water and energy management auditor to project manage and provide technical expertise for a range of...
TRANSCRIPT
WATER MANAGEMENT CONSULTANT
PRESENTED BY:AKINSOLA AKINLOLU
Water and Energy management auditor to project manage and provide technical expertise for a range of utility reduction projects - mainly in the Food & Beverage sectors, along with large commercial buildings
REQUIREMENT FOR ADEQUATE WATER ASSESSMENT
Evaluation of current water use and costs associated with water supply and wastewater discharge
Development of a water balance that provides a detailed breakdown of water use by end-use/process
Evaluation of efficiency opportunities and identification of life-cycle cost-effective measures
Strategic plan for meeting water reduction goals.
The objective of water assessment is to develop an understanding of facility water consumption and identify cost-effective water efficiency measures that will help to achieve the site’s required water reductions
Water Assessment Phases
PHASE I: BACKGROUND DEVELOPMENT AND PREPARATIONHistorical water consumption analysis
Cost data analysis
Team coordination
1. Hold a kick-off meeting to state the goals and objectives of the assessment to the facility team 2. Provide interim progress reports on the preliminary findings of the audits 3. Hold a final meeting to present results of the assessment
1. Calculate marginal cost of water and wastewater 2. Verify whether the facility is on proper water and wastewater rate schedules 3. Estimate the potential future water and wastewater rate escalation (to be used in life-cycle cost analysis of efficiency measures).
1. Collect and analyze at least 2 years of data for total supply, wastewater discharge, and all sub-metered water data 2. Estimate system losses based on system condition and age, and document the method used for determining system losses 3. Develop annual distribution curve (water use over time)4. Develop baselines for both potable water, and industrial, landscaping and agricultural (ILA) use, accounting for consumptive use from both potable and non-potable sources. Document the method used to develop the baseline.
Background data – The facility will provide background information to the assessment team for prioritization of the walk-through audits. This background data includes: 1. Historic water and wastewater bills or data from supply generated and/or treated onsite 2. Sub-metered data on water processes and buildings 3. Building floor space by building type 4. Occupancy data 5. Equipment lists 6. Maintenance schedules 7. Site and individual building maps 8. Distribution system maps
FOR AN EFFECTIVE BACKGROUND DEVELOPMENT
PHASE II: WALK-THROUGH AUDITS
walk-through audits of buildings and applications that were identified in Phase I of the water assessment. The basic documentation requirements for water end-uses are described below: Scope :Only include end-uses and processes that pertain specifically to the site.
1. Domestic plumbing fixtures – Document the following items for toilets, urinals, faucets, and showerheads: Audit approximately 10% of the restrooms at the facility to obtain a gauge on the general age and condition of fixtures
2. Commercial kitchens – Document the following items for ice machines, dishwashing machines, tray conveyor systems, garbage disposals, pre-rinse spray valves, convection steamers, steam kettles and other water consuming appliances: Note the brand and model number of the appliance, measure the flow rate of the appliance if applicable, document the operating schedule of the appliance 3. Irrigation and landscaping : Measure system pressure, Note if there is an irrigation meter, document the operating schedule (noting time of day) and hours per day or week during irrigation season, document the irrigation technology type (make and model of equipment), Estimate the number of sprinkler heads , Identify the overall system condition, noting leaking/maladjusted heads , Identify controls (type of controls and how they are used)
http://www.irrigation.org/Certification/CLIA/Audit_Requirements.aspx)
PHASE II: WALK-THROUGH AUDIT CONT’
4. Evaporative cooling systems Determine the size of the system (this may be in terms of cooling tonnage or recirculation rate), Determine how many days the system operates per year C. Determine if make-up water is metered. If it is not metered, verify whether system water use is tracked by other means, If possible, walk the system to see if leaks or losses are apparent. For any leaks or losses found, measure and quantify the loss.
5. Closed-loop cooling systems Determine whether system losses are known and measured, If possible, inspect the system piping to see if leaks or losses are apparent. If leaks or losses are found, measure and quantify the loss. 6. Single-pass cooling Determine how many days the system operates monthly or annually, Determine flow rate of system.
7. Steam/boiler systems Determine the size of the system (this may be in terms of steam generation or boiler horsepower), determine how many days the system operates per year , Determine whether the make-up water is metered. If it is not metered, verify if the system water use is tracked by other meansDetermine if cycles of concentration are tracked routinely. If they are not tracked routinely, determine if there are operator logs available that include routine measurement of blowdown and make-up conductivity E. Determine whether the system blowdown is automated or done manually F. Verify that steam traps are operating properly and are leak free G. Determine whether the system returns condensate and where condensate losses may be occurring.
