Best Practice

SABP-A-005 6 March 2011

Quick Energy Assessment Methodology
for Energy Efficiency Optimization
Document Responsibility: Energy Systems Unit/ P&CSD

Quick Energy Assessment Methodology

for Energy Efficiency Optimization

Previous Issue: 28 December 2005 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 66
Primary contact: Soliman Nour Eldin, Mahmoud Bahy Mahmoud on 966-3-873604566

Copyright©Saudi Aramco 2011. All rights reserved.

Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Table of Contents
Page
1 Introduction 3
1.1 Definition 3
1.2 Purpose and Scope 3
1.3 Intended Users 3
1.4 Initial Assessment Objectives 4

2 Quick Energy Assessment Overview 4

2.1 Energy Efficiency Optimization Task Description 4
2.2 Solution Method Using Decomposition Approach 5

3 Methodology 5
3.1 Energy Flow Diagrams 7
3.2 Steam and Power Diagram 11
3.3 Fuel Diagram 12
3.4 Energy Saving Housekeeping List 13
3.5 Energy Saving Generic Checklist 14
3.6 Guidelines for Grassroots Projects 17

4A Appendices for Short-cut Calculations and HGP Energy Study 32

4A.1 Basic Steam Mass Balance 32
4A.2 Basic Energy Utility Targeting Using Pinch Method 32
4A.3 Basic Formulas for Some Quick Savings Estimation 64
4A.4 HGP Detailed Energy Assessment Study 66

Page 2 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

1 Introduction

Energy conservation in Saudi Aramco became everyone’s business. It is mandatory for

each process facility to find cost effective solutions to save energy and achieve more
with less in their facilities. Saudi Aramco has constituted a committee called Energy
Management Steering Committee (EMSC) to direct and manage a sustainable process
for energy conservation.

A vital contribution towards the success of the company wide energy conservation
policy comes through documenting the company best practices in methodology, tools
and applications in the field of energy conservation and distributing such knowledge
among our facilities. Hence, a consistent effort has been exerted in Saudi Aramco to
produce Best Practices to help Saudi Aramco plants achieve their energy conservation
targets and disseminate energy conservation knowledge. This particular Best Practice
document for initial energy assessment is a contribution towards this goal. It is expected
to draw the line in conducting energy assessments through a user-friendly methodology.

The theme of this quick energy assessment methodology for energy efficiency
optimization is, “Big Picture First, Details Later”.

Energy assessments, also called energy audits, may be primitive or comprehensive and
detailed. A variety of approaches, methods and tools are available to conduct such
“energy assessments” to improve the energy efficiency of industrial processes.

1.1 Definition

The term “Energy Assessment” refers to the methodology of collecting and

analyzing available energy utilities related data in order to establish the “big
picture” of the breakdown of energy consumption for a particular facility and
identify component-based-energy saving opportunities within the facility.

1.2 Purpose and Scope

The purpose of this best practice document is to describe a methodology and

introduce short cut tools by which quick assessment for energy efficiency
improvement can be conducted faster, cheaper and better. Its scope include
quick energy assessment methodology in a step-by-step manner, simple models
for data representation, checklists for identifying areas for energy savings and
short cut tools for creating and evaluating process initiatives for energy saving
for common use in Saudi Aramco plants.

1.3 Intended Users

This Best Practice manual is intended for use by the energy engineers working

Page 3 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

in Saudi Aramco plants, who are responsible for efficient operation of their
facility. This particular document will enable them to conduct quick energy
assessments systematically.

1.4 Initial Assessment Objectives

 Preliminary review of plant process, system drawings and Data gathering
 Understand the “Big Picture” of the plant-wide operations
 Understand process energy and utility systems
 From the available data, establish your current reality
 Establish your desired result “Targeting”
 Identify All Opportunities for energy savings
 Propose Quick-hit savings
 Propose scope for definitive assessment with some economic analysis
 Propose plant-wide energy-utility strategy or “Total energy Management”

2 Quick Energy Assessment Overview

The first priority in any plant initial energy assessment effort is to define the “quick
hits” for energy cost savings that can be achieved with little or no investment.

The best practice document does not only help plants energy groups conduct a quick
energy assessment for both short and long term energy savings opportunities but also
establish the procedures and checklists that can enable process engineers and operators
make intelligent choices on hour-to-hour basis.

2.1 Energy Efficiency Optimization Task Description

Energy Efficiency Optimization Task aims to specify the near-optimal operation

targets/modes that minimize the plant’s energy consumption at minimum
deficiency in energy supply of the utility systems to the plant’s process.
Following that, the task will be to list all possible operational and design
modifications necessary to achieve the specified/desired target(s). This includes
identification of all related engineering activities in a minimum possible time
using uncertain plant data and without any interruption to the plant’s normal
production. This task shall achieve the following two objectives:
1. Minimum disruption in the energy utility supply
2. Minimum consumption of energy utility.

“Given an industrial facility that consists of several processes and utility plants, define;

Page 4 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

at minimum deficiency in energy utility systems supply to the process; near-optimal

targets for energy consumption minimization, find a list of possible operational and
design modifications to achieve desired target(s) and conduct the engineered
solutions”

2.2 Solution Method Using Decomposition Approach

For simplicity and timely results, Decomposition Techniques will be used in lieu
of the time-consuming Mathematical Programming/Optimization Techniques.

The plant’s energy utility needs will be defined with reasonable level of
flexibility and the energy utility system; electricity, fuel, steam and other
energy-related utilities will be scrutinized one by one to find the near- optimal
consumption of such utilities that guarantee minimum deficiency in the utility
supply to plant processes.

On the macro level the energy system components are generation, distribution
and utilization. The objective will be to minimize waste in energy fresh
resources and capital (de-bottlenecking) in these three components. This can be
done via the continuous upgrade of the efficiency of energy system components
in generation, distribution and utilization. However, the utilization component
has a unique feature, where its boundaries are not completely dictated by the
process. Therefore, the room of improvement in this component is much wider
than the others.

3 Methodology

There are four essential tasks that can be conducted by a small energy focus group of
three engineers:
1. Data, Models and Targets
2. Insights, Opportunities and Estimated savings potential
3. Screen and Formulate Strategy
4. Document, Report and Present

These tasks are exhibited in the 10-Steps procedures below.

1. Site survey through templates, checklists and interviewing of process
owners/proponents to gather the right amount of data that enable the energy
team build the plant’s “big picture” and understand the goals and the
constraints of the facility (What to look for and what to ask)
2. Define the criteria for focusing on potential areas of interest (when to be
rigorous and get to the second level of details)

Page 5 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

3. Develop site energy/utility nominal design/normal operation models with the

appropriate level of details in a high level generic “path” diagrams for, power,
fuel, H2, steam, water, nitrogen and air. Preliminary purpose of these models
will be to understand what is going on in the energy utility system, locate the
“energy consumption elephants” (ECEs) in both process and utility plants and
generate insights for energy saving opportunities
4. Add more depth in the level of details of the energy utility model for each ECE
and/or other criterion of focus
5. Define the effect of disturbances and uncertainty on the energy utility system
models
a. Sources of disturbances
b. Site energy utility balance under disturbances
c. Nominal and dynamic targeting of energy utility systems
d. (Check that the “big picture” depicted for the process and the utility
plants is correct with enough degree of confidence before you proceed)
6. Target (order of magnitude targeting)
a. _ Identify main processing issues that affect utility utilization
b. _ Link utility-utility interactions
c. _ Integrate and qualitatively optimize site utilities (If we do not
coordinate between steam and fuel systems we may stop flaring steam
but flaring fuel) for energy utility saving
7. Integrate core processes among themselves and with utilities
8. Develop a comprehensive initiatives list via identifying and estimating energy
utility savings opportunities
a. Housekeeping list
b. Checklists (generic and process specific)
c. Waste energy recovery (pinch method and others)
d. In-process Modification (pinch method and others)
9. Champion a cross-fertilizing discussion among plant disciplines to prioritize,
screen the initiatives and writing a project sheet, for each initiative, including
a description of the opportunity and energy utility savings estimate
10. Develop “word” strategies for realizing savings from facility goals, analysis of
the results and the mapping of the opportunities onto the facility strategy

Page 6 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

(remember, 50% of something is better than 100% of nothing). Then, report

and present results.

3.1 Energy Flow Diagrams

3.1.1 Overview

Fuel
Energy Sources

Energy
Generation

Boilers & Cogeneration

Steam Energy
Electricity
Distribution

Energy
Buildings & Others Process
Utilization
Energy
Byproducts

The task now is to look for the “Elephants” in the energy-process

system.

