Requirement for Adequate Water Assessment

WATER MANAGEMENT CONSULTANT

PRESENTED BY:AKINSOLA AKINLOLU

Water and Energy management auditor to project manage and provide technical expertise for a range of utility reduction projects - mainly in the Food & Beverage sectors, along with large commercial buildings

http://www.diversey.com/

REQUIREMENT FOR ADEQUATE WATER ASSESSMENT

Evaluation of current water use and costs associated with water supply and wastewater discharge

Development of a water balance that provides a detailed breakdown of water use by end-use/process

Evaluation of efficiency opportunities and identification of life-cycle cost-effective measures

Strategic plan for meeting water reduction goals.

The objective of water assessment is to develop an understanding of facility water consumption and identify cost-effective water efficiency measures that will help to achieve the site’s required water reductions

http://www.akproengineering.com/

Water Assessment Phases

PHASE I: BACKGROUND DEVELOPMENT AND PREPARATIONHistorical water consumption analysis

Cost data analysis

Team coordination

1. Hold a kick-off meeting to state the goals and objectives of the assessment to the facility team 2. Provide interim progress reports on the preliminary findings of the audits 3. Hold a final meeting to present results of the assessment

1. Calculate marginal cost of water and wastewater 2. Verify whether the facility is on proper water and wastewater rate schedules 3. Estimate the potential future water and wastewater rate escalation (to be used in life-cycle cost analysis of efficiency measures).

1. Collect and analyze at least 2 years of data for total supply, wastewater discharge, and all sub-metered water data 2. Estimate system losses based on system condition and age, and document the method used for determining system losses 3. Develop annual distribution curve (water use over time)4. Develop baselines for both potable water, and industrial, landscaping and agricultural (ILA) use, accounting for consumptive use from both potable and non-potable sources. Document the method used to develop the baseline.


Background data – The facility will provide background information to the assessment team for prioritization of the walk-through audits. This background data includes: 1. Historic water and wastewater bills or data from supply generated and/or treated onsite 2. Sub-metered data on water processes and buildings 3. Building floor space by building type 4. Occupancy data 5. Equipment lists 6. Maintenance schedules 7. Site and individual building maps 8. Distribution system maps

FOR AN EFFECTIVE BACKGROUND DEVELOPMENT


PHASE II: WALK-THROUGH AUDITS

walk-through audits of buildings and applications that were identified in Phase I of the water assessment. The basic documentation requirements for water end-uses are described below: Scope :Only include end-uses and processes that pertain specifically to the site.

1. Domestic plumbing fixtures – Document the following items for toilets, urinals, faucets, and showerheads: Audit approximately 10% of the restrooms at the facility to obtain a gauge on the general age and condition of fixtures

2. Commercial kitchens – Document the following items for ice machines, dishwashing machines, tray conveyor systems, garbage disposals, pre-rinse spray valves, convection steamers, steam kettles and other water consuming appliances: Note the brand and model number of the appliance, measure the flow rate of the appliance if applicable, document the operating schedule of the appliance 3. Irrigation and landscaping : Measure system pressure, Note if there is an irrigation meter, document the operating schedule (noting time of day) and hours per day or week during irrigation season, document the irrigation technology type (make and model of equipment), Estimate the number of sprinkler heads , Identify the overall system condition, noting leaking/maladjusted heads , Identify controls (type of controls and how they are used)

http://www.irrigation.org/Certification/CLIA/Audit_Requirements.aspx)


PHASE II: WALK-THROUGH AUDIT CONT’

4. Evaporative cooling systems Determine the size of the system (this may be in terms of cooling tonnage or recirculation rate), Determine how many days the system operates per year C. Determine if make-up water is metered. If it is not metered, verify whether system water use is tracked by other means, If possible, walk the system to see if leaks or losses are apparent. For any leaks or losses found, measure and quantify the loss.

5. Closed-loop cooling systems Determine whether system losses are known and measured, If possible, inspect the system piping to see if leaks or losses are apparent. If leaks or losses are found, measure and quantify the loss. 6. Single-pass cooling Determine how many days the system operates monthly or annually, Determine flow rate of system.