8. Hot water (closed-loop) heating systems Determine if system losses are known and measured If possible, inspect the system piping to see if leaks or losses are apparent. If any leaks or losses are found, measure and quantify the loss Assess domestic hot water heaters for temperature setting and possible leaks. 9. Laboratory and medical facilities – Document the following items for disinfection/sterilization systems, vacuum pumps, water purification systems, photographic and x-ray equipment, glassware washers, vivarium equipment, and other water-using equipment. Note the brand and model number of the equipment, Measure the flow rate of the equipment, if applicable 10. Laundry facilities Determine type of washing machines (note make and model number), Estimate the number of loads washed per day or week, Identify the overall condition of the equipment. 11. Vehicle wash stations Determine the type of wash station , Identify whether the system recycles water. 12. Alternate water sources investigation – Investigate opportunities to access alternate water sources for process on the facility premises to provide a high level recommendation including (but not limited to): [Note a detailed assessment of alternate water sources is outside the scope of a typical facility water assessment.] A. Rainwater harvesting , Grey water, Water reuse, Air conditioning condensate capture, Wastewater reclaim.
PHASE III: WATER BALANCE DEVELOPMENT
The contractor shall develop a water balance that provides water consumption by major end-use categories (as defined in the SOW in Phase II) and system losses. The contractor shall complete the following elements: 1. Water balance – Develop a water balance that estimates current equipment and
process water use by major end-use categories and system losses and compares this total to water supply and ultimate discharge or reclaim of wastewater
2. Graphical elements – Show water balance in graphical form in a flow chart and/or pie chart that breaks out water use by major end-use categories and estimated losses.
SAMPLE BALANCE
Process Plant
Separation Plant
Water Recycle System Plant
Recycled Water, W,recycle
Water flow Winlet, T1
Water Flow Woutlet, R1
Water Flow Woutlet, R2
Water flow Winlet, T3
Water flow Winlet, T2
USING THE LAW OF CONSERVATION OF MATTER
Total Inflow rate of Water = Total Outflow rate of water + Total Water consumed within the system
And for more detailed calculations, component or sub plant usage can be focused on
Investigation and analysis of water efficiency opportunities that include the following elements:
1. Efficiency opportunity assessment – Assess opportunities for water efficiency improvements in each major end-use, including technologies that are detailed above in Phase II of the assessment. Include a consideration for retrofit, replacement, operation and maintenance improvements, and applications for sub-metering
2. Alternate water sources identification – Identify alternate water sources to offset the use of freshwater sources and provide estimated potential of annual water volume, as well as potential applications where the alternate source could be utilized 3. Life-cycle cost analysis – Perform life-cycle cost (LCC) analysis of all measures – the preferred tool for analysis is the Building Life-Cycle Cost (BLCC) analysis program for this analysis activity
PHASE IV: WATER EFFICIENCY INVESTIGATION AND ECONOMIC ANALYSIS
www.femp.energy.gov/information/download_blcc.html.
THE LIFE-CYCLE COST ANALYSIS (LCC)
1. Water and wastewater costs and other ancillary costs of water-consuming equipment, such as energy, operations and maintenance (O&M), and chemicals
2. Estimated water and wastewater escalation rates
3. Available utility rebates for installed measures, if applicable
4. Prioritization of efficiency opportunities – Rank each measure based on LCC effectiveness and installation cost, addressing both short-term and long-term investment opportunities.