The graphs below will enable the Energy Engineer to find the
“Elephants” to focus his/her efforts and decide where to start and insist
on accurate data collection to further proceed with the analysis.

Money-based graphs will help quickly to pinpoint the areas of focus.

Furthermore, the BTU-based graphs will double check the pre-defined

Page 7 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

priority list, direct the study towards the process reasons behind certain
energy “elephant” and find more efficient ways to satisfy the process
target(s).

3.1.2 Overall Energy Flow Diagram ($/yr)

Typical Oil Refinery

$ 0.5 MM
$ 0.9 MM
Other users
Process
Purchase
$ 52.4 MM $ 0.8 MM Machine
$ 24.4 MM Drive

$ 0.0 MM $ 45.9 MM $ 41.5 MM Re-boilers

Steam
heaters

$ 21.5 MM $ 0.4 MM
Flare

$ 20.70 MM
Fuel $ 51.2 MM
furnaces
$ 73.1 MM
$ 0.0 MM
$ 0.3 MM
refrigeration
$ 16.9 MM $ 2.2 MM
power $ 18.4 MM
Motors
$ 19.1 MM
$ 0.40 MM Other users
Total Purchased $ 37.6 MM $ 0.0 MM
Export

Page 8 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Typical Gas Plant

Export
SA Fuel
Purchase Gas
$ 20.018 MM/yr Flare Area
$ 0.0 MM/yr
“ 2.54 MM Ib/hr”
$ 0.0 MM/yr $0.11MM/yr
Steam $19.618 MM/yr Inlet Area
$0.27 MM/yr
$ 19.618 MM/yr $1.72MM/yr
$2.8 MM/yr Utility Area
$ 0.0 MM/yr $0.244MM/yr
$ 20.018MM/yr
Fuel $ 0.4 MM/yr Sulfur Recovery
Area
$0.221MM/yr
$ 0.0 MM/yr $16.6MM/yr Gas Treat
$ 0.0 MM/yr $3.25 MM/yr Area
$ 56.1 MM/yr
power $ 56.1 MM/yr $0.335MM/yr
Gas Comp.
$18.08 MM/yrArea
Total Purchased $ 56.1 MM/yr
$0.609MM/yrLiquid Recovery
“200 MW”
$29.04 MM/yr Area
Note: These Data are Shedgum’s
Gas Plant

Page 9 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

3.1.3 Overall Energy Flow Diagram (Trillion-Btu/yr)

Total Input= 10.56 TBtu 8.38 TBtu

2 TBtu 0.18 TBtu

Electricity Fuel steam

0.39 TBtu 1.8 TBtu -0.19 TBtu 0.5 TBtu 2.11 TBtu 5.77 TBtu 5.46 TBtu 0.12 TBtu - 5.4 TBtu

Boilers Boilers Boilers

Process steam Process steam Process Building steam
Building Building
cogen cogen cogen

-0.19 TBtu 0.0 TBtu

5.59 TBtu 0.18 TBtu -5.4 TBtu 0.0 TBtu

Boiler Conventional Boiler Boiler Conventional

Fuel Conventional Electricity
Electricity Fuel Electricity Fuel

#N
Area #1 #N Area #1 Area #1 #N

Unit #1 #N
Unit #1 #N Unit #1 #N

Heating Cooling/Ref Machine Drive Electro-Chem Other use

7.56 TBtu 0.55 TBtu 1.24 TBtu 0.0 TBtu 0.02 TBtu

Page 10 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

3.2 Steam and Power Diagram

Steam “big picture” shall exhibit at least steam sources, pressure levels, mass
balance, let down valves and turbines, main users and losses such as vents, let
downs and condensate. These information can be used as depicted in the way
below to generate ideas and opportunities for saving under the main theme of
“Big picture first, and details later.”

Steam Targets
103 t/h
Consider replacing turbines with motors Enhance the recovery of
Steam from condensate

Heat integration of process#1 and # 4

98 t/h Estimated saving of 10%
HP Boiler
Enhance condensate recovery
By 10 %
HP
Shut down MP boiler
68 t/h 21 t/h 8 t/h 0.0 t/h 0.0 t/h Reduce letdown via turbine
flow increase or new turbine
Proc. #1

6.28 MW
Reduce it via HP Process
operating at Proc. #2 Condensate
lower pressure
1 t/h
4 t/h
MP Boiler 68 t/h 0.0 t/h
chemicals
MP
Eliminate vent 27 t/h 13 t/h
Vent 30 t/h
MP Process
2 t/h Proc. #4 Condensate
Proc. #1 2 t/h
18 t/h
0.0 t/h Vent
40 t/h
Deaerator 1 t/h 0.0 t/h
30 t/h 0.0 t/h
BFW LP
49 t/h 7 t/h 4 t/h
Raw water Effluent 5 t/h LP Process
Make-up Treatment Plant Proc. #1 Proc. #3
Condensate
Process Condensate
Reduce and make use of boiler blow-down
Est. 50 % Returned

Page 11 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

3.3 Fuel Diagram

Fuel “big picture” shall exhibit at least fuel sources, pressure levels, mass
balance, let down valves and compressors and main users. Hydrogen
composition should also be considered to define the opportunities for recycles.

Hydrogen Off-Gas Fuel Gas

400 psig

380 psig
PSA

350 psig

180 psig

NG

150 psig 150 psig

52 psig

50 psig

boilers furnaces
15 psig

5 psig

Page 12 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

3.4 Energy Saving “Housekeeping” list

1. Establish steam trap auditing program to determine the number of traps
(working, leaking, blocking…etc.) and periodically check it and repair or
replace the defected ones
2. Condensate recovery (maintenance and operation)
3. Piping insulation (maintenance)
4. Shutting off equipment when not required (load management)
5. Minimize slow rolling of steam turbines
6. Boilers and furnaces tuning through better combustion control
7. Preventive maintenance of energy system components such as heat
exchangers, pumps, fans, compressors, turbines, furnaces, boilers (e.g.,
clean the fin fan tubes of gas coolers)
8. Improved cooling water system (maintenance and operation)
9. Optimize air compressors operation
10. Optimize BFW pumps load allocation
11. Energy monitoring and indices/ energy management system
12. Shut down compressors at low feed rate (load management)
13. Steam trap management (consider self regulating electrical tracing)
14. Booster, shipper and condensate pumps load management
15. Compressors load management
16. Consider the use of Economizers and Pre-heater in the boilers
17. Compressed air leaks (maintenance)
18. Minimize boilers and water coolers blow downs
19. Utilize boiler blow-down
20. Turbines load management
21. Upgrade sluggish response control valves since the delay might result in
extra flaring
22. Enhance the efficiency of boilers and furnaces through tight control

Page 13 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

23. Enhance boilers and furnaces insulation

24. Optimize the CHP system
25. Maintain plant steam reserve
26. Minimize/Eliminate the use of steam reducing stations and vents
27. Consider the reuse of turbo-expander to generate power in the HP/LP
pressure control valves
28. Enhance the combustion process in boilers and furnaces via using full
additives as a catalyst

3.5 Energy Saving “Generic” Checklist

1) Replace gas turbines with more efficient steam turbines
2) Increase boiler steam pressure and temperature to the extent that
matches process needs unless electricity generation is the controlling
factor
3) Use auxiliary turbines to minimize steam let downs
4) Use steam in the process instead of venting it
5) Preheat combustion air
6) Use ASD on BFW pumps
7) Reduce process variability using stable ops program
8) Trim/Optimize the fired heaters excess oxygen
9) Optimize the fired heaters stack temperature
10) Re-use the flue gases in process heating
11) Optimize your waste heat boilers
12) Recover valuable gases from your fuel gases
13) Reduce the H2 wheel in your plant
14) Cool down the inlet temperature to compressors
15) Reduce cooling medium return temperature in refrigeration cycles
16) Upgrade, regenerate and replace your catalyst
17) Optimize let down stations and steam turbine operation

Page 14 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

18) Use highest efficiency turbines

19) Maintain your steam turbines to reduce steam consumption
20) Give frequent attention to steam traps and leaks
21) Replace turbine drives with electric motors if more economical since
they are more efficient
22) Boilers and furnaces efficiency enhancement through advanced
process control, on-line performance monitoring and optimization
23) Recover condensate
24) Thermal Heat and power integration (CHP)
25) Better control for dispersion steam to flare stacks
26) Optimize steam use in strippers
27) Minimize live steam utilization
28) Mechanical energy integration
29) Reduce natural gas consumption by understanding fuel gas sinks and
constraints
30) Reduce fuel gas use with energy integration
31) Keep H2 separate from fuel gas system
32) Measure the composition of off-gas streams and recover C2 and C3+
33) Avoid unnecessary processing of off-gas
34) Avoid unnecessary processing of wastes and inert
35) Minimize the unnecessary production of off-gas
36) Use on-line monitoring and APC for furnaces and other control
sensitive fuel users
37) Avoid unnecessary recycles
38) Avoid leaks in the pressure relieve valves to the fuel system
39) Adjust operating pressures and optimize process interaction
40) Clean and maintain pipelines and valves to minimize pressure drops
41) Clean and maintain Boiler tubes from deposits & scale for better
operations