7. Steam/boiler systems Determine the size of the system (this may be in terms of steam generation or boiler horsepower), determine how many days the system operates per year , Determine whether the make-up water is metered. If it is not metered, verify if the system water use is tracked by other meansDetermine if cycles of concentration are tracked routinely. If they are not tracked routinely, determine if there are operator logs available that include routine measurement of blowdown and make-up conductivity E. Determine whether the system blowdown is automated or done manually F. Verify that steam traps are operating properly and are leak free G. Determine whether the system returns condensate and where condensate losses may be occurring.


8. Hot water (closed-loop) heating systems Determine if system losses are known and measured If possible, inspect the system piping to see if leaks or losses are apparent. If any leaks or losses are found, measure and quantify the loss Assess domestic hot water heaters for temperature setting and possible leaks. 9. Laboratory and medical facilities – Document the following items for disinfection/sterilization systems, vacuum pumps, water purification systems, photographic and x-ray equipment, glassware washers, vivarium equipment, and other water-using equipment. Note the brand and model number of the equipment, Measure the flow rate of the equipment, if applicable 10. Laundry facilities Determine type of washing machines (note make and model number), Estimate the number of loads washed per day or week, Identify the overall condition of the equipment. 11. Vehicle wash stations Determine the type of wash station , Identify whether the system recycles water. 12. Alternate water sources investigation – Investigate opportunities to access alternate water sources for process on the facility premises to provide a high level recommendation including (but not limited to): [Note a detailed assessment of alternate water sources is outside the scope of a typical facility water assessment.] A. Rainwater harvesting , Grey water, Water reuse, Air conditioning condensate capture, Wastewater reclaim.


PHASE III: WATER BALANCE DEVELOPMENT

The contractor shall develop a water balance that provides water consumption by major end-use categories (as defined in the SOW in Phase II) and system losses. The contractor shall complete the following elements: 1. Water balance – Develop a water balance that estimates current equipment and

process water use by major end-use categories and system losses and compares this total to water supply and ultimate discharge or reclaim of wastewater

2. Graphical elements – Show water balance in graphical form in a flow chart and/or pie chart that breaks out water use by major end-use categories and estimated losses.


SAMPLE BALANCE

Process Plant

Separation Plant

Water Recycle System Plant

Recycled Water, W,recycle

Water flow Winlet, T1

Water Flow Woutlet, R1

Water Flow Woutlet, R2



USING THE LAW OF CONSERVATION OF MATTER

Total Inflow rate of Water = Total Outflow rate of water + Total Water consumed within the system

And for more detailed calculations, component or sub plant usage can be focused on


Investigation and analysis of water efficiency opportunities that include the following elements:

1. Efficiency opportunity assessment – Assess opportunities for water efficiency improvements in each major end-use, including technologies that are detailed above in Phase II of the assessment. Include a consideration for retrofit, replacement, operation and maintenance improvements, and applications for sub-metering

2. Alternate water sources identification – Identify alternate water sources to offset the use of freshwater sources and provide estimated potential of annual water volume, as well as potential applications where the alternate source could be utilized 3. Life-cycle cost analysis – Perform life-cycle cost (LCC) analysis of all measures – the preferred tool for analysis is the Building Life-Cycle Cost (BLCC) analysis program for this analysis activity

PHASE IV: WATER EFFICIENCY INVESTIGATION AND ECONOMIC ANALYSIS

www.femp.energy.gov/information/download_blcc.html.


THE LIFE-CYCLE COST ANALYSIS (LCC)

1. Water and wastewater costs and other ancillary costs of water-consuming equipment, such as energy, operations and maintenance (O&M), and chemicals

2. Estimated water and wastewater escalation rates

3. Available utility rebates for installed measures, if applicable

4. Prioritization of efficiency opportunities – Rank each measure based on LCC effectiveness and installation cost, addressing both short-term and long-term investment opportunities.


SUMMARY

DELIVERABLES AND SCHEDULE The contractor shall deliver the following items by noted the due dates: Phase I: Background Development and Preparation • [2/12/2012]: Kick-off meeting summary that documents key items addressed by facility team • [3/05/2013]: List of prioritized buildings for walk-through audits

Phase II: Walk-Through Audits • [4/06/2013]: Summary report of walk-through audits that includes major issues or problems encountered during the surveys

Phase III: Water Balance Development • [10/07/2013]: Interim water balance shown in graphical form that shows all major water uses by end-use (as defined in Phase II) and comparison to incoming supply and discharged wastewater that reveals estimated losses of the system