SUMMARY
DELIVERABLES AND SCHEDULE The contractor shall deliver the following items by noted the due dates: Phase I: Background Development and Preparation • [2/12/2012]: Kick-off meeting summary that documents key items addressed by facility team • [3/05/2013]: List of prioritized buildings for walk-through audits
Phase II: Walk-Through Audits • [4/06/2013]: Summary report of walk-through audits that includes major issues or problems encountered during the surveys
Phase III: Water Balance Development • [10/07/2013]: Interim water balance shown in graphical form that shows all major water uses by end-use (as defined in Phase II) and comparison to incoming supply and discharged wastewater that reveals estimated losses of the system
FINAL REPORT• [10/08/2013] Executive summary – Provide a concise overview of the major results of the assessment that includes the following: o Prioritized list of water efficiency opportunities o Baseline water use and method used to determine this value
o Water and wastewater rates, marginal costs of water and wastewater, and other associated costs, such as energy o Water distribution curve that provides water use over time showing historic seasonal fluctuations
o Water balance shown in graphical form that shows all major water uses by end use and comparison to incoming supply and discharged wastewater that reveals estimated losses of the system. Include general methods used to estimate end-use consumption
o Detailed information on efficiency opportunities that include O&M, retrofit, and replacement options for each major water-using piece of equipment, as well as recommendation for sub-metering
o Prioritized list of water efficiency opportunities that provides total water, energy, and cost savings and life-cycle cost effectiveness indicator (such as savings to investment ratio or adjusted internal rate of return)
o Alternate water sources with estimated potential of annual water volume, as well as potential applications where the alternate source could be utilized
o Plan for meeting annual water reduction goals.
PINCH ANALYSIS FOR ENERGY OPTIMIZATION
The process data is represented as a set of energy flows, or streams, as a function of heat load (kW) against temperature (deg C). These data are combined for all the streams in the plant to give composite curves, one for all hot streams (releasing heat) and one for all cold streams (requiring heat).
The point of closest approach between the hot and cold composite curves is the pinch point (or just pinch) with a hot stream pinch temperature and a cold stream pinch temperature. This is where the design is most constrained. Hence, by finding this point and starting the design there, the energy targets can be achieved using heat exchangers to recover heat between hot and cold streams in two separate systems, one for temperatures above pinch temperatures and one for temperatures below pinch temperatures.
In practice, during the pinch analysis of an existing design, often cross-pinch exchanges of heat are found between a hot stream with its temperature above the pinch and a cold stream below the pinch. Removal of those exchangers by alternative matching makes the process reach its energy target.
INDUSTRIAL PROCESS CALCULATIONS
Reactor Design calculation
Process flow designs, Piping and Instrumentation Drawing (P&ID)
Process Control -Feedback Control Systems that minimises waste and enhances process efficiency
Automation Systems – linking system and also deals with plant layout
Lean Techniques- Calculation of Takt time and value stream mapping
Vacuum Still, E-6
Atmospheric Distillation Tower,
E-5
I-2
P-1
P-9
Fuel oil
Lubricants
Heavy gas oil-feedstock
Light gas oil-Diesel oil
Jet fuel
Naphtha-Petrol
Gases-LPG
E-4
E-2
P-2
P-3
P-4
P-5
Centrifugal Pump, E-7
P-6P-7 P-8
E-10
E-11
P-11
E-15
E-14
E-13
E-12
P-12
P-13
P-14
P-15
P-0
SHIP
P-10
Centrifugal Pump
P-0
Shell and tube Heating instrument
,E-3Desalter, E-1
Storage Tank, E-0
Bitumen Plant, E-8
The Process Flow diagram for Industrial Oil ProductionAs at Monday April 30, 2006
4/30/2006
The Process Flow Chart
AKINLOLU, Akinsola (2006) MSc. Project: Semi-automation of Bitumen from conventional refinery residue. Coventry University, UK.
SAMPLE FROM MY MSC RESEARCH WITH FAWLEY REFINERY
3000s
82589.34m3/h150,000 m3/h
151351.35m3 of crude Oil
4/30/2006
Current State Mapping of Bitumen Production Plant
AKINLOLU, Akinsola (2006) MSc. Project: Semi-automation of Bitumen from conventional refinery residue. Coventry University, UK.
9900s21000s8000s12000s
5 days or 7 days
0s
1110.203m3/h
Outlet capacity of 25 MW per cycle
150,000 m3/h
Tanker(For Onshore or
Pipeline)
StorageTank
Temp. 30ºCPress. 1mmHg.
Q (flow rate) Cycle time
I
DesalterProcess
Temp.115-165ºCPress. 103.4mmHg
Q (flow rate)Cycle time. 7500-
9900sec
Heating Process
Temp. 400 ± 40ºCPress. 250mmHg
Q (flow rate)Cycle time. 240,000
barrel per dayAvailable for 20hrs
Large furnace Has capacity 30MW
I
I
I
Vacuum StillProcess
Lubrication Oil for machinesTemp. 340 - 575ºC
(> C60)
Fuel Oil (for ship and Power stations)
Temp. > 490ºC(> C70)
Bitumen (Road & roofs)Temp. > 580ºC
(> C80)
I
II
I
I
Naphtha
1351.35m3
Lubrication Oil Plant
Bitumen Plant
Design Temp. 270 - 300ºC
Press. 0.01 – 0.05 MPa
Air consumption 3,500 – 4000 m3/h
Tar capacity 35 – 40 m3/h
Fuel Oil Plant
LPG
2162.16m3
Light Oil
Heavy Oil
Kerosene
TankerDaily
SHIP(For Offshore or
pipeline)
I-2
Fractional Distillation Process
LPGTemp. < 40ºC
Press. 1.4 – 2.6 atm
Naphtha's
Temp. 25 - 175ºCPress. 2.6 – 5 atm
(Sulphur cont.)