Page 15 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

42) Treat and recycle blow down to force lower cycles of concentration in
cooling towers and boilers
43) Use lowest quality water
44) Maximize use of stripped sour water
45) Minimize generation of wastewater
46) Seek out and repair all hydrocarbon leaks
47) Eliminate direct water injection for cooling purposes
48) Eliminate live steam used for re-boiling and stripping where it is only
used for BTU value
49) Minimize or eliminate live steam consumption in sour water strippers
by replacing it with re-boilers
50) Boiler blow-down could be considered for cooling tower make-up
51) Extract the low pressure steam from the boiler blowdown
52) Consider re-using the boiler blowdown for reserving the boiler
53) Use process water effluent as a source on the next lower water quality
level
54) Eliminate live steam usage since it becomes water and follows an
energy path through the plant consuming more energy to process it
55) Should live steam becomes necessary optimize the amount used
through pressure manipulation
56) Use lowest quality water possible for desalter operation
57) Minimize water used in desalter
58) Automate desalter operation, avoid water slipping through with crude
during desalting/maximize the separation of free water upstream of
the crude desalting (each Ib of water will require roughly Ib steam for
processing)
59) Minimize the water-wheel in the plant
60) Maximize utilization of treated oily-water from the waste-water
treatment plant
61) Install low NOX burners
62) Consider the use of Cogeneration

Page 16 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

63) Adjustable speed motors/devices for pumps, compressors, etc.

64) Increase waste heat steam generation
65) Insulate condensate return lines, valves, flanges, etc.
66) Cooling- tower blow-down should not be treated but segregated to
sewer
67) Boiler blow-down should not be sent to wastewater treatment but
segregate to sewer.

3.6 Guidelines for Grassroots Projects

The purpose of this section is to present some guidelines regarding what need to
be considered during the design and/or the review of a design of any new facility
in Saudi Aramco. It has no intention or claim to be inclusive of all good
guidelines available elsewhere in the subject matter. However, this document
can be used as a quick guide to the subject. For more details, the document user
is advised to visit Saudi Aramco Best Practice documents SABP-P-017;
SABP-A-011; SABP-A-012 and others for more information on the subject
matter.

Background:
 Energy performance improvement is one of Saudi Aramco’s key objectives
and is strongly supported by its management and corporate shareholders.
 Energy improvement not only requires efforts/investment to improve energy
performance of existing units, but also a commitment to ensure that new
additions/modifications also contribute to improved site energy performance.
 New facilities infrastructure optimization should be consistent with the long-
range vision for improvement.
 With several new/large projects in development, there is a need to develop a
set of guidelines to make it easier for the project teams to integrate energy
improvement into their respective projects.
 With each new project there is only one opportunity to make the right
energy-efficient process and equipment decisions. (Retrofitting a process
and/or replacing equipment later is very difficult to justify on energy savings
alone).
 We recognize that the subject topic is a new initiative for us, and that there
has to be adequate discussion and feedback from the proponents and the

Page 17 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Project Teams before these guidelines are integrated into our project
implementation procedures and best practice documents with more details.
 To close the gap between any existing facility and the best SA and/or world-
wide energy efficiency performers, new additions to the facilities and/or
grassroots plants must contribute to improving SA overall energy KPI.
 In line with our objective of improving our SA energy KPI, (e.g., Solomon
EII that beats 80) each major new refining project must be designed such
that its energy consumption is lower than the current energy KPI per
Solomon criteria for refining and SA KPI for oil &gas production and gas
processing.

(This does not mean that new project must get the whole refinery to an EII of 80
or less; it just has to get its own EII impact under 80).
 To ensure that Energy Performance is given due consideration when
implementing major new projects, every project should undergo one or more
energy reviews during the DBSP and project proposal phases in form of big
picture facility energy system assessment study to select best process
licensor and help taking the decisions for power; heating; cooling; and water
production, and more detailed study to optimize the process-utility system
components and last but not least a project-specific energy system value
engineering session for final check up of the design.
 The project utility demands shall be reviewed with the project/proponent
Energy Coordinator in all project phases.
 Energy Performance must be given due weighting in Technology/Licensor
Selection, since energy costs tend to be significant throughout the asset’s
life-cycle.
 Preference should be given to new energy technologies where those
technologies have been proven in the industry.

General Guidelines:

(i) System Level

Energy Integration Approach:

 Cogeneration, Tri-generation and even Quadra-generation is always
recommended practice for the production of utilities in any new project.
 Optimization of cogeneration and its back-up systems for reliability
reasons can have tangible capital cost avoidance.

Page 18 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

 Intra-process and inter-process Energy integration does not only result

energy consumption saving but also capital cost avoidance.
 In support of the energy targets required in any new projects and
recognizing that energy efficiency improvements are best implemented
at the design stage, it is recommended that an analysis of heat
integration options be conducted on the selected process option
including licensed ones, for every project (or affected upstream and
downstream units) that consumes fuel in excess of 40 MMBTUH.

Using pinch design methods and/or mathematical programming

techniques or any other systematic method.
 Where the project is just a modification to an existing plant but the fuel
impact is more than 40 MMBTUH, a heat integration analysis should be
conducted.
 Cross integration between existing units directly and/or indirectly
should be considered wherever such integration will not significantly
impact reliability or reduce operational flexibility.
 Any proposed changes shall be tested against the site energy balance to
ensure the project enhances the facility energy performance (CHP
model can be used to check and confirm).
 In Refining applications utilities balances change with each new project,
consult the energy coordinator for the latest information.
 Heat exchangers network design shall not be only flexible to face short-
term changes but also renders an “accommodating” capability to face
long-term future operations changes due to capacity debottlenecking
needs and/or energy efficiency improvements in a cost-effective way.

(HEN designs shall always be ready to face a high level of operational

changes along its lifetime. These changes are short-term, such as
process disturbances; uncertainty in feed stock conditions and product
demand, and long-term such as the need to process more raw materials
that warrants the debottlenecking of the facility including the HEN to
increase its capacity. Nowadays, and since late seventies of the last
century, another important long-term frequent change is happening due
to the continuous escalation in energy prices in a rate that is higher than
plant energy system equipment cost, that also warrants continual
modification of the facility’s HEN to enhance the plant energy
efficiency along its lifetime that is sometimes reach to fifty years).

Page 19 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

In general, new projects should consider opportunities for integration

with existing facility, if possible:
o To take advantage of unused/under-utilized capacity in existing
units where possible
o To ensure overall steam balance/steam network reliability is
maintained or enhanced
o To minimize reprocessing/slopping during normal operation/start-
up/shut-down
o The design of routine emissions to relief are discouraged and must
be approved in advance by the flare champion and using of flare
recovery through in-process interception and/or end-of-pipe flare
recovery unit is recommended
o Maximize Condensate Recovery by following condensate header /
steam trapping design best practices
o Integration with existing Utility/Infrastructure should not
compromise overall reliability/efficiency

In refining applications in general, the following guidelines may apply:

o Incremental HP BFW is not available without additional facilities.
o 150# steam is in short supply.
o There is currently excess 40# steam which is often vented;
incremental 40# steam production will have no value to the
Refinery.
o The company Best Practice for steam systems is to use steam
primarily for process heating & steam stripping. Steam turbines are
to be used primarily only for let-down purposes to get steam to the
appropriate pressure for process heating. Otherwise, turbines are to
be avoided and preference is given to high efficiency motors as the
main driver and as the spare driver (electric/electric). (The perfect
option is to use a turbo generator to let down steam to various
pressures as needed for process heating).
o Preferentially choose 40# steam re-boilers over fired re-boilers
where steam can provide the needed temperature.
o Condensate recovery is required and it is better to be insulated.

Page 20 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

o New projects must utilize mass integration techniques to optimize

Fuel Gas Production. (Refineries, for instance, routinely operate at
or near a “fuel gas constraint”).
o Projects may be required to go outside the fence of the new project
boundaries to accomplish a fuel balance, if possible (expand the
boundary of integration). Further, it is not desired to design less
efficient furnaces or equipment to purposely use more fuel or
because of ad hoc trade-off between design “acceptability” by the
proponent and energy system efficiency.

