1、 FORE WORD The need for energy conservation in the gas processing industry was recognized in the middle seventies when the Middle East Oil cartel pushed the cost of energy higher and higher. In 1978 the GPA Board of Directors assigned the subject of energy conservation to the Technical Committee. In
2、 turn Section A was charged to develop an energy conservation check list following a format similar to the plant design check list developed by Section A in the early seventies. The initial work group appointed by Section A Chairman, Allen Tarbutton, Mitchell Energy Corp. and Vice Chairman Joe Zanet
3、ell, El Paso Natural Gas Co., was composed of Messrs. Jack Carnal, Pioneer Natural Gas Co., Chairman; Joe Wheeler, Champiin Petroleum Co.; and Charles Guffey, Purvin and Gertz. In addition the following persons contributed to one or more sections of this work. Ed Asmus Bill French Dean B. Knight Lut
4、her Petty S. D. Swenson Don Bunton John Kline John Krogue Barry Kellogg M. V. Stuewe Don Ballard Bill Cummings Tom Jackson Bill Crawford Bruce McMillan R. G. Auld Jim McDougall Glen Van Burkleo Bob Blackburn Bob McKinley Howard Grekel Frank Campana H. L. Slaton D. D. Splawn Oscar Wantiez John Hunt R
5、eid Robertson Amoco Production Co. Amoco Production Co. Amoco Production Co. Amoco Production Co. Champlin Petroleum Co. Champlin Petroleum Co. Champlin Petroleum Co. Cities Service Co. Cities Service Co, Coastal Chemical Co. Coastal Chemical Co. Dresser Engineering Co. El Paso Natural Gas Co. EI Pa
6、so Natural Gas Co. Esso Resources Canada Ltd. Esso Resources Canada Ltd. Exxon USA R. L. Frailey, Inc. Getty Oil Co. HG Consulting Assoc. Ingersoll-Rand Co. Lone Star Gas Co. LoVaca Gathering Co. Mapco Inc. Mobil Oil Corp. Nalco Chemical Co. Gary Graysner Don Ewan Roland Meissner III Carl Alleman Bo
7、b Bellinger Bill Tuckett Clayton Terry Bill Hockersmith Jim Hamilton Walt Calvert Basil R. James Bill McWilliams Charley Wallace Mike Butler Wick Skinner Bob Holmes J. K. Bartels E. J. Hoffman E. B. Oliver Drue Talley Glenn Campbell Dennie Dixon Leon Simank Leeta Murphy Ralph Cole Terry Klare Oklaho
8、ma Gas they are intended for the use of persons in the gas industry, persons who are assumed to be proficient in their area of concern. These check lists are designed to provide the operators and designers of natural gas procesLing facilities with a “tickler” to insure that energy con- servation is
9、maximized. As such the check lists may be used in the day to day operation of the processing facilities by operators, foremen, and engineers or may be used as an aid in the design of new processing facilities. The check lists are not designed nor are they intended to be used as an instruction manual
10、 on energy conservation. Neither are these lists to be used as an “all inclusive listing nor as a rigid guide for design and operations. Consequently, the lists pro- vide simple action statements with little or no explanation as to either the reason for or the quanti- tative saving which can be real
11、ized from such action. The inclusion of operating and maintenance items in the lists were felt necessary because, ultimately, this is where the saving must be realized. Failure to educate and encourage energy conservation at the operations and maintenance level will result in com- plete failure of a
12、ny energy program, no matter how much time and money was spent in an energy saving design. Lack of training and motivation of operating and maintenance personnel, can dump energy dollars faster out the back door with a bucket than design personnel can bring through the front door with a tank car. Fo
13、llowing this introduction is a brief discussion as to the systematic methods available for conducting energy audits. The energy audit serves to determine the usage and to identify possible areas of conserva- tion. The energy audit can be system wide, by plant, or on individual pieces of equipment. L
14、ogs on energy consumption can be maintained to indicate at a glance the energy per mcf processed and/or energyper gdon of product recovered. Logs can also be maintained to indicate such things as loading of compressors and heaters, and efficiency of exchangers. These logs will serve as a historical
15、energy efficiency record for the equipment involved. NO attempt has been made to differentiate between low-cost high-return projects and the reverse. All such considerations are beyond the scope of this manual. Many conservation measures which seem good investments at the onset, when studied careful
16、ly, may even exhaust additional energy andlor be highly expensive. Payout of all proposed projects must be scrutinized very carefully. Evaluations should include a check for interference between earlier and sub- sequent projects to determine how much, if any, a subsequent project will reduce the sav
17、ing from the earlier conservation project. No person should embark on any course of action until all the conse- quences of the action are known and the consequences carefully evaluated. When properly utilized as intended these check lists represent a tool useful in indicating areas that should be in
18、vestigated and observed when energy economy is being sought. EN ERGY AU DIT General The energy audit should be considered as the first step in an energy conservation program. The purpose of the audit is to identify total consumption, the prime users, and the efficiency of energy utilization. The aud
19、it by itself may not produce results; however, it will help focus attention on the critical areas and form a basis to track results. Three levels of energy audit should be considered. They are the (1) historical audit, (2) technical audit, and (3) follow up audit. An explanation of what is involved
20、in each of these types of audits is given below. As each level is completed, it should become obvious whether to proceed to the next level. In many cases the majority of benefits may be realized through completion of the first two levels. Procedural or maintenance oriented conservation activities ma
21、y warrant consideration of the follow up audit. Historical Audit The first level of audit that should be performed is the historical audit. The objective of this audit is to identify historically the energy efficiency of a plant or process and as many subsystems as possible within these boundaries.
