Operational planning optimization of steam power plants considering equipment failure in petrochemical complex

One or more interconnected steam power plants (SPPs) are constructed in a petrochemical complex to supply utility energy to the process. To avoid large economic penalties or process shutdowns, these SPPs should be flexible and reliable enough to meet the process energy requirement under varying conditions. Unexpected utility equipment failure is inevitable and difficult to be predicted. Most of the conventional methods are based on the assumption that SPPs do not experience any kind of equipment failure. Unfortunately, a process shutdown cannot be avoided when equipment fails unexpectedly. In this paper, a systematic methodology is presented to minimize the total cost under normal conditions while reserving enough flexibility and safety for unexpected equipment failure conditions. The proposed method transforms the different conditions into real periods to indicate normal scenarios and virtual periods to indicate unexpected equipment failure scenarios. The optimization strategy incorporating various operation redundancy scheduling, the transition constraints from equipment failure conditions to normal conditions, and the boiler load increase behavior modeling are presented to save cost and guarantee operation safety. A detailed industrial case study shows that the proposed systematic methodology is effective and practical in coping with equipment failure conditions with only few additional cost penalties.