Refinery executes a flawless turnaround without diesel generators
Client: Petroleum Refinery
Location: California
Sectors: Petrochemical and refining
The Challenge
Status quo
The connected load was calculated at 22.8 MVA. Using proprietary monitoring technology and data gathered from past projects, Aggreko quickly determined the load to be excessively large for a project of this size and scope. Following a thorough vetting process, peak demand was dialed back to 10.9 MVA, a 52% reduction in demand, resulting in significant cost savings. While working with the client’s in- house engineering team, multiple 2.4 kW sources were identified, and a feasibility study was performed to determine if available power could be connected in advance without interrupting ongoing production. Aggreko’s electrical engineers proceeded to design a temporary installation using existing house power after the feasibility test declared it was possible.
Key fact
The Impact
Early engagement
A post-project review (PPR) was performed to assess costs, review power usage, and capture improvement opportunities. Three areas were identified:
- Hard savings – total cost of in-house power use vs. diesel generators
- Cost avoidance – 100% elimination of fuel cost vs. fuel cost associated with using similarly-sized diesel generators
- Soft savings – Labor savings and productivity derived from 100% system reliability vs. one at 99.9%.
On a turnaround where the client was spending more than $100M, Aggreko’s on-grid system delivered $2.295M in cost savings and avoidance. Because recorders captured loads, the client could also identify the number of emissions the on-grid system avoided, excluding those generated by the local utility. NOx elimination was more than 30,000 pounds. As an added benefit, the site now knows what the load should be when the next turnaround on the unit occurs three years from now.
The number one critical success factor is early engagement and allowing Aggreko, experts in temporary power, to design a system that meets the unique needs of each turnaround.
The Solution
Use existing resources
Additionally, Aggreko engineers provided ARC flash analysis and labeling per NFPA 70E standards, single line electrical drawings, short circuit breaker analysis, and coordination and scaled plot plans, all of which freed up the end user’s personnel to complete other tasks.The system operated at 100% reliability resulting in no lost work time due to power outages. Without diesel fumes, contractor productivity and morale were never better.