Crude Distillation Unit (CDU) Energy Components and Guidelines | Energy Conservation
- Does the utility operator/engineer make routine check for steam leaks around the facility?
- Does a survey have been conducted to determine the source of “energy” leaks and valves leaks?
- Does each individual line to the flare is being measured and/or gas analysis is made to determine source of release?
- Does the waste gas containing combustibles such as H2S is being recycled to process furnaces?
- Does the flare gas recovery unit been justified?
- Can we recover flare gas, part of it, via in-process modifications such as better cooling capability and better pressure control?
- If the compressor is not justified for flare gas recovery, do the absorption and/or adsorption technologies been investigated?
- Are combustible waste products sent to the incinerator to reduce auxiliary fuel?
- Have the furnaces been considered for excess air control?
- Are pumps and compressors controlled to keep recycle at the minimum possible?
- Are all products specification controlled at the sales specification required?
- Are heat exchanger network controlled to maximize energy recovery?
- Are columns pressure control loop tuned to render fast response to disturbances?
- Are tower control loops been configured to keep reflux at a minimum and consistent with escalation in energy prices?
Combined Heat and Power System
- Is the venting of exhaust steam minimized by shutting down turbines and starting up motors, upon applicable?
- Is the idling of standby boilers minimized?
- Is the idling of standby turbines minimized?
- Can we replace tank heating steam with low level heat source after insulating the tanks?
- Have steam-driven pumps and compressors checked to see the suitability of smaller impellers, if applicable?
- Is all clean condensate recovered and semi-clean segregated, cleaned and recovered?
- Are there any letdown stations that can be by-passed/replaced by turbine?
- Is boiler feed water preheated using waste process heat?
- Does all exhaust steam recovered, in the context of the total steam balance?
- Can we reduce blow down?
- Does blow down flash steam add value to the total steam balance?
- Does the power factor been improved?
- Have single stage turbines replaced with multi-stage ones?
- Is the use of condensing steam turbines minimized?
- Does combustion gas turbine have air inlet cooling system?
- Are old steam lines been replaced?
- Is electrical heat tracing used instead of steam tracing?
- Is steam ejector used to upgrade some exhaust steam?
- Does the throttling of steam to match less pressure demands than the line pressure minimized?
- Are hot flanges, man-ways and pumps insulated with removable insulation?
- Are the medium temperature tanks insulated?
- Are maintenance people proactively minimizing the loss in steam lines via repairing left bare lines right away?
- Are all columns checked for optimal feed tray location and best tray efficiency?
- Have all the towers use the minimum reflux that renders the exact desired specification?
- Does steam flow is just enough to get completely condensed in the steam heater?
- Is over-flash in crude distillation unit too high?
- Is stripping steam minimized via working the stripper at the optimal pressure?
- Has vacuum tower in the vacuum unit been checked for possible low pressure operation?
- Does the light ends towers equipped with inter-cooler and inter-heaters?
- Does the light ends towers checked for among towers integration using different operating pressures?
- Does the vapor compression/ heat pump checked as an option?
- Does sour water stripper checked for correct number of trays?
Furnaces and Boilers
- Is excess air controlled and monitored to keep it as low as possible while using different fuels?
- Have the furnaces been checked for air leaks?
- Is high pressure waste gas available to replace atomization steam?
- Are boilers operating at its optimum combustion conditions; exhaust temperature; CO and excess air in stack?
- Have your furnaces and/or boilers studied for more waste heat recovery?
- Are all draft gauges operating?
- Are all soot blowers operating well and maintained?
- Is fuel oil temperature high enough to insure the right viscosity?
- Are your facility checked for reliable O2 analyzers?
- Is your atomizing steam dry?
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