Energy Saving Technologies:

New projects offer us the opportunity to evaluate the feasibility of adopting

new technology on both the inter-process level and equipment level to
improve energy efficiency.

Examples on the intra- and inter-process level:

 Indirect integration among process with areas of integrity
 Direct and indirect integration among processes

Examples of well-established energy-saving technologies on the equipment

level:
1. Variable-Speed Drives
2. Mechanical Energy Recovery Turbines
3. Plate & Frame and twisted tube heat exchangers
4. Waste heat Hot Oil Systems
5. Low-Grade Waste Heat Recovery (absorption chillers, vacuum cooling
and so on)
6. Heat Pumps

(ii) Equipment Level:

Guidelines for Equipment Cost/Benefit Estimation:

 When selecting equipment consider Total Lifecycle Cost (including
Operating Cost + Maintenance Cost and equipment reliability
considerations) rather than Installed Cost only.
 The current fuel gas cost in KSA is $3.65 /MMBTU.

Page 21 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

 When there is a choice, more energy efficient equipment should be

chosen, as long as the incremental cost meets the hurdle rate for energy
improvement projects (simple payback of 4 years or better).
 Review the equipment guidelines in the upcoming section with the
equipment specialist.

General Guidelines for Compressors, Pumps and Motors:

 Choice of compressors should be made appropriate to service (positive
displacement versus dynamic).
 Where the capital cost pays out in 4 years or less, reciprocating
compressors shall have special control valve/ performance control
system to reduce energy wasted at partial loads (lower capacity).
 Review new and replacement compressor selections with energy and
machinery specialists to ensure that the best compressor type is selected
consistent with minimizing the total cost of ownership.
 Pumps should not be excessively oversized. Where possible, the pump
should be selected such that the rated and normal operating points
straddle the best efficiency point on the pump characteristic curve.
 Premium Efficiency Motors shall be specified. Small motors (typically
250 Hp and less) shall be manufactured to the IEEE 841 standard. Fin
fan motors shall comply with the API 661 standard.
 The use of Variable-Speed Drives (VSD’s) is recommended for all
pumps or at least for one pump per pumping system. Our aim is to
eliminate as many control valves as possible on new construction.
 Exceptions shall be reviewed with the ESU.

Centrifugal Pumps:
 Typical margin of rated over normal capacity is 10% for pumps on flow
and pressure control. Typical margin for pumps on level control is 20%.
 Whenever possible, the normal operating point should be the best
efficiency point on the pump curve.
 Ensure adequate margin between NPSH available and required. For
existing facilities, consider a booster pump instead of a new pump to
meet NPSH requirements.
 Where pump head is excessive, consider larger discharge system piping

Page 22 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

instead of higher head pump.

 Use variable speed drivers unless economics do not justify. Review
exceptions with the ESU.
 Select the highest efficiency pumps that still provide a 4-year simple
payout for the upgrade in efficiency
 Purchase for current capacity, making allowance (if necessary) for
future increase by replacement of impellers.
 Motors must be selected for future expanded capacity to avoid costly
changes on motor, baseplate, etc. Size the motor for the largest
allowable impeller that will fit the pump.
 Select pumps with the lower suction specific speeds which have broader
allowable operating ranges. Pumps with higher suction specific speeds
require recirculation to maintain flow above their minimum continuous
flow rate, resulting in wasted energy.
 Select corrosion resistant impeller material as corrosion increases
internal clearances and deteriorates impeller and surface finish, causing
reduction in efficiency.
 For new pumps, selected impeller shall not be more than 90% of
maximum impeller size.

Motors:
 Avoid over sizing motors as efficiency decreases significantly below
70% load, refer to API 610 and API 617 for sizing standards.
 Premium Efficiency Motors shall be chosen (e.g., motors that carry the
NEMA Premium™ label)
 Synchronous motor normally only economical at low speeds or very
large HP ratings, example: 1250 HP @ 360 rpm or lower, 5000 HP @
600 rpm or lower.
 When there is significant variability in motor load based on operating
mode, use of VSD shall be required.
 Motors should be compared on the basis of Life Cycle Cost (LCC).
 In general, it should be assumed that motors will operate continuously,
24 hr/day, and that they will operate 90% of the days each year or
330 days per year. This allows for 10% of the year for turnarounds and

Page 23 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

downtime.

Steam Turbines:
 Choice of Motor/Turbine should be made considering overall facility
steam balance; however, there is a strong preference for motors,
particularly motors with VSD’s.
 Review any new and replacement turbine selections with the ESU and
machinery specialists to ensure that the best turbine type is selected,
consistent with the minimizing of the life cycle cost.
 Pick high-efficiency models as a minimum; however, we strongly prefer
motors!
 Condensing Turbines should be avoided because of their low cycle
efficiency, except where safety requires the use of a turbine and facility
steam balance makes use of back-pressure infeasible.
 Turbine steam piping/drainage systems should be designed to eliminate
need for slow rolling.
 Turbine steam piping/drainage systems should be designed to eliminate
need for slow rolling.
 To eliminate steam turbine slow rolling, properly designed steam traps
must be provided to prevent accumulation of condensate in the inlet
piping, the turbine case, and in the outlet piping.
 The placement of the traps must be installed at the low point of each
location to easily remove condensate.
 Provide flexible, removable insulation covers for turbine cases.
 Vent back-pressure turbines with elevated exhaust pressures to low
pressure steam header while on stand-by in accordance with standards
 Installation of in-line steam separators is recommended for any of the
turbine inlet lines that are likely to have entrained condensate in the
steam flow. The use of separators in these locations will improve steam
efficiency, and reduce the risk of turbine blade damage from entrained
moisture or condensate slugs.

Distillation Columns:
 Build in flexibility in the energy system to meet all requirements while
optimizing energy efficiency.

Page 24 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

 High Efficiency Trays/packing and internals that create low pressure

drop should be used where suitable.
 Heat Integration opportunities within unit and use of low-temperature
heat recovery devices, such as Heat Pumps, as well as heat integration
among several distillation columns should be considered where
applicable.
 Proper instrumentation to be provided for the effective control and
optimization of the column performance.
 Optimization of reflux vis-à-vis number of trays to be considered in the
design stage of the tower and in the context of the utility system design.
 For vacuum tower overhead systems, consider the use of vacuum pumps
for third and fourth stages instead of steam ejectors since vacuum
pumps are more efficient at low vacuum operation and create less waste
water that need to be handled later with more energy consumption.
 For plants with multiple towers, consider the use of a hot overhead
stream from one tower to provide the re-boiling for another tower as
mentioned above regarding columns integration.
 Evaluate energy savings for heat integrated multi-column fractionation
for complex distillation. (An example for crude fractionation would be
3 stages (Pre-fractionation, atmospheric, vacuum) vs. two stage
distillation (atmospheric, vacuum).
 Design distillation systems such that re-fractionation is minimized.
This requires integrating the distillation design considering other
process units.
 Each column shall be designed for the lowest pressure that can be
effectively maintained during normal operation.
 Overhead cooling shall be sized appropriately to achieve adequate
cooling during the summer to maintain lowest achievable pressures.
Consider the combined use of fin fans, trim coolers, absorption chillers,
etc.
 Consider column inter-coolers and inter-heaters in the context of the
heat exchanger network design.

Furnaces:
 The furnace shall be designed to minimize the stack temperature while
keeping the tube metal temperature above 275°F.

Page 25 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

 Advanced Combustion Control should be built into control scheme for

furnaces when it pays out in 4 years or less.
 Provide adequate flow metering.
 Provide analyzers for %O2/combustibles to monitor combustion.
 Ceramic coating of tubes should be considered for improving radiant
section efficiency.
 Provide adequate sampling points along combustion air/ flue gas
ducting and on furnace to allow O2/draft survey using portable
instruments.
 All instrument readings (including draft, O2, combustibles, and
temperatures) shall be brought into the DCS and PI system.
 Furnace skin temperature indication points shall be installed.
 Adequate inspection ports shall be installed to allow monitoring and
infrared inspections during routine operation.

For Good Thermal Efficiency

 Waste Heat Recovery from Flue Gas

First, consider additional process heating;

Second, Air Pre-heater;

Third, consider steam generation, steam superheating, BFW heating.

