Strategic Energy Management For Resilience

The Good, Bad and Ugly of

Organizations for Energy Efficiency

Norman Lee FIChemE

6 October 2015

1

Actsys Overview

Singapore Based Company

Incorporated 2001

Operating regionally (Malaysia, Indonesia, Thailand, India)

Core expertise

Thermodynamic Performance Analysis

Process Simulation / Pinch Analysis

Utilities System Optimization

Basic Engineering Design

Operations and Maintenance experience

Domain knowledge Power Plants, Refineries, Petrochemicals

Accredited as Energy Service Company by Singapore National

Environmental Agency

About Us Services

2

Actsys Overview

Power Plant Thermodynamic Performance Analysis

Energy Auditing for Improvement Opportunities

Measurement & Verification

Energy Management System

Online Dashboards

ISO50001 Gap Analysis

Process Studies and Front End Design

Training Plant Operating Principles Energy Auditing / Performance Monitoring

About Us Services

3

Actsys Major Customers

4

Agenda

Bad Good

Maintenance X

Operations X

Performance Monitoring X X

Retrofits X X

Energy Dashboards X

Energy Management X X

5

Bad Maintenance

6

Bad Maintenance

7

Bad Maintenance

8

Bad Maintenance

9

Bad Maintenance

10

Bare pipe heat loss :

2” (0.05m) diameter D, 2m length L

Steam temperature Ts 180 degC

Ambient temperature Ta 30 degC

Heat Transfer Coeff Hc 25 W/m2C (normal light wind)

Heat Loss = (πD2/4) * L * (Ts – Ta) * Hc = 15 W

Equivalent to 15 Tons Extra Steam Consumption per

Annum or approximately loss of $900 / Annum

Bad Maintenance

11

Good Maintenance

Regular condition monitoring of equipment to ensure

timely corrective maintenance12

Bad Maintenance

1” steam trap fixed incorrectly in reverse will allow

0.2 Tons/day steam loss worth $4380 per annum13

Energy Training

Energy Measurement

Equipment Performance

Energy Audits

ISO50001 Keywords

14

Bad Operations

Target 2%

Every 1% excess O2will result in 0.2% extra fuel consumption

15

Energy Targets

Energy Deviation Monitoring

Energy Training

Continuous Improvement

ISO50001 Keywords

16

Bad Performance Monitoring

E21254 E21253

E21273

P21252

Crude

Distillation

Column

C21251

To Storage

Tank

Crude from

Storage

Crude to

Furnace

Furnace

Max Target

17

Bad Performance Monitoring

5500 mmBtu/A lostEnergy Recovery $100,000/A

18

Flue Gas Inlet Flue Gas to Stack

Fe

ed

wa

ter

Pre

he

ate

r

E-3

Condensate

Extraction PumpPreheated Water

To Deaerator

V-1

Bypass

Valve

Passing Valve

Good Performance Monitoring

19

Stack temp Vs Feedwater Preheater Temperature

0.90

0.95

1.00

1.05

1.10

1-Jan-05

15-Jan-05

29-Jan-05

12-Feb-05

26-Feb-05

12-Mar-05

26-Mar-05

9-Apr-05

23-Apr-05

7-May-05

21-May-05

4-Jun-05

18-Jun-05

2-Jul-05

16-Jul-05

30-Jul-05

13-Aug-05

27-Aug-05

10-Sep-05

24-Sep-05

8-Oct-05

22-Oct-05

5-Nov-05

19-Nov-05

3-Dec-05

17-Dec-05

31-Dec-05

Stack T

Feedwater Preheater T

Valve Repaired

(Actual) / (New and Clean Performance)

Good Performance Monitoring

20

Energy Performance Indicators

Equipment Performance

Energy Training

Energy Reporting

ISO50001 Keywords

21

Bad Retrofits

VSD Installed forCondenser Fans

22

Bad Retrofits

Operation of Fan VSD

23

Bad Retrofits

Power GenerationLoss due to LowerFan Speed by VSD

24

Good Retrofit

15050

kbbl/d

140

137 142105 110139

115128

113

141

136

HS Legend:

Preflash OVHD

Kero Prod

Kero PA

Diesel

Diesel PA

LSWR

108

112

Pre

-fla

sher

Desalter

251 deg C

25

Good Retrofit

PROPRIETARY INFORMATION

50

kbbl/d

112

A/B

HS Legend:

Preflash OVHD

Kero Prod

Kero PA

Diesel

Diesel PA

LSWR

108

A/B

Pre

-fla

sher

C-1

16

Desalter

E137B E105C E139B E142C

E140B

E136B

E141B

251 deg C

39 deg C 67 deg C 93 deg C 98.5 deg C 131 deg C

150 deg C201 deg C225 deg C

208 deg C

229 deg C

26

Good Retrofit

220

225

230

235

240

245

250

255

260degC

Last cycle before project commissioning

Start-up

Furn

ace

Inle

t Te

mp

erat

ure

27

Energy Audits

Energy Training

Energy Measurement

Energy Performance Indicators

Continuous Improvement

ISO50001 Keywords

28

Good Energy Dashboards

29

Good Energy Dashboards

30

Target Energy

Operating Parameter

Energy Index

Deviation (EID)

Operator

Action /

Maintenance

Planning

Plant Adjustments

and improvements

Actual Energy

Operating Parameter

• Design

• Historical best performance

• Simulation equations

• Performance Test RunsCurrent Plant

Operation

Excess Utility Consumption

(Steam / FG / Electricity)

• Changing set points

• Adjusting control parameters

• Plan for corrective maintenance

• Changed energy index deviations

• Improved plant performance

Good Energy Management

31

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

-

1,000,000.00

2,000,000.00

3,000,000.00

4,000,000.00

5,000,000.00

6,000,000.00

7,000,000.00

8,000,000.00

Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12 May-13

Ene

rgy

Co

st, R

M

ESC

, mm

BTU

/MT

MTBE Energy Specific Consumption & Energy Cost (2008-2012)

Energy Cost

MTBE EnergySpecificConsumption

Savings

RM 2

Million/month

Good Energy Management

32

Bad Energy Management

DB1 EVAP1ECON1

12.40

5443.1

193.05

2786.5

P T

W H

0.07

36142

217.87

215.06

P T

W H

DUCT1

SP1

0.07

36142

536.74

573.08

P T

W H

31.000

Ambient DegC

GTD1

13.00

5443.1

103.00

432.69

P T

W H

4.6552

GT Power MW

16.479

Fuel Energy MW

5.753

Exhaust Dump MW

4.2131

Steam Energy MW

S1

S2 S5 S6

S7

S8

S9

S13

S14

S16 S17

S4

S10

25% thermal Efficiency loss

33

Energy Manager

Equipment Planning

Energy Measurement

Energy Performance Indicators

ISO50001 Keywords

34

50%

40%

60%

30%

10%

10%

30%

70%

50%

30%

10%

30%

Energy Manager

Energy Plannning

Energy Measurement

Energy Reporting

Energy Targets

Energy PerformanceIndicators

Energy DeviationMonitoring

Energy Audits

EquipmentPerformance

Energy Improvementactivities…

Energy Training

ContinuousImprovement

ISO50001 EnMS Gap Analysis

Characteristics of Good and Bad

Organizations for Energy Efficiency

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