KeroseneTemp. 150 - 260ºC
Light gas OilTemp. 235 - 360ºC
Heavy gas Oil Temp. 330 - 380ºC
The Crude Oil Residue
Crude Oil from the Upstream Supplier
CustomersThe requirement per
day on Bitumen.
CustomersThe requirement per
day on LPG, Naphtha, Lubrication oil, Fuel
oil etc.
The Production Control
MRP control
Other Plants
For LPG, Naphtha, Kerosene, Light and
Heavy oil
1351351.35m3 (100,000 Tonnes) from the
Offshore
16216.22m3
(12,000 Tonnes) from the Onshore
91240.46m3/h
I
Almost 30% of the crude is in
the Residue
Customer requirement per day Forecast
Current State Value stream Mapping for Oil Production As at Monday April 30, 2006
Crude Oil from the Upstream Supplier
KEYS
Plant representation
I
Input/ Output symbols for
queues Measured in
m3
Tanker(For Onshore transportation)
The supplier and
Customer symbol
The Critical path arrow for bitumen production The Non critical path
The Production/Control symbol
I-2
SHIP transportation(For Offshore )
Flow rate from the storage to
Desalter is NOT equalHigh flow Low Flow
Available for 20hrs only
High flow
Andon call
Low Flow
Complex Plant
These plants Need to be monitored against spillage and
more information required
Andon call
91240.46m3/h
very Low Flow
18000m3
Spillage may occur. Inlet more than
Plant capacity
For flow through pipesWith flow rate
measured in m3/h
Important comment on process or plant which may
cause uneven flow
91240.46m3/h5789.45m3/h
SAMPLE FROM MY MSC RESEARCH WITH FAWLEY REFINERY
The amount into the system is 150,000m3 and out of the system is 91,240.46m3, if this information is fed into the material equation; the amount the system accumulated in the cause of processing the crude oil is 58,759.54m3.
This cannot disappear into the system without been accounted for within an hour.
The volume of the Desalter tank was also measured and can take up to 160,000m3 of crude oil.
SAMPLE FROM MY MSC RESEARCH WITH FAWLEY REFINERY
SAMPLE FROM MY MSC RESEARCH WITH FAWLEY REFINERY
SAMPLE FROM MY MSC RESEARCH WITH FAWLEY REFINERY
FEEDBACK CONTROL SYSTEM IN THE PREHEATED STORAGE TANK
MAKE USE OF NAVIER STOKE EQUATION FOR MASS, MOMENTUM AND ENERGY BALANCE
The quantity S can be any of the following fundamental quantities •Total mass •Mass of individual component, in the case of distillation column•Total energy•Momentum
PROPOSED CONTROLLED SYSTEM
Study Chemical Process Plant
Lean Techniques
The Current State Value stream
mapping drawn
Plant subdivided to processes with parameters and conditions for
operation
Visual Symbols incorporated to see anomalous
Detection of Bottleneck, Waste reduction, Reorder point technique and uneven processes, flow rate,
etc.Automation system
and Sensory device techniques
Chemical Process Control technique
Areas where sensory devices, Visual and
virtual instrumentations
Arrangement of Plant and links to optimise
process and production
Analysis of chemical Control processes,
areas where sensory devices can be used
Resolved the bottleneck and queue,
uneven processes
Rearrangement with sensory devices for
Automation
The Automated Plant
The Future State Value stream
mapping
The Chemical Plant
4/30/2006
The LeChAs
AKINLOLU, Akinsola (2006) MSc. Project: Semi-automation of Bitumen from conventional refinery residue. Coventry University, UK.
