The equipment availability and limits are the same as in the previous task
We shall run optimization to optimize the operation and find out the corresponding
gas and electricity consumption.
We shall use Period 1 to optimize Day time operation and use Period 2 to optimize
Night time operation.
You should use Task5.xlsm as the starting file for Task 6. If you have not completed the
previous task, load Task5Solution.xlsm to use as starting file.
Enter utility demands
The utility demands are the same as in the previous task, so there is no need to
change them.
Enter equipment availability
The equipment availability and limits are the same as in the previous task. Set the
Max limit for Butane to 9999 for both periods.
Enter prices
In the Energy Cost Summary, enter the price for power import to be $40 for period 1
and $20 for period 2. Reset natural gas price to 1.5 for both tiers
Energy Cost Summary

Legend
Units Min
Period 2
Period 1
Max
Elec
Power Import
MWh
0.00
9999.00
$0.00
$40.00
Elec Sub Total
$0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
$0.00
Total Cost
$0
$20.00
0.00
$0.00
$0.00
0.00
$0.00
$0.00
$0.00
$0.00
Fuel
Butane
GJ
0.00
0.00
0.00
9999.00
250.00
9999.00
$0.00
$6.00
$0.00
$1.50
$0.00
$1.50
Fuel Sub Total
1 - 45
$6.00
$1.50
$1.50
$0
Run optimization for two periods
Run Optimization for period 1 and 2, by setting the ending period to be 2
Task 6 Solution
View the results in the Utility Production Plan, to see the forecast for Natural gas
demand and Power Import.
Note that during night time (period 2) the optimizer recommends to reduce natural gas
import and increase power import. This is because it suggests to switch off the
condensing turbine STG and hence less steam is produced from HRSG during the night
time, hence less gas is needed.

Power
generation
Steam
Generation
Fuel
Steam
Power
Block
GTG
STG
BOILER
HRSG
BUTANE
NATGAS
GTG
HRSG
Natural Gas Header
BOILER
LPUSE
HPUSE
HPGEN
LPGEN
BFWPROC
LETDOWN
VENT
COND
DEARATOR
STG
PUMPDRV
PUMPDRV
GRID
SITEPOW
STGPUMP
PUMPDRV
BFWPUMP
TURBINE
MKUP
AnnCost
Description
Butane
Natural Gas
Boiler Fuel
LP Steam Use
HP Steam Use
HP Steam Generation
LP Steam Generation
LETDOWN - Steam In
VENT - Steam Out
CONDENSATE Return
HP Steam In
Site Power Demand
BFW Pump Power In
Make up Water
Hourly Cost
1 - 46
1
MWe
MWe
tonnes/hr
tonnes/hr
GJ/hr
GJ/hr
GJ/hr
GJ/hr
GJ/hr
GJ/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
tonnes/hr
MWe
MWe
MWe
MWe
MWe
MWe
MWe
tonnes/hr
$/hr
2
20.00
7.00
20.00
142.70
0.00
619.08
242.00
263.99
73.09
73.09
52.00
130.00
53.00
32.00
85.00
30.67
0.00
33.00
25.67
40.03
15.00
0.40
4.91
31.90
0.01
0.00
0.39
0.00
157.13
1125
20.00
0.00
20.00
99.85
0.00
508.48
242.00
153.39
73.09
73.09
52.00
130.00
53.00
32.00
85.00
27.85
0.00
33.00
22.85
0.00
15.00
0.40
11.90
31.90
0.00
0.00
0.32
0.00
154.87
1001
Save the Excel Interface File under the name Task6.xlsm.

From the Aspen Utilities Excel menu, select Close Aspen Utilities.
Then close Task6.xlsm too and all other excel files that may be open
In preparation for the next task you need to do the following:
Task 7 Convert Production Plan to Utilities Plan

The utility planning process usually follows the production planning process. Aspen
Utilities (through its Excel based interface) offers the ability to:
easily transfer a Production Plan originating from the Production Planning

department (in a refinery usually done by supply chain tools like PIMS) ,
convert it into a Demand Forecast and then
send the calculated utility demands into the Aspen Utilities optimizer, to produce an
optimum Utility Plan.
Copy/Paste Database files for 7 periods

First you need to copy the following files from Databases7periods folder :
ProfileData.mdb
DemandData.mdb
TariffData.mdb
Interface.mdb
Paste the files into the following path:

C:\ProgramData\AspenTech\Aspen Utilities Planner V8.4\Example Databases
1 - 47
Open the model file and link to the excel file for Task7
Open the Aspen Utilities Planner file titled Model.auf.