(Check with the energy coordinator to determine whether the facility,
for instance Refinery can supply adequate BFW and whether it needs
the generated steam).
 Air Preheat System

Prefer motor/ VSD on Fan (instead of a turbine) to accommodate

changes in flow and pressure - API 560.
 Consider Damper design
 Instrumentation and Control

Consider analyser selection type, in-situ versus ex-situ.

Specify flue gas analyser for O2 and combustibles measurements.

Page 26 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

ACC (Automatic Combustion Control) scheme required for all furnaces

where the simple payout is four years or less.
 Burner

Potentially coking services may benefit from use of many small burners
rather than fewer large ones to improve flux uniformity.
 Refractory – API 560

Consider Refractory material selection and installation to minimize

casing heat loss. Consider ceramic refractory coatings.
 Tight Firebox-(Minimize Air Ingression)
 Specify U-bends rather than plug-type header
 Use coil tube entry seal bellow (convection and radiation section).
 Casing Wall should be designed to minimize air infiltration at
compartment doors and tube sheets, while still providing good tube coil
visibility through adequate design and the number and placement of
peep sites.

Air Fin Coolers:

 Fans

There should be at least two fans per bundle with the fans covering at
least 40 percent of the bundle.

Fan blades are usually aluminum or plastic; however, we prefer plastic

due to their higher efficiency. The best plastic fan blades are good to
about 350°F. The blades should be at least 70% efficient.

Whereas variable pitch fan blades and louvers have been used in the
past, they are no longer acceptable due to poor reliability. Variable-
Speed Drives shall be used instead for temperature control. Each motor
shall have its own VSD. Any exceptions shall be reviewed with the
Energy Coordinator.
 Fins

Always use aluminum integral fins. (Our preference is for extruded

fins, but embedded fins are acceptable.) Maximum process inlet
temperatures of 5500°F for integral fin is recommended.

Page 27 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

 Belts

Belts shall be high torque positive drive belts (Poly Chain or cog belts).
V-belts are not acceptable due to the higher wear of their pulleys.
 Others

Install tip seals and central (hub) discs to minimize hot air recirculation.
Install inlet bells on all Forced Draft fans to improve fan efficiency by
about 2%.

Heat Exchangers:
 Consider provision for on-line cleaning in critical services and in all
pre-heat trains.
 Install proper instrumentation to assess exchanger performance on all
preheat trains. (Flow, temperature, and pressure drop.)
 Meet the insulation requirements for minimizing heat loss where
applicable.
 Admiralty brass, copper/nickel, or duplex stainless bundles shall be
used in cooling water (C.W.) service; carbon steel tubes are not allowed
on bundles serviced by CWT’s #1, #2, and #3. Carbon steel is
acceptable for closed-loop systems or for brand-new cooling tower
systems where water chemistry is pre-approved for carbon steel tubes
by Utilities Management.
 Chemical cleaning connections on the C.W. side shall be installed on all
C.W. exchangers larger than 5 MMBTUH.
 All C.W. exchangers larger than 5 MMBTUH and all inter condensers
shall have backwash connections equal to pipe inlet size or one size
smaller.
 Any new project plot plan shall allow for normal retrofit of the unit that
warrants adding extra shells and/or new tube bundle.

Cooling Towers:
 All cooling tower fan motors shall be driven with Variable-Speed
Drives.
 Instruments shall be installed to provide console operators with at least
the following:

Page 28 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

- Supply and return water temperatures as well as water flowrate

- Indication on the DCS/ PI system of which motors are operating and

its speed

Steam Generators:
 Adequate blow-down facilities and sampling points shall be installed to
maintain steam quality.
 Special reliable valves shall be installed as manual blow-down valves
on 600# steam generators.
 Provide steam samplers.
 Bring the steam temperature and pressure into the DCS/PI system.
 Condensate recovery shall be maximized.
 Provide flow meters on all pumped condensate streams.
 Apply data reconciliation and validation technique for highly fluctuated
systems with big energy bill ($20 MM/yr or more).

Steam Re-boilers:
 The lowest pressure steam shall be used for each re-boiler. (Use 40#
steam instead of 150# where practical. Provide piping to both pressures
if the design temperature is close to 40# steam.)
 Install pressure transmitters on the steam-side of re-boilers so that
pressures can be monitored in real-time via the DCS/PI. Also, a flow
meter shall be installed on the steam or condensate side so flow can be
monitored by the DCS/PI.
 Heat flux inside the re-boiler is to be maintained 2,000 Btu/hr.ft² or
higher everywhere in the exchanger. Avoid film boiling in all
exchangers.
 Re-boilers should be controlled by throttling steam pressure and should
have a downstream condensate receiving vessel to keep the re-boiler
drained of condensate, and a vent for non-condensable.
 The vent shall be connected to the shell of the re-boiler as opposed to
the control valve downstream piping. Otherwise, steam side corrosion
at the condensate interface and boiling side fouling in the nil heat
transfer condensate flooded region are likely.

Page 29 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

 Condensate discharge from the re-boiler should be evaluated for

adequate pressure under modulating conditions to ensure entry into the
condensate return system.
 Condensate sampling points shall be provided to ensure corrosion
products are not present.
 Sensible heating medium should be routed co-current to the boiling
fluid to facilitate control without fouling.

Instrumentation:
 Provide adequate instrumentation to monitor exchanger fouling.
These instruments will include temperatures, flows, and pressures so
that real-time U-values and pressure drops can be monitored.
 Provide flow meters on all steam producers and consumers of over
5 K#/hr.
 Provide mass flow meters on all utility streams (Natural Gas, Fuel Gas,
hydrogen, air, etc.) of over 50 KSCFH. This will help ensure accurate
monitoring of facility Fuel Gas production and consumption.
 Provide flow meter on the unit relief header downstream of any new
Relief Drum.
 Watch out during design for fouling/coking/plugging of heat transfer
equipment to ensure heat recovery does not deteriorate significantly
between turnarounds.
 Where it is not possible to eliminate fouling of heat transfer equipment,
provide adequate bypass and isolation facilities to allow on-stream
cleaning, or select best equipment in fouling resistance.
 The design should include suitable metallurgy for downstream piping
and equipment so that safe limits are not exceeded during the time when
the exchangers are bypassed.

Insulation:
 Insulation should follow good engineering design.
 Aluminum cladding shall be used in all locations, except where
corrosive environments exist. In those locations, stainless steel cladding
shall be used.
 Insulate valves and HE channel heads with flexible, removable

Page 30 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

insulation covers; however, flanges shall remain un-insulated to allow

access for blinds and also to prevent thermal expansion of the bolts.
Valve bonnets shall not be insulated.
 Use sheds for high hp motors to avoid overheating during summer and
degradation in efficiency.

Buildings – Lighting & Air Conditioning:

 All air conditioners, chillers, and similar units shall utilize the highest
efficiency using life cycle cost analysis method.
 Setback thermostat controls or control systems shall be installed on all
new buildings (permanent, modular, or temporary).
 All new buildings (permanent, modular, or temporary) shall have
infrared motion sensors installed on the lighting controls for each office.
 Rest rooms and conference rooms shall have ultrasonic motion sensors
on their lighting.
 Outside lighting in new plants shall be controlled by DCS out of the
respective console.
 New buildings shall be LEED certified where possible.

Revision Summary
6 March 2011 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with editorial changes.

Page 31 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

4A – Appendices for Short-Cut Calculations and HGP Energy Study

4A.1 Basic Steam Mass Balance

The basic Steam Mass Balance does not require high accuracy as long as the developed
model still makes sound engineering sense. (i.e., output is much higher than input).

Common engineering sense shall be used to estimate what the unknowns. For example
condensate return, blow-down and flares can be defined after getting good idea about
main consumers.

98+5 t/h

98 t/h
HP Boiler

HP
68 t/h 21 t/h 8 t/h 0.0 t/h 0.0 t/h
Proc. #1
1 t/h
6.28 MW
HP Process
Proc. #2 Condensate
0.0 t/h
MP Boiler 68 t/h 0.0 t/h
chemicals
MP
27 t/h 9 t/h
Vent 30 t/h
MP Process
Proc. #4 Proc. #1 Condensate
2 t/h
18 t/h
0.0 t/h Vent
38 t/h 1 t/h
Deaerator 0.0 t/h
30 t/h 0.0 t/h
BFW LP
(42+5) t/h 7 t/h 4 t/h
Raw water Effluent 5 t/h LP Process
Make-up Treatment Plant Proc. #1
Proc. #3
Condensate
Process Condensate
Est. 50 % Returned

4A.2 Basic Energy Utility Targeting Using Pinch Method

The purpose of this section is not to conduct a pinch study but to get some energy
targets regarding the utilities consumption for a desired plant area. This can be done
essentially via three methods, graphical, algebraic and using mathematical

Page 32 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

programming/optimization. In this document, the first two methods are going to be

explained.