FINAL REPORT• [10/08/2013] Executive summary – Provide a concise overview of the major results of the assessment that includes the following: o Prioritized list of water efficiency opportunities o Baseline water use and method used to determine this value

o Water and wastewater rates, marginal costs of water and wastewater, and other associated costs, such as energy o Water distribution curve that provides water use over time showing historic seasonal fluctuations

o Water balance shown in graphical form that shows all major water uses by end use and comparison to incoming supply and discharged wastewater that reveals estimated losses of the system. Include general methods used to estimate end-use consumption

o Detailed information on efficiency opportunities that include O&M, retrofit, and replacement options for each major water-using piece of equipment, as well as recommendation for sub-metering

o Prioritized list of water efficiency opportunities that provides total water, energy, and cost savings and life-cycle cost effectiveness indicator (such as savings to investment ratio or adjusted internal rate of return)

o Alternate water sources with estimated potential of annual water volume, as well as potential applications where the alternate source could be utilized

o Plan for meeting annual water reduction goals.


PINCH ANALYSIS FOR ENERGY OPTIMIZATION

The process data is represented as a set of energy flows, or streams, as a function of heat load (kW) against temperature (deg C). These data are combined for all the streams in the plant to give composite curves, one for all hot streams (releasing heat) and one for all cold streams (requiring heat).

The point of closest approach between the hot and cold composite curves is the pinch point (or just pinch) with a hot stream pinch temperature and a cold stream pinch temperature. This is where the design is most constrained. Hence, by finding this point and starting the design there, the energy targets can be achieved using heat exchangers to recover heat between hot and cold streams in two separate systems, one for temperatures above pinch temperatures and one for temperatures below pinch temperatures.

In practice, during the pinch analysis of an existing design, often cross-pinch exchanges of heat are found between a hot stream with its temperature above the pinch and a cold stream below the pinch. Removal of those exchangers by alternative matching makes the process reach its energy target.

http://en.wikipedia.org/wiki/Pinch

http://en.wikipedia.org/wiki/Thermal_energy

http://en.wikipedia.org/wiki/Heat_exchangers

http://en.wikipedia.org/wiki/Heat


INDUSTRIAL PROCESS CALCULATIONS

Reactor Design calculation

Process flow designs, Piping and Instrumentation Drawing (P&ID)

Process Control -Feedback Control Systems that minimises waste and enhances process efficiency

Automation Systems – linking system and also deals with plant layout

Lean Techniques- Calculation of Takt time and value stream mapping



Vacuum Still, E-6

Atmospheric Distillation Tower,

E-5

I-2

P-1

P-9

Fuel oil

Lubricants

Heavy gas oil-feedstock

Light gas oil-Diesel oil

Jet fuel

Naphtha-Petrol

Gases-LPG

E-4

E-2

P-2

P-3

P-4

P-5

Centrifugal Pump, E-7

P-6P-7 P-8

E-10

E-11

P-11

E-15

E-14

E-13

E-12

P-12

P-13

P-14

P-15

P-0

SHIP

P-10

Centrifugal Pump

P-0

Shell and tube Heating instrument

,E-3Desalter, E-1

Storage Tank, E-0

Bitumen Plant, E-8

The Process Flow diagram for Industrial Oil ProductionAs at Monday April 30, 2006

4/30/2006

The Process Flow Chart

AKINLOLU, Akinsola (2006) MSc. Project: Semi-automation of Bitumen from conventional refinery residue. Coventry University, UK.

SAMPLE FROM MY MSC RESEARCH WITH FAWLEY REFINERY

3000s

82589.34m3/h150,000 m3/h

151351.35m3 of crude Oil

4/30/2006

Current State Mapping of Bitumen Production Plant


9900s21000s8000s12000s

5 days or 7 days

0s

1110.203m3/h

Outlet capacity of 25 MW per cycle

150,000 m3/h

Tanker(For Onshore or

Pipeline)

StorageTank

Temp. 30ºCPress. 1mmHg.

