BP Site Gains $2.5 Million Annual Benefit Using Asset Optimization Technology In Emerson's Plantweb® AMS™ Suite Software | Automation.com

BP Site Gains $2.5 Million Annual Benefit Using Asset Optimization Technology In Emerson's Plantweb® AMS™ Suite Software

January 122004
Implementation of AMS Suite: Real-Time Optimizer on BP's Grangemouth Utilities and Ethylene plants delivers cost savings, increased plant throughput, and improved environmental status

TEESSIDE, U.K. (January 12, 2004) - The BP petrochemical facility at Grangemouth, Scotland, reports $2.5 million annual savings by using AMS Suite: Real-Time Optimizer from Emerson Process Management. This includes $1.5 million energy savings from utilities optimization, and $1 million benefit driven by a 4 percent increase in plant throughput from the KG Ethylene optimization application. A key component of Emerson's efficiency-increasing PlantWeb® digital plant architecture, the AMS Optimizer has also 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," said Tim Desmond, Utilities Optimization Engineer, BP. "The optimizer has been instrumental in reducing our energy costs, which is a strategic goal for the site, saving us approximately $1.5M per year and reducing our CO2 emissions by up to 25 kilotonnes. BP has worked very closely with Emerson on several optimization systems and this project reaffirms why they are a key supplier of optimization technology at the Grangemouth site."

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 set points 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 is also calculated and used by management at each start-of-day meeting.

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

This optimizer has been upgraded with each plant expansion. This is the third closed-loop optimizer commissioned by Emerson on the KG site and has been instrumental in increasing throughput and improving operational performance.

"The AMS Optimizer has increased plant throughput by 4%, resulting in benefits of over $1M per year on the recently expanded KG ethylene plant," said Simon Lopez, Lead Control Engineer - Commercial & Optimization Team, BP. "The optimizer has been instrumental in pushing the operating boundaries of the plant, specifically the compressor trains that were a major constraint on throughput. By selecting the loading on each of the operating cracking furnaces, the AMS Optimizer is able to achieve improved product yields from the available feed stocks and, based on the product prices on the day, targets the optimal product spectrum. Since the optimizer is closed loop, we are able to achieve maximum benefit with no delay in the implementation of the set points."

"The plant operators and management, who see the AMS Optimizer as an integral part of the plant control system and operating procedures, have embraced the technology. We are committed to this leading-edge technology and have formed a close working relationship with Emerson over the last 10 years. This has been evident with the success of the optimizers on the KG and G4 plants which were instrumental in a third optimizer recently being commissioned on the site's utility station. AMS Optimizer from Emerson has been, and will continue to be, a success across the Grangemouth site."

"Emerson's strong relationship with BP around the world is based on delivering solid results like they've experienced in these projects, " said Craig Llewellyn president of the Asset Optimization division of Emerson Process Management. "As companies face the challenge of managing operations in more dynamic environments, it is mission-critical to use the most advanced technologies and services to maximize throughput at best cost. The enhanced visibility into all aspects of operations provides the necessary foundation to help companies gain the most from their production facilities."

AMS Suite is an integrated family of applications for predictive maintenance, performance monitoring and economic optimization. AMS Suite enables companies to dramatically improve availability, plant throughput and product quality, while reducing operations, maintenance and utility costs.

About Emerson Process Management

Emerson Process Management (www.emersonprocess.com), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the chemical, oil and gas, refining, pulp and paper, power, food and beverage, pharmaceutical and other industries. Asset Optimization, www.assetweb.com, a division of Emerson Process Management, is a leading worldwide supplier of services and technologies to increase the availability and performance of production assets for improved bottom line results. Asset Optimization plays a key role in Emerson's mission of combining superior products and technology with industry-specific engineering, consulting, project management and maintenance services to help customers achieve the potential of their operations. Emerson brands include PlantWeb®, Fisher®, Micro Motion®, Rosemount®, DeltaVTM, Ovation®, AMS Suite, and CSI.

About Emerson

St. Louis-based Emerson (www.gotoemerson.com) is a global leader in bringing technology and engineering together to provide innovative solutions to customers in process control; electronics and telecommunications; industrial automation; heating, ventilating and air conditioning; and appliances and tools. Sales in fiscal 2003 were $14 billion.

PlantWeb, Fisher, Micro Motion, Rosemount, DeltaV, Ovation, AMS, MDC, and CSI are marks of Emerson Process Management. Other marks are property of their respective owners.
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