Crude Oil inlet from pipe
Composition of the incoming crude is collected for control
parameter modification
Preheated for non-
viscous flow crude
Request Creator for the
composition Analyser
Error/Control
Storage Process
Desalter Process
Error/Control
Need for flow, Temperature and
Pressure measuring error evaluator
reader
Decision need to be made for the set point
for Temp., Level in the storage tank
etc.
The Water Treatment
and Recycling
Plant
Process Divider
Decision need to be made for the set point
for Temp., Level in the Desalter etc.
Water in
Water out of Recycling Plant
Water in to the
Desalter Plant
Water out of the Desalter
Plant
The Furnace
Need for flow, Temperature and Pressure measuring error
evaluator reader Error/Control
Decision need to be made on Temp.,
Press., Level of Crude
control
The Fractional Distillation Column (Atmospheric
Pipe Still)
Composition of the incoming crude is collected for control
parameter modification
1
1
The Vacuum Still Plant
Bitumen Plant
Thursday June 8, 2006The Flow Chart for the Future/Automated Plant
6/8/2006
The System Flow chart
AKINLOLU, Akinsola (2006).MSc Project:Semi-automation of Bitumen Plant
From Conventional refinery residue. Coventry University, UK
Stop
The Computer for Supervisory
Control
Decision made from measured Temp.,
Compositon concentation etc.
2
2
Key
Transmission lines
Flow of crude
start
Indicator
Process
Error indicator
Request creator
Decision controller
On page ref.,
Product Fractions
hs (level set point)
-hL
E-1
V-3
E-4
E-6
V-4
V-7
V-8
V-13
V-10
V-12
V-6
V-14
V-15
V-11
Thermistor
Level Measuring Device (Float-actuated)
Th
erm
oc
ou
ple
Level Measuring Device (Differential Pressure Cell,
DPC)
Controller
Controller
Co
ntr
olle
r
Controller
Controller
Co
ntro
ller
Controller
Controller
Co
ntr
olle
r
P-2
P-3
P-4
ε
Ts
Set point ε
- Ti
ε- hD
hSi
P-6
Wa
ter
in
Effluent water out to
recycling plant
V-2
V-9
P-6
Level set point
Lev
el M
ea
su
rin
g
(Liq
uid
he
ad
pre
ss
ure
d
ev
ice)
ε
hs (level set point)
-hL
P-9
P-7
Heater in (Naphtha)
I-3
I-1
I-2
V-1P-1
I-4
T
I-5
P
I-6
P-5
He
ate
r fu
el
in
Composition Analyzer (I)
using the NMR spectroscope
Control:Uses the estimate of bottom product
composition
Computer:Using the Temperature, T1, T2, T3.
Composition Cf1, Cf2, Cf3 on concentration rate
Set point
3
1 2
3
The ComputerFor Supervisory
Control
P-10
Fuel oilPlant
Lubrication oilPlant
Bottom Product (Bitumen) to
Bitumen Plant.
Computer
I-7
August 27, 2006Automation/Controlled Oil Production Process
6/9/2006
Automation of Bitumen production Plant.
AKINLOLU, Akinsola (2006) MSc. Project: Semi-automation of Bitumen Plant from conventional refinery residue. Coventry University, UK.
E-2
Crude oil inlet
pipe
E-3
V-5
P-8
KEYS
--------------------Equipment-------------------
E-1V-1, Preheater /Furnace for
crude oil
E-2, The covered Storage Tank
E-4V-11
E-3, Crude oil Desalter Plant
E-5
MB
E-5
The Atmospheric/ Vacuum Still column
--------------------------------------------------------------Instrument/Sensor Control symbols-------------------------------------------------------------------------------------
T P № Controller
Flow metre (Venturi meter)
Recording Element
(Indicator/recorder
Temperature sensor
(Bimetallic strip thermometer)
Pressure sensor
(Piezoelectric element)
Error detector element
Condenser and Reboiler
Transmission line number
Final control element
(Diaphragm valve)
Final control element
(Relief valve)
Transmission line
The intelligent implementing
device
Heat supplier/remover device
(tubular coil)
CICI
CIContinuous
ImprovementEngineer/Operator
Operator Interface Terminals
(Visual Control system)
Water Treatment
PlantRecyclingInformation
stored and retrieved
Complex Plant need
close monitoringOther
Processing Plants
V-16 V-15
Controller
Composition Analyzer (I) using the NMR spectroscope
Composition Analyzer (I) using the NMR
spectroscope
Controller
Steam supplied
P-11
DISCUSSION ON SAFETY ISSUES IN THE BOILER SYSTEMS