Strategic Energy Management For Resilience
The Good, Bad and Ugly of
Organizations for Energy Efficiency
Norman Lee FIChemE
6 October 2015
1
Actsys Overview
About Us
Services
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Singapore Based Company
Incorporated 2001
Operating regionally (Malaysia, Indonesia, Thailand, India)
Core expertise
 Thermodynamic Performance Analysis
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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
2
Actsys Overview
About Us
Services


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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
3
Actsys Major Customers
4
Agenda
Bad
Good
Maintenance
X
Operations
X
Performance Monitoring
X
X
Retrofits
X
X
Energy Dashboards
Energy Management
X
X
X
5
Bad Maintenance
6
Bad Maintenance
7
Bad Maintenance
8
Bad Maintenance
9
Bad Maintenance
10
Bad Maintenance
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
11
Good Maintenance
Regular condition monitoring of equipment to ensure
timely corrective maintenance
12
Bad Maintenance
1” steam trap fixed incorrectly in reverse will allow
0.2 Tons/day steam loss worth $4380 per annum
13
ISO50001 Keywords
Energy Training
Energy Measurement
Equipment Performance
Energy Audits
14
Bad Operations
Target 2%
Every 1% excess O2
will result in 0.2%
extra fuel consumption
15
ISO50001 Keywords
Energy Targets
Energy Deviation Monitoring
Energy Training
Continuous Improvement
16
Bad Performance Monitoring
Crude to
Furnace
E21254
Crude from
Storage
To Storage
Tank
E21253
E21273
P21252
Max
Target
Furnace
Crude
Distillation
Column
C21251
17
Bad Performance Monitoring
5500 mmBtu/A lost
Energy Recovery
$100,000/A
18
Good Performance Monitoring
Condensate
Extraction Pump
Bypass
Valve
Preheated Water
To Deaerator
V-1
E-3
Flue Gas Inlet
Feed water
Preheater
Passing Valve
Flue Gas to Stack
19
0.90
31-Dec-05
17-Dec-05
3-Dec-05
19-Nov-05
5-Nov-05
22-Oct-05
8-Oct-05
24-Sep-05
10-Sep-05
27-Aug-05
13-Aug-05
30-Jul-05
16-Jul-05
2-Jul-05
18-Jun-05
4-Jun-05
21-May-05
7-May-05
23-Apr-05
9-Apr-05
1.10
26-Mar-05
12-Mar-05
26-Feb-05
12-Feb-05
29-Jan-05
15-Jan-05
1-Jan-05
Good Performance Monitoring
Stack /temp
Vsand
Feedwater
Temperature
(Actual)
(New
Clean Preheater
Performance)
Stack T
Feedwater Preheater T
1.05
1.00
0.95
Valve Repaired
20
ISO50001 Keywords
Energy Performance Indicators
Equipment Performance
Energy Training
Energy Reporting
21
Bad Retrofits
VSD Installed for
Condenser Fans
22
Bad Retrofits
Operation of Fan VSD
23
Bad Retrofits
Power Generation
Loss due to Lower
Fan Speed by VSD
24
Good Retrofit
137
HS Legend:
Preflash OVHD
Kero Prod
Kero PA
Diesel
Diesel PA
LSWR
105
142
150
108
139
Desalter
110
251 deg C
140
Pre-flasher
50
kbbl/d
141
136
128
112
115
113
25
Good Retrofit
67 deg C
E137B
HS Legend:
Preflash OVHD
Kero Prod
Kero PA
Diesel
Diesel PA
LSWR
93 deg C
E105C
131 deg C
98.5 deg C
E139B
Desalter
E142C
251 deg C
E140B
E136B
PROPRIETARY INFORMATION
229 deg C
Pre-flasher
C-116
50
kbbl/d 39 deg C
201 deg C
225 deg C
112
A/B
150 deg C
108
A/B
E141B
208 deg C
26
Good Retrofit
260
degC
Start-up
Furnace Inlet Temperature
255
250
245
240
Last cycle before project commissioning
235
230
225
220
27
ISO50001 Keywords
Energy Audits
Energy Training
Energy Measurement
Energy Performance Indicators
Continuous Improvement
28
Good Energy Dashboards
29
Good Energy Dashboards
30
Good Energy Management
• Design
• Historical best performance
• Simulation equations
• Performance Test Runs
Current Plant
Operation
Actual Energy
Operating Parameter
Target Energy
Operating Parameter
• Changed energy index deviations
• Improved plant performance
Energy Index
Deviation (EID)
Plant Adjustments
and improvements
Operator
Action /
Maintenance
Planning
Excess Utility Consumption
(Steam / FG / Electricity)
• Changing set points
• Adjusting control parameters
• Plan for corrective maintenance
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Good Energy Management
MTBE Energy Specific Consumption & Energy Cost (2008-2012)
8,000,000.00
Savings
14.00
7,000,000.00
RM 2
Million/month
12.00
Energy Cost
10.00
5,000,000.00
8.00
4,000,000.00
ESC, mmBTU/MT
Energy Cost, RM
6,000,000.00
MTBE Energy
Specific
Consumption
6.00
3,000,000.00
4.00
2,000,000.00
2.00
1,000,000.00
Nov-07
Jun-08
Dec-08
Jul-09
Jan-10
Aug-10
Feb-11
Sep-11
Apr-12
0.00
Oct-12 May-13
32
Bad Energy Management
5.753
25% thermal
Efficiency loss
4.2131
Exhaust Dump MW
Steam Energy MW
0.07 P T 536.74
12.40 P T 193.05
36142W H 573.08
5443.1W H 2786.5
13.00 P T 103.00
5443.1W H 432.69
S7
16.479
S14
Fuel Energy MW
S9
S10
S8
S13
S2
S5
S6
SP1
0.07 P T 217.87
S4
31.000
DB1
Ambient DegC
S16
EVAP1
ECON1
36142W H 215.06
S1
S17
GT D1
DU CT1
4.6552
GT Power MW
33
ISO50001 Keywords
Energy Manager
Equipment Planning
Energy Measurement
Energy Performance Indicators
34
Characteristics of Good and Bad
Organizations for Energy Efficiency
ISO50001 EnMS Gap Analysis
Energy Manager
Continuous
Improvement
Energy Plannning
50%
Energy Training
Energy Improvement
activities…
Energy Measurement
40%
30%
60%
10%
30%
30%
Energy Reporting
10%
10%
50%
Equipment
Performance
30%
70%
Energy Targets
Energy Performance
Indicators
Energy Audits
Energy Deviation
Monitoring
35
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