22、An indicator of energy efficiency is the energy consumed per unit of production. In the case of gas processing facilities this could be the amount of fuel gas used per gas volume throughput. This energy efficiency indicator forms a basis for 1 GPA TITLE*LBL f* tracking conservation efforts. In addit
23、ion it may help focus attention on areas where conservation can provide the greatest benefits. Technical Audit The second level in the audit process is the technical audit. This audit is a detailed analysis of a process or subsystems within the process. The objective of this audit is to identify ene
24、rgy conserva- tion opportunities and the incentives for modifications or changes. In most cases it will be necessary to per- form a mass and energy balance for the system being examined. Information that is needed to carry out this level of audit will include operating data and detailed specificatio
25、ns of the energy consuming components within the system or process. Much of the information that is required, such as temperatures, pressures, and flow rates, may be obtained from process flow sheets. Not all components will be easy to analyze; however, through appropriate estimates the major energy
26、 users and their efficiency can be determined. . W 3824699 O001840 7 = Once energy consuming components (systems) are identified, the respective checklist can be em- ployed to help identify ways to reduce consumption. An economic analysis will show whether or not conservation measures are justified.
27、 Follow Up Audit The final level in the energy audit process is follow up. In many cases conservation will result from procedural or maintenance oriented changes. The objective of this step is to ensure that conservation is maintained on a day-to-day basis. Boilers and process heaters, for example,
28、are the largest energy users in a plant. If continuous excess oxygen control is not feasible, a periodic check of the amount of excess oxygen should be carried out to ensure optimum operation of this equipment. Summary The three levels of energy audit form a natural progression. Results from each le
29、vel of audit will provide a better picture of energy consumption and may also result in a more efficient operation. 2 GPA TITLE*LBL * W 3824699 OOOL84L 9 1.00 1.10 1.20 1.30 1.40 1.50 1.60 2.00 2.10 2.20 2.30 2.50 2.60 2.70 2.80 2.90 3.00 3.10 3.20 3.30 3.40 3.50 3.60 4.00 4.10 4.20 4.30 4.40 SECTIO
30、N 2 BUILDINGS Design General Study published energy conservation literature Size building to minimize energy requirements Consider optional designs, such as multiple story or below ground installation Design for the most efficient comfort zone, considering occupant physical and mental comfort Isolat
31、e equipment generating high heat Omit unnecessary energy consumers, (such as sump pumps) where practical Environment Consider climatic extremes such as outside temperatures, wind direction and speed, sun angle, and radiation Orientate building based on sun, wind, and temperature considerations Utili
32、ze natural site features to reduce energy consumption Consider process equipment and piping heat rejection characteristics Utilize excess heat generated by equipment for heating Utilize evaporative cooling from lakes or process ponds Incorporate renewable sources such as solar Design roof overhang l
33、ength and configuration to utilize solar angles for cooling and heating effect Materials of construction Select materials with consideration to climate extremes Utilize building material to reduce heating and cooling Limit moisture vapor migration by proper material selection Utilize building materi
34、al mass consideration in locating areas within building requiring special heating or cooling Use skylights in roof Furnish additional structural strength and space for the future addition of solar equipment Insulation Optimize insulation thickness Consider additional duct and piping insul- ation abo
35、ve design minimum Adequately seal and/or weather strip all con- struction joints, including windows and door casements Insulate foundations where feasible; insulate around the perimeter of facilities using slab- on-grade construction 4.50 4.60 4.70 4.80 4.90 5.00 5.10 5.20 5.30 5.40 6.00 6.10 6.20 6
