IT in Manufacturing


Soteica Visual MESA solution for thermal power plants

November 2017 IT in Manufacturing

Improving efficiency and increasing contribution margin from the production and sale of heat and electric power are among the main objectives in thermal power plants (TPP) around the world.

However, many TPPs face problems in optimal load distribution and optimal planning of equipment, operational monitoring of key performance indicators, as well as avoiding penalties by minimising harmful emissions.

Currently, the solution for such issues is not possible without the use of modern computer techniques and information technologies that can be attributed to systems-level MES, and Yokogawa believes that Soteica Visual MESA offers a compelling solution.

The basis of Visual MESA serves as an integrated model of all energy flows. In addition to energy units, the system considers money equivalents of energy flows, which is a necessary condition for the solution of minimising energy costs and maximising profit from the sale of thermal and electric energy. The system has an intuitive environment for adjustment, maintenance and modernisation of the design decisions of the system through the built-in library of pre-configured functional blocks with a graphical way to organise data flows between functional units by means of communication lines, which also contain thermodynamic and energy characteristics of the process streams (pressure, temperature, enthalpy, calorific value, and heat capacity).

Visual MESA allows Yokogawa to obtain the results of the optimisation of the distribution of thermal and electrical loads, the planning and configuration of the power equipment, with the aim to obtain the maximum profit from the sale of heat and electric energy, based on forecast data for the price of electric energy, heat consumption requirements, and the composition of the equipment for the days ahead, including the possibility of operational adjustments. Also, additional constraints on emissions (the single integrated model can account for and calculate emissions of CO2, SO2, NOx based on the stoich­iometry of combustion and correlations), contract penalties and restrictions (e.g. strict selection of the natural gas in equal parts), and technological limitations (e.g. minimum downtime of the boiler, the simultaneous startup of equipment, etc.) can be incorporated.

Yokogawa believes that Visual MESA provides the most accurate optimisation solution in the energy sector, which can be configured specifically for use with the systems that generate steam and electricity. Unlike some software available on the market, it allows Yokogawa to solve problems in large-scale system modelling and optimisation.

Features

Visual MESA provides users with the following key features: monitoring, auditing, accounting, calculation of key performance indicators, operational reports, and optimisation and planning.

Although applicable to almost all industries, Visual MESA specifically for TPP contains a combination of two sets of functional licences:

• Visual MESA ERTO Open Loop (energy real-time optimisation) with recommendations for optimal use in a report).

• Visual MESA-MPO (multi-period optimisation for optimal planning of equipment configuration to time limits, e.g. maximum or minimum uptime). This module operates offline.

Economic benefits

The primary economic effect in the implementation of Visual MESA is achieved by implementing the following functions:

1. Optimisation of the distribution of energy flows

• Operation optimisation of loads of parallel running equipment (boilers, turbines).

• Choice of the cheapest energy source taking into account production, environmental, and contractual constraint.

2. Optimal planning and scheduling

3. Leveraging utilities auditing and accounting features to detect and eliminate wasted steam

• Identification of wasted steam and operating problems.

• Alerting for changes by periodic scan of all the flow meters inside the model and warning of any changes that occur which exceed predefined thresholds.

4. Emissions management and monitoring

• NOx and SOx constraints.

• CO2 trading (according to Kyoto Protocol).

• Equipment performance monitoring.

• Utilities planning and scheduling.

5. Evaluate effect of production plans on utilities system

6. Planning of shutdowns

7. Export nominations

8. Investment planning and basic engineering

• Plant expansion, process changes.

• Change of configuration of the energy system (e.g. a new co-generation unit).

9. Soft cost savings can be found through allowing the entire organisation:

• To access the site-wide energy system through one model and one environment.

• Visibility into all the decision variables and associated constraints (which are sometimes hidden or ignored).

• Optimal centralisation of system responsibilities.