Graphical Method:

Background:

Any heat exchanger can be represented as a hot stream that is cooled down by another
cold stream and/or cold utility and a cold stream that is heated up by a hot stream and/or
hot utility with a specified minimum temperature approach between the hot and the cold
called ∆Tmin.

The process exhibited below in the graph shows the situation when the two streams do
not have a chance of overlap that produce heat integration between the hot and the cold.

Feed Product
H PROCESS C

120
T HOT UTILITY

100

80

60

40

20

0
0 10 20 30 40 50 60 H
COLD UTILITY

Page 33 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Moving the cold stream to the left on the enthalpy axis without changing its supply and
target temperatures till we have small vertical distance between the hot stream and the
cold stream we obtain some overlap between the two streams that result in heat
integration between the hot and the cold and less hot and cold utilities. As been
depicted in the graph below with shrinkage in the hot and cold lines span.

Feed Product
H PROCESS C

120
T HOT UTILITY

100

HEAT
80
RECOVERY

60
Pinch
(MAT)
40

20

0
0 10 20 30 40 50 60
H
COLD UTILITY

For demonstration, all hot streams will be represented in the process by one long hot
stream to be called “the hot composite curve”. Same thing be done for all cold streams
in the process.

The next step will be drawing the two composite curves/lines on the same page in
Temperature (T)-Enthalpy diagram with two conditions:
1. The cold composite curve should be completely below the hot composite curve,

Page 34 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

and
2. The vertical distance between the two lines/curves in terms of temperature should
be greater than or equal to a selected minimum approach temperature called global
∆Tmin.

The resulting graph is depicted below and known as thermal pinch diagram:

Net Heat Sink

Above the Pinch

Opportunity for
heat recovery

Net Heat Source

Below the Pinch

Page 35 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

1. Constructing the composite curves (step-by-step)

The above mentioned process can proceed as follows:

Stream Type Supply Temperature (ºC) Target Temperature (ºC) FCp (kW/ ºC)
1-Hot 170 70 10
2-Hot 120 30 20
3-Cold 50 90 40
4-Cold 20 110 18

i- Draw the hot composite curve and the cold composite curve via developing
the following tables.
Note: The tables list all the hot and cold streams temperatures in an ascending
order with the cumulative enthalpy corresponding to the lowest hot
temperature and lowest cold temperature respectively equal to zero.

ii- In every temperature interval, the cumulative hot load is calculated using the
following formula:

H = FCp * (Tsupply – Ttarget)

iii- In every temperature interval, the cumulative cold load is calculated using the
following formula:

H = FCp * (Ttarget – Tsupply)

Hot streams temperature list Cumulative Enthalpy (H)

T0=30 H0=0.0
T1=70 H1=800
T2=120 H2=2300
T3=170 H3=2800

Cold streams temperature list Cumulative Enthalpy (H)

T0=20 H0=0.0
T1=50 H1=540
T2=90 H2=2860
T3=110 H3=3220

Page 36 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Temperature (T)- Enthalpy (H) Diagram

Hot composite curve

Cold composite curve

30

20

Cold composite curve is not completely below the hot composite curve

Page 37 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

As we mentioned before the cold composite curve shall lie completely below the hot
composite curve and this can be done via dragging the cold composite curve to the right
on the enthalpy axis (H). This process shall stop at a vertical distance between the cold
and the hot composite curve for a temperature equal to the minimum temperature
approach selected earlier.

Temperature (T)- Enthalpy (H) Diagram

Minimum Heating Utility

T
Qh=480 kW

Hot composite curve

Cold composite curve

Minimum Temperature Approach

30

20
Qc=60 kW

Minimum Cooling Utility

Page 38 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Algebraic Method:

Information needed

Explained via another example.

Given a unit with a list of hot streams to be cooled and cold streams to be heated.

Stream Flowrate*Average Supply Target

Type
ID Specific Heat (FCp) Temperature Temperature
1 hot 10 520 330
2 hot 5 380 300
3 cold 19 300 550
4 cold 2 320 380

1. Constructing temperature interval diagram

1.1_ Draw two temperature scales one for the hot streams and another for the cold
streams.

1.2_ Select reasonable minimum temperature approach between the hot streams
and the cold stream (for instance, 10ºC).

1.3_ Draw all the hot streams (in the table hot section) to be cooled according to
the hot steam scale as arrows that start at the supply temperatures and end at
the target temperatures.

1.4_ Repeat step 1.3 for all cold streams in the cold section of the table.

1.5_ Start at the highest temperature of any hot stream in the hot section and draw a
horizontal line that span along the two sections of the table, the hot and the
cold.

1.6_ Draw horizontal lines again at the start and the end of any arrow representing
the hot streams in the hot section of the table.

1.7_ Repeat step 1.6 for any arrow representing cold stream in the cold section (at
the start and the end of any arrow).

1.8_ Count the number of segments generated and number them starting at the
highest temperature (they are called temperature intervals).

Page 39 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

1.9_ Make sure that each temperature interval has now temperature value on both
the hot temperature scale and cold temperature scale. The difference is the
desired minimum temperature approach (for instance the 10ºC used in this
example).

These procedures are depicted in the figure below:

Note: This structure means that within any temperature interval it is thermodynamically
feasible to transfer heat from the hot streams to cold streams. It is also feasible to
transfer heat from a hot stream in an interval “x” to any cold stream which lies in an
interval below.

The Temperature Interval Diagram

∆ T minimum = 10 K

T* Interval
Hot Streams Cold Streams
T t
555 560 550

1 H1
515 520 510

2
385 390 380

375 3 H2 380 370

4 330 320
310
5 310 300 C2
305
6 C1
295 300 290
Hot Streams:H1; F1Cp1= 10 kW/K Cold Streams:C1; F1Cp1= 10 kW/K
H2; F2Cp2= 5 kW/K C2; F2Cp2= 5 kW/K

Page 40 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Note: The temperature symbol T* is interval inlet temperature used later on selecting the
suitable energy utility after calculating the targets using what is known as grand
composite curve.

To calculate T* we take the average interval inlet temperature of the hot and cold
temperature scale.

2. Constructing tables of exchangeable heat loads and cooling capacities

2.1 Determining individual heating loads and cooling capacities of all process
streams for all temperature intervals using this formula:

Qnm = F1Cp1* (Ts-Te) in energy units (kW)

Ts is the interval start temperature and

Te is the interval end temperature
“n” is stream number and “m” is the interval number

Example 1:

Interval # 1 in the hot section:

The interval start temperature is 560 K
The interval end temperature is 520 K
Q11 (Q for stream #1 in interval #1) = F1Cp1*(560-520)
Since there is no H1 stream in this interval, hence, F1Cp1=0.0
Q stream # 1 (exchangeable load) in this interval = 0.0*(560-520) = zero

Example 2:

Interval # 2 in the hot section:

The interval start temperature is 520 K
The interval end temperature is 390 K
The flow specific heat F1Cp1= 10 kW/K

Then,
Q stream #1(exchangeable load) in interval #1 = 10*(520-390) = 1300 kW

Page 41 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Example 3:

Interval # 1 in the cold section:

The interval start temperature is 550 K
The interval end temperature is 520 K
The flow specific heat of this cold stream is F1Cp1 = 119 kW/K
Then,
Q stream #1(cooling capacity) in interval #1= 19*(560-520) = 760 kW

Upon the completion of this step

2.2 Obtain the collective loads (capacities) of the hot (cold) process streams.

These collective loads (capacities) are calculated by summing up the

individual loads of the hot process streams that pass through that interval and
the collective cooling capacity of the cold streams within the same interval.
Table of Exchangeable Loads for Process Hot Streams Intervals
These calculations for the above problem are shown in the following tables:

Table of Exchangeable Loads for Process Hot Streams Intervals

Interval Load of H1, kW Load of H2, kW Total Load, kW

0.0*(560-520)= 0.0 0.0*(560-520)= 0.0 0.0+0.0= 0.0

1

2 10*(520-390)= 1300 0.0*(520-390)= 0.0 1300+0.0= 1300

3 10*(390-380)= 100 0.0*(390-380)= 0.0 100+0.0= 100

4 10*(380-350)= 500 5*(380-330)= 250 500+250= 750

5 0.0*(330-310)= 0.0 5*(330-310)= 100 0.0+ 100= 100

6 0.0*(310-300)= 0.0 5*(310-300)= 50 0.0+50= 50

Page 42 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned
TableUpdate: TBD Capacities for Process Cold Streams Intervals
of Cooling for Energy Efficiency Optimization

Table of Cooling Capacities for Process Cold Streams Intervals

Interval Capacity of C1, kW Capacity of C2, kW Total Load, kW

19*(550-510)= 760 0.0*(550-510)= 0.0 760+0.0= 760

1

2 19*(510-380)= 2470 0.0*(510-380)= 0.0 2470+0.0= 2470

3 19*(380-370)= 190 2*(380-370)= 20 190+20= 210

4 19*(370-320)=950 2*(370-320)= 100 950+100= 1050

5 19*(320-300)= 380 0.0*(320-300)= 0.0 380+ 0.0= 380

6 0.0*(300-290)= 0.0 0.0*(300-290)= 0.0 0.0+0.0= 0.0

3. Constructing thermal cascade diagrams

This diagram is constructed using the total hot loads and cooling capacities
obtained in the previous step for each temperature intervals.

