Plant Wide Energy Assessments

Plant Wide Energy Assessments

Petro Chemical Energy specializes in energy efficiency and reliability improvement.

We will provide you with a system wide energy system assessment addressing all aspects of energy generation, distribution, and consumption. The Assessment will include a review of historical operating data provided by the Company (no measurements will be made by the assessor). The process of working with on-site personnel in both a meeting room and field settings will be followed as is described below.

The Assessment will follow the Pareto Principle with the intent of identifying the majority of the opportunities with minimal resources. A focus of identifying low to no cost opportunities will be maintained while still collecting all potential savings opportunities. Site personnel will be involved in discussions and inspections during the entire on-site process. Personnel involved often include utility engineer, operations representative, process engineer, maintenance representative, etc.

The assessment process will include:

Energy Assessment Preparation (completed prior to on-site assessment)

  • Trend recent energy consumption and costs for analysis
  • Compute energy per unit of product
  • Develop one-line utility balances
  • Select members of core Survey team and facility area participants
  • Complete pre-audit surveys by outside parties (as necessary)
  • Compute/confirm unit costs for all utilities
  • Evaluate utility supply options
  • Review past energy activities considered but never implemented
  • Develop detailed Survey schedule

An Opening Session to discuss:

  • Focus and objectives
  • Production process overview
  • Evaluation of operating characteristics of affected energy systems, O&M procedures, and unusual operating constraints
  • Review and refine energy balances for major utilities consumed
  • Review of facility’s energy management practice and provide recommendations for improvement where applicable
  • Discuss the tools, methods, measurement, metering and diagnostic equipment to be used
  • Identify normal energy system operating conditions
  • Review of energy costs and consumption profiles
  • Inventory of major energy use systems
  • Review of architectural/engineering plans of utility equipment and distribution systems
  • Review plant data and past assessment results
  • List of major energy conservation measures (ECMs) within facility’s control

Facility walk through:

  • with data collection, interviews, and identification of energy savings measures (ECM)
  • Visual inspection of energy distribution systems
  • Review of log sheets and maintenance procedures
  • Visual inspection of major energy generating, consuming equipment

Idea collection

  • Brainstorm ECM, group like items
  • Review the process of developing economics for the ECM
  • Rank ECM based on a voting methodology

Discussion of Next Steps

  • Summarize ideas
  • Review opportunities for implementation and tracking
  • Agree to timeline for deliverables

Closing meeting and presentation of initial findings and recommendations

  • A comprehensive Assessment Report will be presented 30 days after site visit with the following contents:
  • Assessment Goals and Scope
  • Energy Consumption Profiles
  • Recommendations
  • Executive Summary
  • Facility Information
  • Description of Systems Studied
  • Identified Opportunities (includes items not found to be economical at this time)

Objectives and Deliverables

  • Identify significant energy conservation opportunities
  • Focus on the identification of Low/No-cost opportunities
  • Optimize energy utilization, resulting in significant improvements in profitability
  • Group projects as expense or capital in nature
  • Include preliminary engineering estimates and calculation basis
  • Prepare preliminary specification for procurement of recommended expense equipment
  • Complete audit report
  • Focus on energy consumption in the process at the point-of-use
  • Initiate no-cost items with department leadership immediately
  • Quantify economics of major recommendations
  • Outline steps for continuing energy management program and employee involvement
  • Break down total energy cost by utility
  • Identify possible capital equipment recommendations as audit follow-up projects for long-term implementation