In addition to direct benefits from the introduction of Visual MESA and new approaches to monitoring energy efficiency, TPPs will receive a number of additional advantages:

• The possibility of convenient analysis of the operation of energy systems in real time, the availability of direct access to the indicators of the entire energy system of site from a unified model and a unified environment.

• Ability to monitor all process variables and related constraints, which in some cases may not appear or be ignored.

Conclusion

The economic benefits from the implementation of Visual MESA are estimated to be in the range of a 1-5% increase in power plants. Thus, the implementation of MES technology is an important tool for solving problems in maximising the marginal profit of TPPs, optimising and improving operational processes in the planning regimes, and the composition of power equipment within the requirements of energy and environmental management.

For more information contact Christie Cronje, Yokogawa South Africa, +27 (0)11 831 6300, [email protected], www.yokogawa.com/za



Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Siemens’ PAVE360 to support new Arm Zena Compute Subsystems
IT in Manufacturing
Siemens Digital Industries Software is expanding its longstanding relationship with Arm and adding support for the newly launched Arm Zena Compute Subsystems in its PAVE360 software, designed for software-defined vehicles

Read more...
Fortifying the state in a time of cyber siege
IT in Manufacturing
In an era where borders are no longer physical, South Africa is being drawn into a new kind of conflict, one fought not with tanks and missiles, but with lines of code and silent intrusions. The digital battlefield is here, and cyber space has become the next frontier of conflict.

Read more...
Levelling up workplace safety - how gamification is changing the rules of training
IT in Manufacturing
Despite the best intentions, traditional safety training often falls short, with curricula either being too generic, too passive, or ultimately unmemorable. Enter gamification, a shift in training that is redefining how businesses train for safety and live by those principles.

Read more...
Reinventing data centre design: critical changes to meet surging
Schneider Electric South Africa IT in Manufacturing
AI technologies are pushing the boundaries of what is possible which, in turn, is presenting data centres with a whole new set of challenges. Fortunately, several options are emerging which include optimising design and infrastructure for efficiency, cooling and management systems

Read more...
Watts next - can IT save the planet
IT in Manufacturing
The digital age’s insatiable demand for computing power has collided with an urgent and pressing need for sustainability. As data centres and AI workloads consume unprecedented energy, IT providers are pivotal in redefining how technology intersects with environmental stewardship.

Read more...
South Africa’s digital revolution:
IT in Manufacturing
South Africa stands at a pivotal moment in its technological evolution, poised to redefine itself as Africa’s leading digital powerhouse. Over the past two years, political leaders and media narratives have painted a picture of rapid digital transformation, underscoring the government’s ambition to position South Africa at the forefront of innovation.

Read more...
Smart manufacturing, APC and the SA marketplace
Schneider Electric South Africa IT in Manufacturing
Manufacturers are prioritising the integration of smart technologies into their daily operations to stay one step ahead of the competition. In South Africa, some experts believe the country has the potential to leapfrog its global peers through the creation of smart factories.

Read more...
Schneider Electric’s Five-Pillar Strategy takes the guesswork out of equip
Schneider Electric South Africa IT in Manufacturing
Schneider Electric’s Field Service Cycle, otherwise known as the Five-Pillar Strategy, is a structured approach to managing the lifecycle of equipment to prolong asset lifespan while reducing the total cost of ownership for customers.

Read more...
Enhancing operational safety and efficiency through advanced risk-based modelling
IT in Manufacturing
Now, more than ever, capital and operational cost can be reduced while enhancing operational safety and increasing production uptime by applying transformative methods such as Computational Fluid Dynamics modelling.

Read more...
Laying the groundwork in IT/OT
IT in Manufacturing
In the realm of manufacturing, the core mandate is to deliver value to stakeholders. For many in the industry, this is best achieved through a risk-averse approach. Only upon establishing a robust foundation should a business consider venturing into advanced optimisation or cutting-edge technological innovations such as industrial AI.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved