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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
35
36
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