Open the Excel interface file Task7Starter.xlsm
Next you will link the Excel file to the Aspen Utilities model file, using the following
steps:
From the Aspen Utilities Add-In menu, select Open Aspen Utilities
Point to the Model.auf and select Open.
When prompted with the following question, press Cancel
The Excel file and the Aspen Utilities model are now linked.
Review tab FromPimsOrion
Overview of Production Plan Table (rows 3-13)
The Production Plan Table (rows 3-13) includes a production plan for the week (7 days)
coming from the production planning department. By clicking on the button Load Tags
from Mapping File these data has automatically populated the table from another
worksheet.
The data includes the following information for three process units (HYD, IGAS, FCC):
Feeds and Product rates
Mode of operation and
Season
Overview of Equations Table (rows 25-38)
The Equations Table includes demand forecasting correlations that calculate individual
utility usages (steam, power, BFW, natural gas) for each of the 3 process units, as a
function of their production rates and the other production parameters.
1 - 48
When you navigate to any cell within the table you can see the formulas used for these
calculations. The formulas have been produced by regressing historical data.
Overview of Targets Table (rows 15-23)
The Targets Table sums up the individual consumptions by utility type to calculate the
total demands per utility type as represented inside the Aspen Utilities model. For
example the LPUSE for all these process units is added up to a total amount . The totals
shows on the Targets table are automatically sent to the Demand tab, as inputs to the
model. So if a new production plan is loaded in the top table, then the Demand tab
will be automatically updated with the corresponding utility demands.
Objective of Task 7
Start with a Process Production Plan for the coming week (7 days)
Convert this to a Utility Production Plan for the week
Evaluate the impact on cost if we shut down the condensing turbine STG for
maintenance during the week
First we shall run optimization for the 7 periods, assuming STG is Available
Then we shall run optimization for the 7 periods setting STG to Not Available
Then we shall compare the power import profiles for the two cases and the total
weekly cost
Review tab Demand

View the Demand tab and observe that all the demands originate from the Targets
Table and that there is variation in the utility demands between the periods
Review Equipment Availability
The equipment availability and limits have been set to the default values for all the
periods. Note that the new steam TURBINE is Not Available and that the BOILER is
Must Be On
Review Prices
The default prices have been set for all periods (Power :40$/MWH, NatGas:1.5 $/GJ,
Butane 6$/GJ)
Run optimization for 7 periods
Run Optimization by setting the ending period to be 7:
1 - 49
View Results
View the results in the Utility Production Plan and the Graphs tabs, to see the forecasted
Power Import and costs. The costs are reported as hourly cost for each day of the week
and as a weekly total. Save the file as Task6STGAvailable.xlsm
Rerun the model with STG down
In the Availability tab, change the STG Availability to Not Available for all periods
and re-optimize. View the results and save as Task6STGDown.xls.
Task 7 - Solution
Case 1 Results STG Available
Case 2 Results STG Not Available
The cost of shutting down the STG during this week will be $14,420. This is the
difference between the weekly cost for case 1 (187,480) and case 2 (201,900).
1 - 50
Task 8 Evaluate Capital Investment

Objective of Task 8
Over the years, new process plants have been added to this industrial site. This has
impacted the overall steam balance, and as a result of this, there is quite often a large
steam let-down flow between the HP and LP steam headers. Apart from the BFW
pump steam drive, there is no other steam turbine between the two steam headers.
The objective of task 8 is to evaluate the potential energy cost savings and payback
period if we install a new steam turbo-generator between the HP and LP steam levels.
The new steam turbine has operating limits of 3.5-7 MW and has estimated capital
cost of $3.8 Million. This new steam turbine is already in the flowsheet but has been
Not Available in the previous tasks.
Available Information and Methodology
To evaluate the total annual cost savings from this potential investment, we have
identified the 7 most typical operating cases and the corresponding hours for which
each case occurs during the year. These are shown in the table below.
Operating Case
Hours/year
1
900
2
1100
3
1500
4
1500
5
2000
6
500
7
500
The utility demands for each operating case have been entered in the
Task8Starter.xlsm file, in the Demand tab, in each of the 7 periods.
First we shall calculate the total annual operating cost for the 7 operating cases
without the new turbine
Then we shall calculate the total annual operating cost with the new turbine being
Available
By comparing the cost for the two options, we can estimate the potential energy cost
savings from the investment in the new turbine
Solution Steps
Open Task8Starter.xlsm file. This will automatically link to the model file
View the Demand tab to see the utility demands for the 7 operating cases.
In the Availability tab, set the NEW TURBINE to Not Available
View the optimized results in the Production Plan tab.
Fill in the data for the hours of operation per year for each period (yellow cells)
1 - 51
This allows the total annual operating cost to be calculated 9,394,084 $/year
Save the excel file with the name Task8NoNewTurb.xlsm
Next we will find out the annual operating cost, if the new turbine is put in place
In the Availability tab, set the NEW TURBINE to Available and its capacity
limits to be between 3.5 7 MW for all periods
View the optimized results in the Production Plan tab.
The total annual operating cost with the new turbine in place is 7,511,204 $/year
Save the excel file with the name Task8NewTurb.xlsm
The operating cost savings from the new turbine is 1,882,880 $/year
The cost of the new turbine is 3.8 $Million, this gives a payback of approximately 2
years
1 - 52

EAU901.088.01 Virtual

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

EAU901.088.01 Virtual

Transféré par

Droits d'auteur :

Formats disponibles

Energy Management: Optimizing

Site Wide Utilities to Save Energy

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop

2015 AspenTech. All Rights Reserved

Energy Management - Aspen Utilities Planner

Aspen Technology, Inc.

EAU 901 Application Workshop