The temperature intervals are drawn as “rectangular” with two inlets and two
outlets.

The inlet from the left is the total hot load available in this interval (for instance,
1300 kW in case of interval # 2).

The inlet from above is the utility input load, in case of the first interval, or the
input from interval above in case of second, third,……,N intervals.

The output from the right is the total cooling capacity of this interval (for instance,
2470 kW in case of interval #2).

The output from the bottom is the difference between the total inputs and the
cooling capacity of the interval.

Page 43 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

The heat balance around each interval will be conducted as follows:

First Interval Heat Balance

Hot Load From Utility Source

“Top Input”

Hot Load From Process Source Cooling Capacity From Process Source

“Left Input” “ Right Output”

1

Residual Hot to Subsequent Interval

“Bottom Output” from first interval

Heat Balance

Top Input+ Left Input- Right Output = Bottom Output

Page 44 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Numerical Example of First Interval Heat Balance

Hot Load From Utility Source

“Top Input”= 0.0 kW

Hot Load From Process Source Cooling Capacity From Process Source

“Left Input”= 0.0 kW “ Right Output”=760 kW

1

Residual Hot to Subsequent Interval

“Bottom Output” from first interval = - 760 kW

Heat Balance

Top Input+ Left Input- Right Output = Bottom Output

0.0 + 0.0 - 760 = - 760 kW

Page 45 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Subsequent Intervals Heat Balance

Hot Load From Above Interval

“Top Input”

Hot Load From Process Source Cooling Capacity From Process Source

“Left Input” “ Right Output”

N

Residual Hot to Subsequent Interval

“Bottom Output”

Heat Balance

Top Input+ Left Input- Right Output = Bottom Output

Page 46 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Numerical Example for Subsequent Intervals Heat Balance

For instance; Interval # 2

Hot Load From Above Interval

“Top Input” = -760

Hot Load From Process Source Cooling Capacity From Process Source

“Left Input”= 1300 “ Right Output”= 2470

2

Residual Hot to Subsequent Interval

“Bottom Output” = - 1930

Heat Balance
Top Input+ Left Input- Right Output = Bottom Output
- 760 + 1300 -2470 = -1930

Page 47 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Upon the completion of heat balance around each interval the following diagram
will be produced:

Thermal Cascade Diagram (Un-Balanced)

Note: During this step the input from Hot Utility to the first interval is equal to zero

0.0

0.0 1 760
- 760
1300 2 2470
- 1930
100 3 210
- 2040
750 4 1050
-2340
100 5 380

- 2620
50 0.0
6
- 2570

The maximum difference between the available hot loads and cooling capacities
from the heat balances of these intervals is – 2620 kW.

This deficiency in heat will be supplied via outside hot utility.

Page 48 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

This value will be the input (from the top of the first interval) and the same heat
balance calculation conducted above will be repeated to produce the balanced
thermal cascade diagram below.

Thermal Cascade Diagram (Balanced)

Note: During this step the input from Hot Utility to the first interval is equal to zero
Minimum Q-heating = 2620 kW

0.0 1 760
1860
1300 2 2470
690
100 3 210
580
750 4 1050
280
100 5 380
Thermal Pinch
0.0
50 0.0
6

Minimum Q-cooling = 50 kW

With the completion of this step, now the minimum heating utility and minimum
cooling utility required are 2620 kW and 50 kW respectively.

These targets can give some idea about the potential of utility saving in the facility.

To get better idea in terms of utility types needed, diagram known as grand
composite curve shall be drawn to be used in defining kind of utilities needed and
compare it with the current facility needs from such utility. This step will help in
capturing some potential savings upon the heat integration of certain process area.

Page 49 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

4. Constructing the grand composite curve (G.C.C)

This curve will be drawn between T* calculated before and the corresponding top
heat inputs to each interval.

These data are depicted below:

Data Required To Construct The G.C.C

T* (K) Enthalpy ( kW)

555 2620 kW
1
T* (K) 515 1860 kW
2
385 690 kW
3
375 580 kW
4
310 280 kW
5
305 0.0 kW
Thermal Pinch
6
295 50 kW

Enthalpy ( kW)

Page 50 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Drawing these data as T* versus Enthalpy results in the following diagram that can
be used to define different levels of utilities that can be used to satisfy the process
heating utility requirement as shown below.

Grand Composite Curve (G.C.C)

Should Be Drawn To Scale

T* (K) Total hot utility required is equal to 2620 kW

600
Hu3
Hu2

500

Hu1

400

300

Enthalpy ( kW)
200
700 1400 2100 2800

Page 51 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Multiple utility targeting/selection using Grand Composite Curve (GCC)

Upon maximizing heat recovery in the heat exchanger network, those heating
duties and cooling duties not serviced by heat recovery must be provided by
external utilities.

The most common utility is steam. It is usually available at several levels. High
temperature heating duties require furnace flue gas or a hot oil circuit. Cold
utilities might be refrigeration, cooling water, air cooling, furnace air preheating,
boiler feed water preheating, or even steam generation at higher temperatures.

Although the composite curves can be used to set energy targets, they are not a
suitable tool for the selection of utilities. The grand composite curve drawn above
is a more appropriate tool for understanding the interface between the process and
the utility system. It is also as will be shown in later chapters a very useful tool in
studying of the interaction between heat-integrated reactors, separators and the rest
of the process.

The GCC is obtained via drawing the problem table cascade as we shown earlier.

The graph shown above is a typical GCC. It shows the heat flow through the
process against temperature. It should be noted that the temperature plotted here is
the shifted temperature T* and not the actual temperature. Hot streams are
represented by ∆Tmin/2 colder and the cold streams ∆Tmin/2 hotter tan they are in
the streams problem definition. This method means that an allowance of ∆Tmin is
already built into the graph between the hot and the cold for both process and
utility streams. The point of “zero” heat flow in the GCC is the pinch point.
The open “jaws” at the top and the bottom represent QHmin and QCmin
respectively.

The grand composite curve (GCC) provides convenient tool for setting the targets
for the multiple utility levels of heating utilities as illustrated above.

The graphs below further illustrate such capability for both heating and cooling
utilities.

Page 52 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

The above figure (a) shows a situation where HP steam is used for heating and
refrigeration is used for cooling the process. In order to reduce utilities cost,
intermediate utilities MP steam and cooling water (CW) are introduced.
The second graph (b) shows the targets for all the utilities. The target for the MP
steam is set via simply drawing a horizontal line at the MP steam temperature level
starting from the vertical axis until it touches the GCC. The remaining heat duty
required is then satisfied by the HP steam. This maximizes the MP steam
consumption prior to the remaining heating duty be fulfilled by the HP steam and
therefore, minimizes the total utilities cost. Similar logic is followed below the
pinch to maximize the use of the cooling water prior the use of the refrigeration.

The points where the MP steam and CW levels touch the GCC are called utility
pinches since these are caused by utility levels. The graph (C) below shows a
different possibility of utility levels where furnace heating is used instead of HP
steam. Considering that furnace heating is more expensive than MP steam, the use
of the MP steam is first maximized. In the temperature range above the MP steam
level, the heating duty has to be supplied by the furnace flue gas. The flue gas

Page 53 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

flowrate is set as shown in graph via drawing a sloping line starting from the MP
steam to theoretical flame temperature Ttft.

If the process pinch temperature is above the flue gas corrosion temperature, the
heat available from the flue gas between the MP steam and pinch temperature can
be used for process heating. This will reduce the MP steam consumption.

In summary, the GCC is one of the basic tools used in pinch technology for the
selection of appropriate utility levels and for targeting for a given set of multiple
utility levels. The targeting involves setting appropriate loads for the various utility
levels by maximizing cheaper utility loads and minimizing the loads on expensive
utilities.

T-tft
(C)

T*

MP

CW

Refrigeration

Page 54 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Normally, Plant’s Operations have choices of many hot and cold utilities and the
graph below shows some of available options. Generally, it is recommended to use
hot utilities at the lowest possible temperature while generating it at the highest
possible temperature. And for the cold utilities it is recommended to use it at the
highest possible temperature and generate at the lowest possible temperature.
These recommendations are best addressed systematically using the grand
composite curve.

Hot and cold utilities

Boiler House
And Power Plant

Fuel

Steam W
Turbines

Gas W
Turbines
BFW
Hot Oil preheat
Circuit

Heat W
Process Pump

Furnace

Cooling W
Towers
Refrigeration
Air preheat

Page 55 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Understanding the Grand Composite Curve:

The graph below shows that utility pinches are formed according to the number of
utilities used. Each time a utility is used a “utility pinch” is created. It also shows
that the GCC right noses sometimes known as “pockets” are areas of heat
integration/energy recovery. In other words it does not need any external utilities.
These right noses/pockets are caused by;
- Region of net heat availability above the pinch
- Region of net heat requirement below the pinch

Page 56 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Applying the Grand Composite Curve:

GCC curve can be used by engineers to select the best match between utility profile
and process needs profile. For instance, the steam system shown below needs to be
integrated with the process demands profile to minimize low pressure steam flaring
and high or medium pressures steam let downs. Besides it helps selecting steam
header pressure levels and loads.

HP Boiler

HP

Proc. #1

HP Process
Proc. #2 Condensate

MP Boiler
chemicals
MP
Vent
MP Process
Proc. #4 Proc. #1 Condensate

Vent

Deaerator

BFW LP
Raw water Effluent LP Process
Make-up Treatment Plant Proc. #1 Proc. #3
Condensate
Process Condensate

Page 57 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Superimposed Utility Profile with Process Profile

Nominal Case Supply-Demand Matching Problem

T HP

MP

Process GCC

LP

BFW
CW
H

The superimposed steam system on the process grand composite curve shows that
while process heating needs can be achieved electricity can also be generated to
satisfy process demands and/or export the surplus to the grid.

Page 58 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

The graph below shows how we can use the GCC not only to select utility type,
load but also to define the steam headers minimum pressure/temperature to
minimize driving force and save energy.

T Qh
HP

MP

LP

BFW

CW

Qc
H

Page 59 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Grand Composite Curve can also be utilized to select the load and return
temperature of hot oil circuits. The graph below shows that while in many cases
the process pinch can be our limiting point in defining the load (slop of the hot oil
line) and the return temperature of the heating oil. In some other cases, the
topology of the GCC is the limiting point not the process pinch. This is also shown
in the second graph below. This practical guide to select the load and the target
temperature of the hot oil circuits is also applicable to furnaces as will be shown
later in this chapter.

Process Pinch temperature is the Limiting temperature for the Hot oil return temperature

T*

T supply

Hot Oil

T return

Process CW
Pinch

Refrigeration

Page 60 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Process Pinch temperature is not the Limiting temperature for the Hot oil return temperature
But the topology of the GCC curve
T* T supply

Hot Oil

CP-min

T return

Process CW
Pinch

Refrigeration

Page 61 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Grand composite curve (GCC) can also be used to select the process refrigeration
levels and the synthesis of the multiple-cycles refrigeration systems as we did in
the steam system. The schematic graph below shows a simplified refrigeration
system.

Schematic Diagram for multi-level Refrigeration System

Condenser 25ºC

CW

Process -5ºC
0ºC

-40ºC
Process
-35ºC

-70ºC
Process
-65ºC

Work
Compressor

Page 62 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

The GCC as we mentioned before can be used to place the refrigeration levels as
we did with steam levels. The graph below shows how we can do that.

We can place the refrigeration levels like steam levels.

Maximizing the highest temperature load to minimize the lower temperature loads

Tcw

- 5 ºC

- 40 ºC

- 70 ºC

Page 63 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

When a hot utility needs to be at a high temperature and/or provide high heat
fluxes, radiant heat transfer is used from combustion of fuel in furnace. Furnace
designs vary according to the function of the furnace, heating duty and type of fuel,
and method of introducing combustion air.

4A.3 Basic Formulas for Some Quick Savings Estimation

_Compression Energy % Savings Due to Decrease in compressors Inlet temperature

% Energy saving in a compressor energy consumption = {1- (Tnew/Told)} * 100

Tnew is the new inlet temperature

Told is the old inlet temperature

_ Turbines gland steam leakage:

Steam leakage in kg/hr = Flow of steam measured- Flow of steam utilized/required

Flow of steam required = work shaft required/ {Estimated Isentropic efficiency*(Inlet

enthalpy- outlet isentropic enthalpy)

Outlet isentropic enthalpy can be obtained from steam tables knowing outlet isentropic
entropy and outlet temperature or pressure

Outlet isentropic entropy = inlet entropy

Inlet entropy can be obtained from steam tables at inlet temperature and pressure

_ Back pressure turbines energy available for integration

Thermal energy available for Integration (Q) = Outlet steam flow*

(Vapor enthalpy- liquid enthalpy)

Outlet steam flow= Inlet steam flow (1- actual wetting factor)

Actual wetting factor can be assumed between (8 to 15) %

_ % Energy saving in heat pumps/refrigeration cycles due to decrease in reject

temperature

Page 64 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

W2/W1 = (T reject 2 – Tc)/ (T reject 1 – Tc)

Treject is the temperature at which heat is rejected to the cooling medium (water)

Tc is the temperature at which heat is taken into the refrigeration) cycle

_ Material balance for the cooling tower

Assuming the system is at equilibrium

Make-up = Evaporation+ Blowdown+ Windage loss

Cooling towers cycles of concentration (C)

C= concentration of solids in the circulating water/ concentration of solids in

make-up water

_ Energy saving in adjusting of combustion in a natural gas fired boiler/furnace

Analysis on the exhaust from the boilers sometimes or most of the times in some places
reveals excess oxygen levels which result in unnecessary energy consumption. This
excess air defines a low efficiency on the combustion process. Portable or even on-line
flue gas analyzer can be used as a part of a rigorous boilers/furnaces inspection
program.

The optimum amount of O2 in the flue gas of a gas fired boiler is 2%, which
corresponds to 10% excess air. Controlling the combustion process could lead to at
least 2% fuel saving upon bringing the excess O2 from for instance 6% to 2%.

Cost saving $/year= Energy usage per year* % possible fuel savings* fuel cost per
unit of energy

Energy saving in adjusting of combustion in a an oil fired boiler/furnace.

Analysis on the exhaust from the boilers sometimes or most of the times in some places
reveals excess oxygen levels which result in unnecessary energy consumption. This
excess air defines a low efficiency on the combustion process. Portable or even on-line
flue gas analyzer can be used as a part of a rigorous boilers/furnaces inspection
program.

The optimum amount of O2 in the flue gas of an oil fired boiler is 4%. Controlling the
combustion process could lead to at least 1% fuel saving upon bringing the excess O2
from for instance 6% to 1%.

Page 65 of 66
Document Responsibility: Energy Systems Unit/UPED/P&CSD SABP-A-005
Issue Date: 6 March 2011 Quick Energy Assessment Methodology
Next Planned Update: TBD for Energy Efficiency Optimization

Cost saving $/year= Energy usage per year* % possible fuel savings* fuel cost per
unit of energy

Energy saving in preheating boiler/furnace combustion air with stack’s waste heat:

If the intake air (air drawn from outside into the natural gas boiler) is at ambient outdoor
temperature unnecessary fuel will be consumed to heat up this combustion air. In order
to reduce fuel consumption, it is recommended to install recuperative air pre-heater on
the air intake of the boiler to preheat combustion air using heat which is exhausted
along with the combustion from the boiler.

Stack exhaust losses are part of all fuel-fired processes. They increase with the exhaust
temperature and the amount of excess air the exhaust contains. A high quality air pre-
heater could recover more than 40% of this waste heat. Therefore, the potential savings
from the installation of air pre-heater on the boiler is:

Cost saving = fuel cost ($)/unit of energy* Energy Consumed/year*(boiler

efficiency)*percent of energy recovered by air pre-heater
Note: The following attached pages are two curves and a table that can be used to estimate
the percentage of fuel savings.

4A.4 HGP Detailed Energy Assessment Study

Final Report, SAER-5995,”Detailed Energy Assessment at Hawiyah Gas Plant”,

June 26, 2005

Page 66 of 66