36、.30 6.40 7.00 7.10 7.20 7.30 7.40 7.50 7.60 e 1.00 2.00 3.00 4.00 3 Utilize heat containment insulation on hot process equipment Adequately insulate areas housing extremely hot or cold atmospheres from remaining areas Insulate to isolate spaces not heated or cooled Utilize insulated type exterior do
37、ors, especially for widths over three feet Utilize exterior wall and ceiling insulation Painting Paint the exterior to minimize heat and cold conduction and radiation Paint interior to enhance lighting quality Provide heat reflecting, transparent coating on windows where applicable Protect exposed i
38、nsulation with durable surfacing Door and window units Provide thermal-type windows, or windows with tint or coating Utilize automatic door and window closing devices Utilize exterior foyer on exterior doorways -Utilize wall louvers with manual or automatic control Special equipment Utilize motor or
39、 naturally driven roof ridge vents with controllable louvers Use slow-speed exhaust fan in exterior walls Provide forced draft air curtains on all exterior doorways or other openings which are subject to frequent use Provide heat eductors to redistribute or remove heat or circulate cold Provide hand
40、-powered crane and other lifting systems where feasible. Consider the use of compressed air (where air is available) over electricity, if the unit must be powered Where building size merits, provide for a fully computerized heat and air conditioning plant Operations Check energy consumption periodic
41、ally to determine areas of increased or excessive heat gain or loss Inspect the building periodically for the condition of all weather sealing joints in walls and foundations Determine quality and integrity of existing buildings Maintain records of energy consumption for future comparison and for de
42、cision making purposes GPA TITLE*lBl If 3824b 0001842 O 5.00 Keep all exterior openings closed as needed Repair or replace any leaking or inadequate 6.00 Operate louvers and exhaust fans only when heat or cold containing materials needed 3.00 Consider replacement of or the addition to inadequate ins
43、ulation on existing buildings Maintenance 4.00 Maintain paint and other coatings used in reduction of energy usage Maintain energy related motors and fans in 2.00 1.00 Review records of energy consumption and take appropriate measures to reduce excessive energy losses good mechanical condition 5.00
44、4 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.70 2.00 2.10 2.20 2.30 2.40 3.00 3.10 3.20 3.30 1.00 1.10 1.20 1.30 1.40 1.50 1-00 1.10 1.20 SECTION 3 HEATING AND COOLING EQUIPMENT BUILDING HEATING AND COOLING Design 1.30 Check and clean periodically all condensers and the cooling water system 1.40 Replace o
45、r clean air filters frequently 1.50 Replace or repair defective equipment 1.60 Calibrate thermostatic controls General Select heating and cooling equipment based on the availability and the efficiency of various Choose efficient units Consider the use of low grade steam or any waste heat source avai
46、lable for heating or cooling Consider heat pump Size the equipment properly for loading Insulate all air ducts adequately Consider solar heating Auxiliary equipment Size air handling grills, ducts, and coils to minimize air resistance Provide an automatic flue damper Utilize humidity control only wh
47、ere the building air is outside the comfort range Install a dependable, efficient thermostatic control unit Control considerations Provide a control sequence capable of utilizing outside air during periods of switchover from heating to cooling, or the reverse Interlock heating and cooling systems to
48、 pre- vent simultaneous operation Properly locate thermostatic sensing element energy sources Operations General Set heater controls for the lowest and cooling control for the highest temperatures which are practical for comfort Shutdown or reduce heat or cooling during periods of non-occupation Hea
49、t or cool only space in use Report any equipment malfunction noted Survey heat loss Maintenance General Maintain combustion system equipment in top condition through an on-going maintenance program Properly adjust burners and pilots for proper combustion PROCESS HEATERS Design 1.00 Preheat combustion air 1.10 Regeneration preheater - indirect type heat exchanger 1.20 Recupereative preheater - direct type heat exchanger 1.30 Indirect preheater using pumped fluid 1.40 Preheat air with flue gas or gas engine or gas turbine exhaust or other waste heat