Q (flow rate) Cycle time

I

DesalterProcess

Temp.115-165ºCPress. 103.4mmHg

Q (flow rate)Cycle time. 7500-

9900sec

Heating Process

Temp. 400 ± 40ºCPress. 250mmHg

Q (flow rate)Cycle time. 240,000

barrel per dayAvailable for 20hrs

Large furnace Has capacity 30MW

I

I

I

Vacuum StillProcess

Lubrication Oil for machinesTemp. 340 - 575ºC

(> C60)

Fuel Oil (for ship and Power stations)

Temp. > 490ºC(> C70)

Bitumen (Road & roofs)Temp. > 580ºC

(> C80)

I

II

I

I

Naphtha

1351.35m3

Lubrication Oil Plant

Bitumen Plant

Design Temp. 270 - 300ºC

Press. 0.01 – 0.05 MPa

Air consumption 3,500 – 4000 m3/h

Tar capacity 35 – 40 m3/h

Fuel Oil Plant

LPG

2162.16m3

Light Oil

Heavy Oil

Kerosene

TankerDaily

SHIP(For Offshore or

pipeline)

I-2

Fractional Distillation Process

LPGTemp. < 40ºC

Press. 1.4 – 2.6 atm

Naphtha's

Temp. 25 - 175ºCPress. 2.6 – 5 atm

(Sulphur cont.)

KeroseneTemp. 150 - 260ºC

Light gas OilTemp. 235 - 360ºC

Heavy gas Oil Temp. 330 - 380ºC

The Crude Oil Residue

Crude Oil from the Upstream Supplier

CustomersThe requirement per

day on Bitumen.

CustomersThe requirement per

day on LPG, Naphtha, Lubrication oil, Fuel

oil etc.

The Production Control

MRP control

Other Plants

For LPG, Naphtha, Kerosene, Light and

Heavy oil

1351351.35m3 (100,000 Tonnes) from the

Offshore

16216.22m3

(12,000 Tonnes) from the Onshore

91240.46m3/h

I

Almost 30% of the crude is in

the Residue

Customer requirement per day Forecast

Current State Value stream Mapping for Oil Production As at Monday April 30, 2006

Crude Oil from the Upstream Supplier

KEYS

Plant representation

I

Input/ Output symbols for

queues Measured in

m3

Tanker(For Onshore transportation)

The supplier and

Customer symbol

The Critical path arrow for bitumen production The Non critical path

The Production/Control symbol

I-2

SHIP transportation(For Offshore )

Flow rate from the storage to

Desalter is NOT equalHigh flow Low Flow

Available for 20hrs only

High flow

Andon call

Low Flow

Complex Plant

These plants Need to be monitored against spillage and

more information required

Andon call

91240.46m3/h

very Low Flow

18000m3

Spillage may occur. Inlet more than

Plant capacity

For flow through pipesWith flow rate

measured in m3/h

Important comment on process or plant which may

cause uneven flow

91240.46m3/h5789.45m3/h


The amount into the system is 150,000m3 and out of the system is 91,240.46m3, if this information is fed into the material equation; the amount the system accumulated in the cause of processing the crude oil is 58,759.54m3.

This cannot disappear into the system without been accounted for within an hour.

The volume of the Desalter tank was also measured and can take up to 160,000m3 of crude oil.




FEEDBACK CONTROL SYSTEM IN THE PREHEATED STORAGE TANK

MAKE USE OF NAVIER STOKE EQUATION FOR MASS, MOMENTUM AND ENERGY BALANCE

The quantity S can be any of the following fundamental quantities •Total mass •Mass of individual component, in the case of distillation column•Total energy•Momentum

PROPOSED CONTROLLED SYSTEM

Study Chemical Process Plant

Lean Techniques

The Current State Value stream

mapping drawn

Plant subdivided to processes with parameters and conditions for

operation

Visual Symbols incorporated to see anomalous

Detection of Bottleneck, Waste reduction, Reorder point technique and uneven processes, flow rate,

etc.Automation system

and Sensory device techniques

Chemical Process Control technique

Areas where sensory devices, Visual and

virtual instrumentations

Arrangement of Plant and links to optimise

process and production

Analysis of chemical Control processes,

areas where sensory devices can be used

Resolved the bottleneck and queue,

uneven processes

Rearrangement with sensory devices for

Automation

The Automated Plant

The Future State Value stream

mapping

The Chemical Plant

4/30/2006

The LeChAs


Crude Oil inlet from pipe

Composition of the incoming crude is collected for control

parameter modification

Preheated for non-

viscous flow crude

Request Creator for the

composition Analyser

Error/Control

Storage Process

Desalter Process

Error/Control

Need for flow, Temperature and

Pressure measuring error evaluator

reader

Decision need to be made for the set point

for Temp., Level in the storage tank

etc.

