BP asserts that Emerson’s productivity tool has helped increase throughput and improve operational performance at its Grangemouth, Scotland, utilities and ethylene plants.
Implementing a process optimization tool at BP's Grangemouth, Scotland, utilities and ethylene plants has resulted in a $2.5 million cost savings, increased plant throughput and improved environmental status. It is the third closed-loop optimizer commissioned by Emerson Process Management, Austin, Texas, at the BP petrochemical site. BP asserts that Emerson's "Real-Time Optimizer" productivity tool has been instrumental in increasing throughput and improving operational performance. The current savings includes $1.5 million energy savings from utilities optimization and $1 million benefit driven by a 4 percent increase in plant throughput.

The utilities optimizer delivers operational benefits by reducing fuel usage and increasing generation of electricity. AMS Optimizer, a component of Emerson's AMS Suite, provides recommendations for the optimal steam and power generation. The recommended setpoints are displayed for the operators, including the amount of opportunity that is lost (i.e., the difference in cost between current and optimal operation). The cumulative opportunity lost on a shift-by-shift basis also is calculated and used by management at each start-of-day meeting.

The KG Ethylene closed-loop optimizer generates the optimal operating setpoints based on current operating conditions. These are sent directly to the distributed control system (DCS) controllers. Operators are able to open and close the loop between the optimizer and plant controllers at any time. Engineers also have the ability to use an open-loop optimizer that specifies the operating margin assuming that each variable has moved to its full range of operation.

This is the third closed-loop optimizer commissioned by Emerson on the KG site, and the optimizer has been upgraded with each plant expansion. A key component of Emerson's PlantWeb digital plant architecture, the AMS Optimizer also has enabled BP to achieve consistent plant operation, improve control of daily key performance indicators and enhance the planning process through improved equipment selection.

"Following the installation of Emerson's AMS Optimizer package on the power station, we have been able to realize and improve our plant operations," says Tim Desmond, utilities optimization engineer, BP. "The optimizer has been instrumental in reducing our energy costs, which is a strategic goal for the site, and reducing our CO2 emissions by up to 25 kilotonnes."