The Water Treatment

and Recycling

Plant

Process Divider

Decision need to be made for the set point

for Temp., Level in the Desalter etc.

Water in

Water out of Recycling Plant

Water in to the

Desalter Plant

Water out of the Desalter

Plant

The Furnace

Need for flow, Temperature and Pressure measuring error

evaluator reader Error/Control

Decision need to be made on Temp.,

Press., Level of Crude

control

The Fractional Distillation Column (Atmospheric

Pipe Still)

Composition of the incoming crude is collected for control

parameter modification

1

1

The Vacuum Still Plant

Bitumen Plant

Thursday June 8, 2006The Flow Chart for the Future/Automated Plant

6/8/2006

The System Flow chart

AKINLOLU, Akinsola (2006).MSc Project:Semi-automation of Bitumen Plant

From Conventional refinery residue. Coventry University, UK

Stop

The Computer for Supervisory

Control

Decision made from measured Temp.,

Compositon concentation etc.

2

2

Key

Transmission lines

Flow of crude

start

Indicator

Process

Error indicator

Request creator

Decision controller

On page ref.,

Product Fractions

hs (level set point)

-hL

E-1

V-3

E-4

E-6

V-4

V-7

V-8

V-13

V-10

V-12

V-6

V-14

V-15

V-11

Thermistor

Level Measuring Device (Float-actuated)

Th

erm

oc

ou

ple

Level Measuring Device (Differential Pressure Cell,

DPC)

Controller

Controller

Co

ntr

olle

r

Controller

Controller

Co

ntro

ller

Controller

Controller

Co

ntr

olle

r

P-2

P-3

P-4

ε

Ts

Set point ε

- Ti

ε- hD

hSi

P-6

Wa

ter

in

Effluent water out to

recycling plant

V-2

V-9

P-6

Level set point

Lev

el M

ea

su

rin

g

(Liq

uid

he

ad

pre

ss

ure

d

ev

ice)

ε

hs (level set point)

-hL

P-9

P-7

Heater in (Naphtha)

I-3

I-1

I-2

V-1P-1

I-4

T

I-5

P

I-6

P-5

He

ate

r fu

el

in

Composition Analyzer (I)

using the NMR spectroscope

Control:Uses the estimate of bottom product

composition

Computer:Using the Temperature, T1, T2, T3.

Composition Cf1, Cf2, Cf3 on concentration rate

Set point

3

1 2

3

The ComputerFor Supervisory

Control

P-10

Fuel oilPlant

Lubrication oilPlant

Bottom Product (Bitumen) to

Bitumen Plant.

Computer

I-7

August 27, 2006Automation/Controlled Oil Production Process

6/9/2006

Automation of Bitumen production Plant.

AKINLOLU, Akinsola (2006) MSc. Project: Semi-automation of Bitumen Plant from conventional refinery residue. Coventry University, UK.

E-2

Crude oil inlet

pipe

E-3

V-5

P-8

KEYS

--------------------Equipment-------------------

E-1V-1, Preheater /Furnace for

crude oil

E-2, The covered Storage Tank

E-4V-11

E-3, Crude oil Desalter Plant

E-5

MB

E-5

The Atmospheric/ Vacuum Still column

--------------------------------------------------------------Instrument/Sensor Control symbols-------------------------------------------------------------------------------------

T P № Controller

Flow metre (Venturi meter)

Recording Element

(Indicator/recorder

Temperature sensor

(Bimetallic strip thermometer)

Pressure sensor

(Piezoelectric element)

Error detector element

Condenser and Reboiler

Transmission line number

Final control element

(Diaphragm valve)

Final control element

(Relief valve)

Transmission line

The intelligent implementing

device

Heat supplier/remover device

(tubular coil)

CICI

CIContinuous

ImprovementEngineer/Operator

Operator Interface Terminals

(Visual Control system)

Water Treatment

PlantRecyclingInformation

stored and retrieved

Complex Plant need

close monitoringOther

Processing Plants

V-16 V-15

Controller

Composition Analyzer (I) using the NMR spectroscope

Composition Analyzer (I) using the NMR

spectroscope

Controller

Steam supplied

P-11

DISCUSSION ON SAFETY ISSUES IN THE BOILER SYSTEMS

THANK YOU

Hope you enjoy the presentation


Documents

Requirement for Adequate Water Assessment